DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117 IMPORTANT - READ CAREFULLY The Dixon ZTR Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operator's manual carefully, and become completely familiar with the controls.
INDEX 1. SAFETY Pages 1- 3 2. WARRANTY POLICY Page 4 3; SPECIFICATIONS Page 5 4. SET UP AND SERVICE Pages 6-11 5. OPERATION INSTRUCTIONS Pages 12-13 6. CARE AND MAINTENANCE Pages 14-20 7. TROUBLE SHOOTING Pages 21-23 8. PARTS ILLUSTRATIONS Pages 24 - 29 9.
SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED. CAN CAUSE SERIOUS INJURY. The following examples are the most common causes of injury to the operator or bystander. 1. BLADE CONTACT: The operator or bystander inserts a hand or foot into the discharge chute or under the mower deck and into the path of the cutting blade. Never run the mower blades when there are people nearby. Always turn the engine off when cleaning or working around the mower deck. 2.
SAFETY Page 2 SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION 1. Wear appropriate, safe clothing when mowing - close fitting jeans or slacks and heavy leather or safety shoes with rough soles. Never operate this mower with bare feet or open sandals. 2. Do not operate on wet or slippery grass. 3. Always mow at the slowest speed that will cut satisfactorily. 4. Keep hands and feet away from the blade at all times. 5. Keep persons clear of the discharge chute.
SAFETY REMINDERS; (continued) 16. Use A. B. C. Page 3 care when pulling loads or using heavy equipment. Use only approved drawbar hitch points. Limit loads to those you can safely control. Do not turn sharply. Use care when backing. 17. Watch out for traffic when crossing or near roadways. 18. Keep the mower in good operating condition, and keep safety devices in place and working. 19. Keep all nuts, bolts and screws Light to be sure the mower is in safe working condition. 20.
SPECIFICATIONS Page 5 Chassis: 11 GA - rectangular tube. Body: Two piece scratch service service - made of DR acrylic reinforced with fiberglass, color fast, and impact resistant. Front body contains access panels for battery and engine to mower deck belt removal. Rear body tilts up to allow on the entire drive system. Seat: Economically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests. Seat is adjustable fore and aft.
SET UP AND SERVICE 1. Seat assembly instructions. 2. Upper control lever installation. 3. Mower deck installation. 4. Deck leveling procedure. 5. Final preparation.
Page 7 SEAT ASSEMBLY INSTRUCTIONS 1. Assemble seat as shown in picture. Do not fully tighten the bolts -,-'hich secure left and right arm rest brackets to seat bottom until seat back and tool box are installed. This will aid alignment of all parts. 2. Place seat assembly on rear body cover, connect seat safety switch. 3. Insert the (2) rear studs of the seat slide into the rear holes of the body cover.
Page 8 UPPER CONTROL LEVER INSTALLATION 1. Raise rear body cover to fully open position. 2. Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer. 3. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See Illustration) 4. Tighten jam nut. Proper tightness or tension on jam nut is achieved when swing out movement of upper control levers requires some pressure.
MOWER DECK INSTALLATION Page 9 1. To remove front body from chassis, disconnect headlights and remove acorn nut 1n middle of body. 2. Install rear hanger rods on 11ft frame, as shown In the diagram. Slide lift plate on hanger rods, small holes 1n 11ft plate will face rear of mower and start nylok nuts on each hanger rod until approximately 1/4 inch of' threads are exposed. 3. Position mower deck under chassis. 4. Place lift lever in 3rd hole from highest cut, position #5 on quadrant. 5.
Page 10 MOWER DECK LEVELING PROCEDURE Leveling Principals: A. There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. Deck should be level or pitched slightly higher in rear. Leveling the Deck: A. Place the mower on a smooth level surface, check tire pressures to insure the mower has a correct stance.
Page 11 FINAL PREPARATION 1. Remove battery from chassis. 2. Fill each cell with electrolyte (acid) to ring at bottom of fill cap. 3. Allow battery to Sit for (10) minutes, re-check acid level and top off any cells that are low. 4. Trickle charge battery using a charger of less than (8) amps until all cells are gassing freely. Hydrometer readings may be taken, if desired 5. Install permanent battery caps and wash any accumulated acid from battery before re-installation on chassis. 6.
Page 12 OPERATION INSTRUCTIONS The safe and successful operation of the Model 503 will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgments about the terrain to be mowed. Never allow anyone to operate the mower without complete knowledge of all controls and their functions. Sound judgment by the owner will prevent accidents. Controls and their functions. All controls described from operators position.
Page 13 OPERATION INSTRUCTIONS (continued) THROTTLE CONTROL LEVER: Controls engine speed, has positive detent in fully opened position to insure adequate cooling of the engine and maintain mower deck blade speed in a mowing application. Throttle will automatically return to idle position if not locked into the positive detent located on control panel to operator's right. MOWER DECK CUT HEIGHT LIFT LEVER: Controls the cutting height of the mower deck.
Page 14 CARE AND MAINTENANCE - MODEL 503 This portion of the Model 503 owners manual deals with normal service items which can be performed by the owner. Please remember that if you are in doubt as to the correct service procedures to be followed, these and other service situations can be handled by a Dixon ZTR Dealer who is familiar with the service of your mower.
Page 15 CARE AND MAINTENANCE - MODEL 503 MOWER DECK SERVICE: CUTTER BLADE REMOVAL - BELT TENSION. "CAUTION" The removal of the cutter blades for either sharpening or replacement is best accomplished by removing the deck assembly from the mower Do not attempt to raise or lift the front of the mower unless proper safety equipment is available to support the mower. If you do not have the necessary equipment, entrust this task to your dealer. DECK REMOVAL: 1. Remove front belt access cover from body.
(1) FORWARD LEVER STOP ADJUSTMENT Page 18
Page. 19 CARE AND MAINTENANCE - MODEL 503 LUBRICATION: CHASSIS AND MOWER DECK: LOCATIONS: Number of grease zerks used (2) (1) each front wheel caster SERVICE INTERVALS: RECOMMENDED GREASE: Every (50) hour? of operation Name brand wheel bearing or multi-purpose grease CAUTION: The use of compressed air pressure greasing methods is not recommended as damage to seals and bearings could occur.
Page 20 CARE AND MAINTENANCE - MODEL 503 CLEANING THE MOWER: A clean machine is a source of pride to the owner. However, cleaning by use of high pressure commercial washes is not recommended. The high water pressure, combined with solvents or alkaline detergents, can lead td corrosion of electrical components or damage to the sealed bearings used on your mower. A better approach is the use of mild household soaps and low water pressure. A stiff brush can be used to loosen excess grass and dirt build up.
Page 21 TROUBLE SHOOTING MOWER CUT QUALITY: There are many variables that can effect the cut quality of any multi blade mower. Type and condition of grass, ground speed, blade speed, and conditions are some of the variables that interact creating differences in cut quality results. In most cases, a smooth, even cut will be achieved without further adjustment. The Trouble Shooting Chart suggests practices and adjustments that may be helpful in improving cut quality.
Page 22 TROUBLE SHOOTING Drive System: SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment Adjust per operators manual Consult your dealer for repair Loss of drive power on one T-Box belts slipping side or the other Adjust per operators manual Consult your dealer for repair Loss of power on both wheels after being operated for a length of time Adjust per operators manual Consult your dealer for repair Poor driving performance Oil leaks Belt from engine to T-Box 1s slipp
Page 23 TROUBLE SHOOTING ELECTRICAL SYSTEM: SITUATION CAUSE REMEDY Starter will not turn engine over Blown fuse Inspect and replace fuse If fuse continues to burn consult your dealer for repair Starter will not turn engine over Dead battery Battery discharge Poor connections on battery Battery water low Wrong battery Installed 1n mower Battery discharge Engine electrical system not functioning correctly Battery discharge Engine being operated at too low an RPM Electric clutch will not engage m
1993 T-Box, Gearbox & Hydrostats Assembly Model ZTR 503
1993 Fuel & Hydraulics Tanks & Fittings Assembly Model ZTR 503
1993 Mower Deck Assembly Model ZTR 503
1993 Chassis Assembly Model ZTR 503
1993 Body Assembly Model Zl R 5O3
ZTR 503 1300 1384 Belt Tank Mount Bracket (Short) 1385 1469 1470 Tank Mount Bracket (Long) LH Slide Angle RH Slide Angle 1627 1657 1668 1675 1682 1701 1714 1715 1732 1733 1734 1739 1743 1745 1752 1763 1765 3/8" Pipe Elbow Spring - Belt Idler Drive Pulley Clutch Anchor L-Rod Wheel/Deck Hub Bearing T-Box Drive Belt Rear Wheel & Tire Pulley - T-Box Pulley - T-Box Pulley Hydrostat Hydrostat Idler Bracket Hydrostat .
Page 31 ZTR 503 Parts List 3339 3343 Snap Ring - 5/8" Hub Bolt-Drilled 3347 3348 3349 3403 3511 3521 Washer-1.033 X 1.5 X .
Page 32 ZTR 503 Parts List 5623 5624 Electric Clutch Tank Cap 5627 5628 5631 5632 5633 5635 5636 6075 6100 6101 6111 Left Fan Right Fan 3/8" Hose - 21" 3/8" Hose - 5" 5/8" Hose - 2" Reservoir Assembly Brass Ferrule Engine Idler Spacer Outer Shaft Key Center Shaft Key Deck Drive Belt 6168 6257 6744 7034 8172 8175 8176 Trash Guard Blade Washer Spring Belt Keeper Frame - 503 Upper Body Assembly - 503 Lower Body Assembly - 503 8576 8577 9017 9023 9024 9031 9035 9049 9055 9056 9057 9065 9066 9067 Rear Wh
