Dixon 503 User Manual

IMPORTANT - READ CAREFULLY

DIXON INDUSTRIES, INC
A BLOUNT COMPANY
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 O945
316 251 2OOO

FAX [phone]

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.

The information in this operator's manual applies to all Dixon ZTR Model 503 Mowers. Your Dixon
dealer will gladly provide a check-out ride, and answer any questions.

See your dealer for warranty service, parts and repairs.

INDEX

1. SAFETY

2. WARRANTY POLICY

3; SPECIFICATIONS

4. SET UP AND SERVICE

5. OPERATION INSTRUCTIONS

6. CARE AND MAINTENANCE

7. TROUBLE SHOOTING

8. PARTS ILLUSTRATIONS

9. PARTS LIST

Pages 1 - 3

Page 4

Page 5

Pages 6-11

Pages 12-13

Pages 14-20

Pages 21-23

Pages 24 - 29

Pages 30 - 32

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. RUN-OVER: This situation occurs when a bystander is run-over or backed over by the
"mower The most frequently cited examples are with small children who wander
into or are allowed to play, in an area where the mower is being operated.
Never run the mower blades when there are people nearby, especially children.
Young children should be indoors and watched by an adult. Always look behind
you before backing up.

3. TIP-OVER: This occurs when the mower tips over, usually sideways or to the rear.
This situation is due to operation of the mower on steep inclines or near a drop
off.

Mow across the slope to slightly uphill.
Mow slopes when the grass is dry and watch for bumps, holes and other

obstacles.
Test the slope with the blades off. A good rule of thumb is "Don't mow on a
slope you can't back up". Stay clear of drop-offs, especially if they are on the
down side of a slope.

4. THROWN OBJECTS: The fast spinning mower deck blade can strike stones or other
objects which can be hurled into the path of a bystander. To prevent this from
happening, never remove the safety discharge chute from the mower deck, or
operate the mower when other people are around.

5- FIRES: Most accidents of this type occur during re-fueling of the mower or placing

the mower in a storage situation. The exhaust system and related engine
components operate at very high temperatures which can ignite any fuel spilled
on or near them. Always allow the mower to cool before re-fueling or placing in
storage.

6. OPERATION BY CHILDREN: This mower is not a toy or recreational vehicle.

Never allow children to operate the mower in any manner or to ride as a
passenger.

NOTE: .The six examples are the most frequently cited injury causing situations.

Please review all the safety precautions outlined on the following pages prior
to operation of the mower. Our aim is to enhance the safe and satisfactory use
of this product.

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. Do not operate mower unless deflector is
in place.

6. When mowing hills or slopes, use extreme caution. Reduce speed, do not make
sudden starts, stops or turns.

7. Always disengage blades before taking the mower across walks or objects that
project above the surface.

8. Stay alert for holes, rocks and roots in the terrain, and other hazards. Keep away
from drop-offs.

9. When the mower is not in use, turn the engine off and remove key. Never leave the
engine running unattended. Your Dixon mower is equipped with a weight-sensitive
switch that kills the engine when operator leaves the seat while blades are engaged.

Note: This important safety feature must be tested prior to each mowing.

This
may be done by starting engine, engaging blades and then ' rising
slightly from seat. If engine does not stop, see your dealer for necessary
repair.

10. Before adjusting or servicing your mower, turn off the engine and let it cool. Be
sure all moving parts are stopped. Never run the 503 with the body open.

11. Never run the engine indoors; the fumes are dangerous.

12. Before backing your Dixon Mower; stop, turn around and look.

13. Handle gasoline with care - it is highly flammable.

A. Use approved gasoline container.
B. Never remove the fuel cap of, or add gasoline to, a running or hot engine, or an

engine that has not been allowed to cool after running. Never fill the tank
indoors and always clean up spilled gasoline.

C. Never store the mower, with gasoline in the tank, inside the building where

fumes may reach an open flame or spark. Allow the engine to cool before storing
in any enclosure.

14. Never lift lawnmower by the body; lift only by the frame.

15. Never carry passengers.

SAFETY REMINDERS; (continued)

Page 3

16. Use care when pulling loads or using heavy equipment.
A. Use only approved drawbar hitch points.

B. Limit loads to those you can safely control.
C. 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. To reduce fire hazard, keep the engine free of grass, leaves or excessive grease.

21. The mower should be stopped and inspected for damage after siriking a foreign
object or if it starts vibrating, and any damage should be repaired berore
restarting and operating the mower.

22. When mowing, proceed as follows:

A. Mow only in daylight or in good artificial light.
B. Shut the engine off when removing the grass catcher or unclogging chute.

C. Check the blade mounting bolts for proper tightness at frequent intervals.
D. Never operate the. machine when using medication or under the influence of

alcohol or drugs.

SPECIFICATIONS

Page 5

Chassis: 11 GA - rectangular tube.

Body: Two piece - made of DR acrylic reinforced with fiberglass, color fast,

scratch and impact resistant. Front body contains access panels for battery
service and engine to mower deck belt removal. Rear body tilts up to allow
service 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.

Mower Deck: 12 GA stamped steel construction, (3) blades, 50" cut vidth, cut height

1" to 4" via 7 position lift handle. Self cleaning design, smoothly
curved front, aides discharge of grass.

Blade Drive: Warner electric clutch.

Drive System: Each rear wheel is independently driven by a Sundstrand BDU-10L

Series 70 hydrostatic transmission, which is powered by a
permanently lubricated Peerless gearbox. The hydrostatic trans­missions, in turn, power a fully enclosed Agri-Fab gearbox. The
gears in the Agri-Fab gearbox are permanently lubricated using a
special grease which completely eliminates the need for any type of
maintenance.

The Sundstrand BDU-10L Series 70 hydrostatic transmissions are
serviced with any high quality (10W-30) motor oil. The oil is
filtered by a (10) micron oil filter. Recommended service interval
for both oil and filter is after the first (150) hours of
operation, then after every (400) hours of operation, unless the
system has been contaminated by dirt or other foreign debris.

Engine; 20 HP Onan Twin Cylinder with cast iron cylinders, pressure lubrication and

vacuum powered pulsating diaphragm fuel pump.

Starting System: Electric by key switch operation with safety interlocks on

parking brake and blade drive clutch.

Tires: Front 11 x 4.10 x 5, smooth thread.

Rear 20 x 10 x 8, turf savers.

Capacities: Fuel - 4.8 gallons total (dual tanks) with fuel gauges.

Hydrostat oil tank - 3 quart with inline (10) micron filter.
Hydrostat oil recommendation - name brand SAE (10W-30) motor oil.

Dimensions: Width - 60"

Height - 45"

Length - 72"

Weight - 630 Ibs.

NOTE: Additional Information provided 1n strvlci Instructions under<the

Individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

SET UP AND SERVICE

Page 6

1. Seat assembly instructions.

2. Upper control lever installation.

3. Mower deck installation.

4. Deck leveling procedure.

5. Final preparation.

Page 7

NOTE:

HARDWARE FOR CONTROL LEVER ASSEMBLY

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.
Firmly hold seat assembly against body cover with one hand while rear body is
raised to fully open position. Continue to hold seat against body to prevent damage
to seat safety switch wiring.

4. Install (1) flat washer and (1) nylok nut on (1) of the rear studs extending
through body cover and seat frame, tighten a few threads to hold seat assembly in
place.

5. Position seat on front holes and install all remaining washers and nylok nuts.
Tighten all nuts fully.

SEAT ASSEMBLY INSTRUCTIONS SEAT

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. Levers

should not fall to the side or be sloppy in movement.

5. Repeat above procedure on left side.

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. Using (1) of the deck support rods, Insert the rod at the corner of the lift frame
and the front of the mower chassis in the groove provided on the lift frame. Pry
backwards on the lift frame enough to connect the brake link into the hole on the
tab of the 11ft lever. This will allow for belt installation in step #7.

6. Raise mower deck at the rear and slide (1) of the deck support rods through the
mower deck lift plate and the tabs of the mower deck. "Note" A length of 2x4
board turned on end and placed under the mower deck for support will make this
task easier if the installation 1s being done by one person, due to the weight of
the mower deck.

7. Raise front of mower deck and slide front support rod through lift frame and tabs
on mower deck. Install hair pin clips on front and rear support rocs.

8. Move lift lever to lowest cut position, install engine to mower deck drive
belt on top center pulley. Check belt routing after installation to make
certain that belt is centered in groove of electric clutch pulley.

9. Move lift lever toward high cut position and remove brake link from hole on lift
lever.

10. Install deflector chute on mower deck by using nuts and bolts provided.
Never operate mower without deflector chute in place.

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. Inflate tires as required:

B. Remove the discharge chute from the mower deck. Rotate or turn each outer

blade tip to align with the edge of the deck or side to side.

C. Measure from the surface up to the bottom of the blade tip on the discharge side

of the mower deck. Retain this measurement. Move to the opposite side and check
that measurement is the same. If adjustment is required, turn the nut on the
bottom of the front threaded adjuster up or down until both side to side
measurements are equal. Retain measurement.

Front - (40 - 46 Ibs. maximum)
Rear - (20 - 24 Ibs. maximum)

NOTE:

D. Rotate or turn both outer blades to align with the deck in a front to rear

manner. Move to the left rear threaded adjuster, "left rear is designated from
operator position on the mower". Turn adjuster nut up or down until rear of
mower deck is positioned level to l/8th of an inch higher than the side to side
measurement. At this time, the mower deck will hang or be suspended on (3)
points. Move the right rear adjuster and take out the slack which will be
present by turning adjuster lock nut up. Confirm the measurement used on the
left rear of the deck. Re-install discharge chute.

This will place the mower deck in a base measurement position. Additional
adjustment may be required to achieve desired cut for the type of grass or
conditions being mowed.

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. Observe proper battery polarity when re-connecting leads on chassis. Aiwcy
positive lead first.

Engine Service:

1

; connect

1. Final preparation of engine should be completed using engine service manual
provided with mower.

Initial Start and Hydrostat Transmission Check:

1. Final hydrostat checks have been performed at the factory, however, it is
necessary to check that the pressure relief bypass on each hydrostatic
transmission is completely released before attempting to drive mower.

2. Each hydrostat has a bypass relief pin located at the rear of each hydrostatic
unit. A bypass keeper is provided to allow the mower to be rolled around without
complete servicing of the unit. To accomplish this, the bypass keeper must be
positioned to depress the bypass relief pin. After the use of bypass keeper, each
must be removed from the bypass relief pin before the unit can be operated.

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.

PARKING BRAKE:

The parking brake used on the Model 503 is designed to hold the mower from moving
and is not intended for use in stopping the mower while it is in motion. An
additional safety feature of the parking brake is that the engine cannot be started
unless the brake is applied.

THE HYDROSTATIC DRIVE SYSTEM:

Allows the mower to turn on its own axis (zero radius). Each lever controls one
side of the mower. The pressure required to operate the mower is very light and
a minimum of 1/2 hour should be spent simply driving the mower in a non-mowing
application to gain the confidence necessary to mow like a pro.

LEVER MOVEMENTS:

No shifting or clutching required.

TO GO FORWARD:

Release parking brake. From neutral position, gently push both drive levers
forward; to increase speed, move levers farther forward.

TO GO BACKWARD:

From neutral position, gently pull both drive levers toward you.

TURNING:

Turning is controlled by moving one drive lever slightly forward or rearward of the
other. To turn left, move left lever rearward of right lever. To turn "square
corners" move lever of desired direction to neutral. To turn on mower's own axis
(zero radius) reduce speed and move one lever to reverse position and the other to
forward position.

BRAKING:

To brake mower, move both levers in direction opposite of travel, release
levers to neutral, set parking brake. When stopping on incline, it may be
necessary to hold slight pressure on levers in direction opposite of slope
until parking brake is set.

GROUND SPEED:

Ground speed (controlled by movement of hand levers) must be carefully
controlled for safety and best mowing results. Never operate at high speed in
unfamiliar areas or on slopes.

CHOKE CONTROL LEVER:

"Used to start a cold engine. (Engine has not been operated for a length of time.
Located on control panel to operators right.

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. Seven positions of adjustment in
which the very top, or highest notch, is used for transporting the mower in a non­mowing situation. Located in front of operator on the right side of mower.

BLADE DRIVE:

To engage the mower deck cutter blades, lift switch up lightly and push
forward. To disengage blades, pull switch backward. Switch is clearly
marked "on and off".

LIGHT SWITCH:

The headlights are activated by pushing the switch forward. Failure to turn off the
lights, once the engine is stopped, will result in rapid discharge of the battery.

FUSE BLOCK:

Protection of the electrical system is by (1) 15 AMP fuse. To remove the fuse for
inspection, just simply lift upon fuse block lid. If fuse burns quickly, please
consult your dealer for inspection and repair. Never attempt to bypass the fuse by
any method.

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.

NOTE:

;,\

The disassembly and repair of the Sundstrand BDU 10 L hydrostatic transmissions is
best left to a qualified Sundstrand repair and service facility. These repair
centers are equipped with the necessary tools and service information to accurately
perform all service required. Due to the precision nature of these transmissions,
field repairs cannot be recommended.

MAINTENANCE SCHEDULE:

To insure a long and trouble free service life on all the components used on
the Model 503 a regular and thorough maintenance schedule should be followed.
As with any type of precision made equipment, a certain amount of initial
bedding in or seating of the components will take place. The following items
should be checked after the first (10) hours of operation and on a weekly basis,
or each (40) hours of use:

1. Drive system, belts and controls.

2. Mower deck belts

3. Tire pressures.

4. Hydrostat oil.

5. Tightness of all nuts and bolts.

Refer to engine service manual provided with your mower for maintenance schedules and
procedures to be used on the engine.

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. Stand in front of 'he mower, grasp
lift quadrant lever with left hand. Move lever to align with the (5th) hole
from the bottom on the quadrant plate. At this time, connect brake link into
hole on lift lever. Move lift lever toward lowest cut position and remove
belt from the top of center deck hub assembly,

2. Remove the hair pin cotters from the ends of the deck support rods Slide deck
support rods from deck while supporting deck assembly whh a suitable brace,
or by the use of an assistant to hold the deck while rods are removed. Slide
deck from under chassis.

3. Reverse procedure to re-install deck assembly.

CUTTER BLADE REMOVAL:

1. Carefully place deck assembly in a manner which will allow access to the blade
bolts. Hold blade from turning while bolt is removed from the center of each hub
assembly. "Caution" wear heavy, thick gloves when holding onto cutter blade,
avoid the sharp edge of the blade.

2. When re-assembling blades to hub assemblies, fully tighten blade bolts to
a minimum of (35 ft. lbs.) torque. The use of air impact tools is recommended for
installation to insure bolt tightness.

BELT TENSION:

1. The engine to mower deck drive belt on the Model 503 is automatically held in

proper tension by springs which push the deck assembly forward, and does not
require any additional adjustment to be made. Both the belt and the idler
system should be periodically inspected due to the nature of the job they
perform.

2. Serpentine deck belt tension is maintained by a manual adjustment rod
which is located on the top of the mower deck assembly. Proper belt

:

tension is critical to insure cut quality. If adjustment is required,
tighten lock nut on adjustment rod until belt free play or movement
between pulleys is approximately 1/4 of an inch.

(1) FORWARD LEVER STOP

Page 18

ADJUSTMENT

Page. 19

CARE AND MAINTENANCE - MODEL 503

LUBRICATION:

CHASSIS AND MOWER DECK: Number of grease zerks used (2)

LOCATIONS: (1) each front wheel caster

SERVICE INTERVALS: Every (50) hour? of operation

RECOMMENDED GREASE: 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.

Using a hand pressure grease gun, lubricate each front caster to allow even
distribution of grease within the caster, rotate or spin each front wheel caster
after (3) pumps of the grease gun. Repeat process until the appearance of grease is
noted completely around each caster.

ENGINE OIL CHANGES: "Refer to separate owners manual furnished by

OIL RECOMMENDATIONS: the engine manufacturer."

SERVICE INTERVALS:

Please dispose of used oils at proper collection centers. Protect your environment.

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. Avoid directing water pressure onto the mower deck

hub assemblies, electrical wiring and engine components such as air filter openings.

To remove excess water which accumulated during washing of the mower, either blow off

with compressed air, if available, or start the engine, allowing a long enough

operation time to dry thoroughly. It is advisable to engage the mower deck for

a short time to disperse all water from pulleys and belts.

Please help protect the environment by avoiding all chemicals which may damage or cause

harm to plants and animals in your area.

Page 21

TROUBLE SHOOTING

manual

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. Your Dixon ZTR Dealer is also available to
provide assistance to you.

SITUATION

Poor cut quality

Poor cut quality

Poor cut quality

Poor cut quality

CAUSES

Ground speed

Loose belts

Engine RPM too low

Dull or bent blades

REMEDY

Reduce mowing speed

Adjust per operators
manual

Increase engine RPM to
maximum

Sharpen or replace as
required

Poor cut quality

Poor cut quality

Poor cut quality

Poor cut quality

Unlevel mower deck

Grass build-up under
mower deck

Improper blades

Uneven tire pressures

Adjust per operators
manual

Clean out underside of
mower deck

Replace with original
equipment blades which
are designed for the
Model 501

Check and adjust as
required per operators

Page 22

TROUBLE SHOOTING

Drive System:

SITUATION

Mower pulls to one side

CAUSES

Drive adjustment

or the other

Loss of drive power on one

T-Box belts slipping

side or the other

Loss of power on both
wheels after being
operated for a length of

Belt from engine to T-Box
1s slipping

time

Poor driving
performance

Operation of mower

Oil leaks

Loose or missing hose
clamps

REMEDY

Adjust per operators manual

Consult your dealer for
repair

Adjust per operators manual
Consult your dealer for

repair

Adjust per operators manual
Consult your dealer for

repair

Review operators section of
owners manual

Tighten or replace as
required

Page 23

TROUBLE SHOOTING

ELECTRICAL SYSTEM:

SITUATION

Starter will not turn
engine over

Starter will not turn
engine over

Battery discharge

Battery discharge

Battery discharge

Electric clutch will
not engage mower deck
blades

Head lights do not
operate

CAUSE

Blown fuse

Dead battery

Poor connections on
battery

Battery water low
Wrong battery Installed 1n

mower

Engine electrical system
not functioning correctly

Engine being operated at
too low an RPM

Low battery condition
Poor connections on clutch

switch
Broken wiring

Poor connection on lights
Broken wiring Bad bulb

REMEDY

Inspect and replace fuse
If fuse continues to

burn consult your
dealer for repair

Charge battery

Tighten or replace as
required

Have electrical
system checked by
your dealer

Increase engine RPM
Consult your dealer

for information
Repair or replace as

required
Consult your dealer

for repair

Repair or replace as
required

Note:

Electrical system failures are generally simple 1n nature, always check the
obvious first and then move onto the more complicated parts used. Poor battery
service, loose connections, corrosion, frayed or broken wiring, are more likely
than component failure.

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 Parts List

Page 3C

1300 Belt

1384 Tank Mount Bracket (Short)

1385 Tank Mount Bracket (Long)
1469 LH Slide Angle

1470 RH Slide Angle

1471 Seat Slide

1627 3/8" Pipe Elbow

1657 Spring - Belt Idler
1668 Drive Pulley
1675 Clutch Anchor
1682 L-Rod
1701 Wheel/Deck Hub Bearing

1714 T-Box Drive Belt
1715 Rear Wheel & Tire
1732 Pulley - T-Box
1733 Pulley - T-Box
1734 Pulley Hydrostat
1739 Hydrostat Idler Bracket
1743 Hydrostat .Flat Idler Pulley HD
1745 Pulley

1752 Plastic Idler
1763 Tie Down w/Insulator
1765 V-Belt

1801 Seat Strap

2128 Sleeve
2164 Support Sprocket Spacer
2173 Bushing

2928 3/16" X 1" Key
3002 5/16" - 18 X 2i HH Bolt Gr 8
3003 5/16" - 18 UNC X Ij" HH Bolt Gr 5
3005 5/16" - 18 UNC Hex Nut

3006 5/16" - 18 X U" HH Bolt Gr 5

3008 ¼ " ID X 3/4" OD Flat Washer

3009 5/16" - 18 UNC X 1-3/4" HH Bolt Gr 8
3012 3/8" - 16 UNC Hex Nut
3014 l/4"-20 UNC X 3/4" HH Bolt Gr 5

3019 5/16" Helical Lock Washer

3020 5/16" STd Flat Washer

3023 1/4" Helical Lock Washer

3029 Front Grommet
3031 5/16"-18 UNC Acorn Nut

3033 1/2" SAE Flat Washer

3048 3/8"-16 UNC X 1J" HH Bolt

3052 3/32" Dia X 1" Cotter Pin
3056 5/16" Fender Washer
3057 3/8" Std Flat Washer

3061 5/16"-18 UNC X 3/8" Soc Set Screw

3066 3/16" Std Flat Washer
3072 1/8" X 1-3/4" Hair Pin Cotter
3074 5/16"-24 UNF Hex Jam Nut
3081 #6-32 UNC Hex Nut

3082 #6 Lock Washer

3087 5/16"-18 UNC X 3/4" HH Bolt Gr 5

3088 l/4"-20 X 1" HH Bolt Gr 5
3091 l/2"-20 UNF Hex Lug Nut
3093 5/16"-18 UNC X 1" HH Bolt Gr 5
3101 7/16" Helical Lock Washer
3106 1/4" X 1" Spirol Pin
3130 1/2" Contact Bellville Spring
3133 #832 X 1/2" TR 3 Screw

3140 1/4" ID Disc Spring
3145 Washer .170 I.D.
3161 5/16"-24 UNF Nut LH Thread
3163 1/2 " Int Tooth Lock Washer

3169 3/8"-16 X 1" HH Bolt Gr 5
3175 l/2"-13 X 1-1/2" HH Bolt
3178 3/8"-16 X 2-1/2" HH Bolt Gr 5

3182 Flip Lock Bushing
3184 5/16"-18 X 1-1/4" Pan Hd Phillips Screw
3186 #12-14 X 1" Drill & Tap Screw
3193 Washer .43 X 1.38 X .25
3195 Face Nut l/2"-27

3196 Face Nut 7/16"-28

3203 3/8" ID Flat Washer (Narrow)

3204 l/4"-20 Hex Nut w/Nylok

3205 5/16"-18 Hex Nut w/Nylok

3206 3/8"-16 Hex Nut w/Nylok

3208 #10-24 Hex Nut w/Nylok

3220 7/16"-20 X 2-3/4" HH Bolt Gr 5
3224 5/16:-18 X 1" HH Bolt w/Nylok Gr 5
3225 3/8"-16 X 2-1/4" HH Bolt
3228 5/8"-ll X 6-1/4" Carriage Bolt

3231 9/16" Std Flat Washer
3235 #10-24 X 5/8" Phillips Pan Hd Screw
3237 Eye Bolt 5/16" X 6.00

3243 5/16"-18 X 3-1/4" HH Bolt Gr 5

3245 3/8"-16 Thin Prof Nylok Nut
3247 #6-20 X 1/2" Phillips Pan Hd Screw
3248 5/16" ID X 1/8" Thick Washer

3257 7/16" Int Tooth Lock Washer

3260 l/4"-20 X 1/2" HH Bolt Gr 5

3263 5/8"-ll Thin Profile Nylok Nut
3264 5/16" Disc Spring HD

3265 #10-24 X 3/4" Truss Hd Phillips Screw

3266 1/4" Int Tooth Lock Washer

3267 5/16"-18 X 1-3/8" HH Bolt Gr 5
3268 3/8"-24 X 1-1/4" HH Bolt Gr 8 x/Nylok
3269 5/16"-18 X 1" Soc HB

3271 1"-14 Thin Prof Nylok Nut
3272 5/16" Int Tooth Lock Washer
3273 8-18 X 3/8" Phil Pan HD
3274 #6-32 X 1/2" Truss Hd Ph Screw

3281 Clip

3297 l/2"-13 Thin Prof Nylok

3298 Washer .515 X .874 X .031

3300 Foam Pad
3301 Foam Pad 1/8" X 1" X 4"

3310 5/16"-18 Thin Prof Nyl
3318 3/8"-16 X 2-1/4" HH Bolt Gr 8
3319 Idler Shock Mount
3321 5/16"-18 X 8" HHB Gr 8
3322 5/16"-18 X 5-1/2" HHB Gr 8
3323 5/16"-18 X 1-1/2" HHB Gr 8

3325 3/8"-16 X 3-1/2" HHB Gr 8
3326 3/8"-16 X 4 HHB Gr 8
3331 M6 X PI X 8MM HHB Gr 8.8

3334 l/4"-20 Thin Prof Nyl

3336 9/16" Int Tooth Lock Washer
3337 Retaining Ring

3338 M8 X 1.25 P Tap Screw

ZTR 503 Parts List

Page 31

3339 Snap Ring - 5/8"

3343 Hub Bolt-Drilled

3344 Grease Zerk

3347 Washer-1.033 X 1.5 X .06
3348 5/16-18 X 3/4" Tap Screw

3349 #806 Woodruff Key
3403 Bushing
3511 Adhesive Bumper Pad

3521 Engaging Cam Mount Bushing

3531 Decal - OPERATING INSTRUCTIONS

3536 Decal - DANGER
3554 Fuel Cap/Gauge

3585 Decal - CUTTING HEIGHT

3589 Spacer (Electric Clutch)

3590 Key 1/4" Sq X 1/2"

3600 Rebound Mount

3601 Load Mount

3602 Spacer Tube

3603 ISO Mount Insert

3617 Decal - DIXON

3635 Tee-Fuel Line

3646 Fuel Line 20"

3649 Fuel Line Clamp

3653 Floor Pad Left Front

3654 Floor Pad Right Front

3655 Floor Pad Left Rear

3656 Floor Pad Right Rear

3669 Decal - CAUTION

3675 Fuel Line Clamp
3695 J-Bolt
3702 Pulley
3705 Velcro Strip - Hook
3706 Velcro Strip - Latch
3710 Handle Grip
3711 Hour Meter
3712 Handle Grip

3713 Foam Tube
3715 End Cap
3717 3/8" Hose Clamp
3718 5/8" Hose Clamp
3720 Tie Wrap
3721 Decal - DANGER

3723 Decal - RESERVOIR

3729 Handle Grip
3731 Control Panel

3746 Decal - PARKING BRAKE
3747 Deflector Spring

3772 By-Pass Keeper

3773 Left Rod End
3774 Right Rod End

3797 Fuel Tank - Plastic
3813 Protective Cap
3838 Muffler
3840 1/4" Hose - 21"
3844 Decal - HYDRO GEAR
3847 Ignition Nut
3848 Cap Nut
3852 Spring
3876 Caster Spring
3878 Caster Plug

3887 Chrome Lug Nut

3889 Drive Pulley 1.13 Bore
3890 Bearing
3896 Hub Cover
3897 Decal - DIXON
3898 Clutch Spacer - 503
4013 Wire Tie
4075 15 Amp Fuse
4146 Nylon Washer
4198 Blade Drive Clutch Switch

4199 Light Switch
4201 Switch Key

4217 Battery
4242 Deck Switch
4256 Utility Box, Plastic
4274 Choke Control
4276 Headlight Assembly
4384 Relay
4446 Wire Cover 36"
4453 Access Cover Assembly
4467 Fuse Holder
4582 Battery Cable
4585 Battery Ground Cable
4587 Wire Cover
4589 Covered Key

4594 Wire Cover 14"
4605 Model Decal - 503
4687 Battery Cover Assembly
4701 Michigan Seat 50"

5070 3/16" Sq X .88 Key

5085 Brake Band
5087 Spacer 3/8" X 1/2"
5101 Brake Link
5170 Spring

5189 Bushing
5257 Brake Drum
5283 Link *
5500 T-Box
5501 Mount Plate
5502 Mount Shim

5503 T-Box Guide Left

5504 T-Box Guide Right
5515 Idler Cable
5522 Brake Link Right
5525 Brake Link Left
5530 Control Pivot Shaft
5531 Adjustable BUshing

5537 Control Arm

5540 Control Tube

5550 Hydrostat

5551 Hydrostat

5558 Hose Fitting

5560 Elbow - Male
5561 Adapter - Male (For 3/8" ID Hose)
5562 Adapter - Male (For 5/8" ID Hose)
5563 Tee
5564 Filter Head

5565 Oil Filter
5585 Tab
5595 Hose 5/8" X 14"
5602 Hose Guard Spring
5615 Connector/Elbow Assembly

ZTR 503 Parts List

Page 32

5623 Electric Clutch
5624 Tank Cap

5625 Gearbox

5627 Left Fan
5628 Right Fan
5631 3/8" Hose - 21"
5632 3/8" Hose - 5"
5633 5/8" Hose - 2"

5635 Reservoir Assembly
5636 Brass Ferrule
6075 Engine Idler Spacer
6100 Outer Shaft Key
6101 Center Shaft Key
6111 Deck Drive Belt

6113 Blade Washer

6168 Trash Guard
6257 Blade Washer
6744 Spring
7034 Belt Keeper
8172 Frame - 503
8175 Upper Body Assembly - 503
8176 Lower Body Assembly - 503

8177 Caster Tire - 50"
8178 Caster Rim - 50"
8179 Caster Bearing - 50"
8180 Bearing Retainer 50"
8328 Greasable Shaft 9225
8573 Headlight Socket Assembly

8576 Rear Wheel
8577 Rear Tire
9017 Seat Frame
9023 Engine Mount - Fwd
9024 Engine Mount - Rear
9031 Lift Tube
9035 Lift Frame
9049 Lift Bushing Bracket
9055 Lift Cam Left
9056 Lift Cam Right
9057 Front Lift Rod
9065 Lift Handle
9066 Lift Shaft
9067 Control Rod

9076 Seat Frame Cable

9082 Seat Frame Pivot Rod
9098 Hanger Rod
9110 Tank Cover
9142 Rear Lift Rod
9156 Right Swivel Plate
9157 Left Seivel Plate
9158 Control Lever w/Grip Left
9159 Control Lever w/Grip Right
9164 Brake Plate

9165 Brake Plate

9168 Brake Shaft
9171 Spacer 1.75
9172 Spacer 1.50
9174 Brake Rod
9175 Spring Anchor
9179 Brake Lever

9191 Connecting Link
9192 Tie Bar
9195 Tie Bar
9196 Plate
9212 Spring (Belt Tensioner)
9219 Deck Hub
9224 Outer Shaft
9228 Deck Hub Bearing Spacer
9242 Pulley Guard
9254 Lift Plate

9261 Deflector Tab

9262 Rod 5/16" X 10

9264 Deflector Sub Assembly
9265 Mower Blade Hi-Lift
9273 Mower Deck

9276 Idler Arm
9280 Engine Plate
9298 Caster Tube Assembly
9309 Caster Axle LH
9310 Caster Axle RH
9312 Bumper Weldment

9315 Caster Wheel & Tire