Dixon 966985401 manual

Ram Ultra 61, 25 K OH / 966985401 Ram Ultra 61, 25 K OH BF / 966985402 Please read the operator man ual carefull y and make sur e y ou understand the instructions befor e using the machine. Operator Man ual[...]

©2009 HTC All rights reserved. Beatrice, NE. Printed in U.S.A. In order to implement improvements, specications and designs can be altered without prior notication. Note that no legal demands can be placed based on the information contained in these instructions. Use only original parts for repairs. The use of other parts voids the warranty [...]

     [...]

W ARNING! Failure to follow cautious operating practices can result in serious injury to the operator or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower . Each person operating the mower must be of sound mind and body and must not be under the in[...]

 5 Congratulations Thank you for purchasing a Dixon ride-on mower . This machine is built for superior efciency to rapidly mow primarily large areas. A contr ol panel easily accessible to the operator and a hydrostatic transmission regulated by steering contr ols both contribute to the machine’s perfor mance[...]

 6 Good Service Dixon’s products ar e sold only in specialized retail stores with complete service. This ensur es that you as a customer receive only the best support and service. Before the pr oduct is delivered, the machine has, for example, been inspected and adjusted by your retailer . See the cer ticate[...]

  7 R N These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. IMPORT ANT INFORMA TION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. Reverse Neutral Fast Slow Choke Fuel W arning! Parking Brake CE[...]

  8 Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key befor e distance fr om no greater Manual perfor ming any the machine than 10° maintenance or repair work Whole body Severing of ngers Do not open or Careful backing up, Careful going exposure to and [...]

 9 Safety Instructions These instructions are for your safety . Read them carefully . General Operation Read, understand, and follow all instructions on • the machine and in the manual before starting. Do not put hands or feet near rotating parts or • under the machine. Keep clear of the discharge opening at all times. Only al[...]

 10 Operate machine only in daylight or good articial • light. Do not operate the machine while under the • inuence of alcohol or drugs. W atch for trafc when operating near or crossing • roadways. Use extra care when loading or unloading the • machine into a trailer or truck. Always wear eye protection when opera[...]

 11 Personal Safety Equipment Make sure that you have rst aid equipment close • at hand when using the machine. Never use the machine when barefoot. • Always wear protective shoes or boots, pr eferably • with steel toe caps. Always wear approved pr otective glasses or a full • visor when assembling or driving. Always we[...]

 12 8011-517 Ne ver allo w children to operate the machine 8011-518 K eep children awa y from work area Children T ragic accidents can occur if the operator is not alert to the presence of children. Childr en are often attracted to the machine and the mowing activity . Ne v er assume that children will r emain out of the path of d[...]

 13 8011-516 Ne ver fill the fuel tank indoors Safe Handling of Gasoline T o avoid personal injur y or property damage, use extreme car e in handling gasoline. Gasoline is extremely ammable and the vapors ar e explosive. Extinguish all cigarettes, cigars, pipes, and other • sources of ignition. Use only approved gasoline con[...]

 14 8011-515 Ne ver driv e the machine in an enclosed space General Maintenance Never operate machine in a closed area. • Keep all nuts and bolts tight to be sure the • equipment is in safe working condition. Never tamper with safety devices. Check their • proper operation r egularly . Keep machine free of grass, leaves, or [...]

 15 Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, re or eye injury . Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery . Use protective goggles. • Ensure that the fuel ller c[...]

 16 IMPORT ANT INFORMA TION The parking brake is not sufcient to lock the machine in place during transport. Ensure that the machine is well fastened to the transport vehicle. Always reverse the machine onto the transport vehicle to avoid tipping it over . W ARNING! Escaping hydraulic oil under pressure can have sufcient for[...]

 17 This operator’s manual describes the Dixon Zero T ur n Rider . The rider is tted with a Kohler 25 HP* four - stroke overhead valve engine. T ransmission from the engine is made via belt-driven hydraulic pumps. Using the left and right steering controls, the ow is r egulated and thereby the direction and speed. Co[...]

 18 8050-200 Steering controls Steering Control Levers The machine’s speed and direction ar e continuously variable using the two steering controls. The steering controls can be moved forwar d or backward about a neutral position. Further more, ther e is a neutral position, which is locked if the steering controls ar e mov[...]

 19 Throttle Control The throttle contr ol regulates the engine speed and thereby the rate of r otation of the blades, assuming the blade switch is pulled out, see Engaging the Mower Deck. In order to incr ease or decrease the engine speed, the control is moved forwar d or back respectively . Avoid idling the engine for long[...]

 20 Choke Control The choke control is used for cold starts in order to provide the engine with a richer fuel mixtur e. For cold starts the control should be pushed to the ON position. W ARNING! Gasoline is highly ammable. Observe caution and ll the tank outdoors (see the safety instruction). 8061-017 Choke control Bla[...]

 21 Seat Adjustment Lever The seat can be adjusted lengthways. When making adjustments, the lever under the front edge of the seat is moved to the left (as seen by the driver in the seat), after which the seat can be moved backward or forward. 8011-441 Lengthwa ys adjustment Hour Meter The hour meter displays the total opera[...]

 22 Fuel Shut Off V alve The fuel shut off valve is located in the fuel line under the seat. Tilt seat forward for access. The fuel valve is ON when the valve is parallel to the fuel line. Rotate the valve ¼ turn clockwise to tur n fuel OFF . 8050-010 Fuel shut off valv e in the OPEN position. IMPORT ANT INFORMA TION In ord[...]

 23 Fuel T ank Read the safety instructions before r efueling. The machine has one fuel tank, just behind the seat. The tank capacity is 5.7 gallons (22 liters). Make sure the fuel cap is pr operly tightened and the cap gasket is not damaged. The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Envir[...]

  24 Read the Saf ety section and following pages, if you are unfamiliar with the machine. T raining Zero turn mowers are far mor e maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be reviewed in its entir ety prior to attempting to move the mower under its ow[...]

  25 8061-010 Activate parking brak e Before Starting Read the sections Safety Instructions and • Controls befor e star ting the machine. Perfor m the daily maintenance before starting • (see Maintenance Schedule in the Maintenance section). Check that there is sufcient fuel in the fuel tank. • Adjust the seat to[...]

  26 Move the steering controls outwar d to the locked (outer) neutral position. Move the throttle to the middle position. 8061-017 Set the throttle 8061-021 Place controls in neutral position If the engine is cold, the choke lever should be pushed to the ON position. 8061-017 Set the choke control W ARNING! Engine exhaus[...]

  27 8050-135 T ur n to ST ART position 8050-136 Release ignition to the R UN position 8050-010 Open the fuel valv e Open the fuel valve. Press in and turn the ignition key to the start position When the engine starts, immediately release the ignition key back to the run position. IMPORT ANT INFORMA TION Do not run the st[...]

  28 8011-642 Jumper cab le connection IMPORT ANT INFORMA TION Y our mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system. Do not use your mower to start other vehicles. If your battery is too weak to star t the engine, it should be recharged. (See Ba[...]

  29 W ARNING! Ensure that no one is near mower when engaging blade control lever . Running Release the parking brake by moving the lever 1. downward. NOTE: The mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without rst setting the parking b[...]

  30 W ARNING! Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes. IMPORT ANT INFORMA TION When in reverse, control levers return to neutral when released. This may cause the mower to suddenly stop. Operating On Hills Read the Safety Instructions “Driving on Slopes” in the ?[...]

  31 Mowing Tips Observe and ag rocks and other xed objects to • avoid collisions. Begin with a high cutting height and reduce it until • the desired mowing r esult is attained. The average lawn should be cut to 2½" (64 mm) during the cool season and over 3" (76 mm) during the hot months. For healthie[...]

  32 Stopping the Engine Allow the engine to idle a minute in order to attain normal operating temperature before stopping it, if it has been worked hard. A void idling the engine for longer periods, as there is a risk of the spark plugs fouling. Disengage the mower deck by despressing the • blade switch. Raise the mowe[...]

  33 Manual T ransport IMPORT ANT INFORMA TION Tighten the valve moderately . Do not overtighten the valve when closing. That can damage the valve seat. 8061-006 Pump release valv e Pump Release V alves Pump release valves ar e located at the front and rear of the pump. They are used to r elease the system so the machine [...]

 34 Maintenance Schedule The following is a list of maintenance procedur es that must be perfor med on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by Check the parking brake ● Check the engine’s oil level (every refueling) ■ Ch[...]

 35 1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, r eplace every 50 hours. 2) In dusty conditions, cleaning and replacement ar e requir ed more often. 3) For daily use, the machine should be lubricated twice weekly . 4) Perfor med by authorized service workshop. ?[...]

 36    Battery Y our mower is equipped with a maintenance free battery that does not need servicing. However , periodic charging of the battery with an automotive type battery charger will extend its life. Keep battery and ter minals clean. • Keep battery bolts tight. • Recharge at 6-10 amperes for 1 ho[...]

 37 Safety System The machine is equipped with a safety system that prevents starting or driving under the following conditions. The engine can only be started when: 1. The mower deck is disengaged. 2. The steering controls ar e in the outer , locked neutral position. 3. The driver is sitting in the driver’s seat.[...]

 38 V -belts Check every 100 hours of operation. Check for severe cracking and large nicks. NOTE: The belt will show some small cracks in normal operation. The belts are not adjustable. Replace belts if they begin to slip from wear . Deck Belt Park on a level surface. Apply parking brake. 1. Lower the deck into the [...]

 39    Cutting Blades In order to attain the best mowing ef fect, it is important that the blades are well sharpened and not damaged. Bent or cracked blades or blades with large nicks should be replaced. Damaged blades should be replaced when hitting obstacles that result in a br eakdown. Let the service wo[...]

 40 W ARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.    Blade Replacement Remove blade bolt by turning counterclockwise. 1. IMPORT ANT INFORMA TION T o ensure proper assembly , center hole in blade must align with star on cutter housing. IMPORT [...]

 41     Adjusting the Mower Deck W ARNING! Before performing any service or adjustment checklist: 1. Engage the parking brake. 2. Place the Blade switch in the disengaged position. 3. T urn ignition switch to “OFF” position and remove the key . 4. Make sure the blades and all moving parts have comple[...]

 42 Anti-Scalp Rollers Anti-scalp rollers are pr operly adjusted when they are just slightly of f of the ground when the deck is at the desired cutting height in the operating position. Anti-scalp rollers then keep the deck in the proper position to help prevent scalping in most terrain conditions. IMPORT ANT INFORM[...]

 43 2 1 3 Caster Wheels Check every 200 hours. Check that wheels rotate freely . If wheels do not rotate freely take the unit to your dealer for service. Foam lled tires or solid tir es will void the warranty . Removal and installation of caster wheel Remove nut (1) and caster bolt (2). 1. Pull the wheel out of t[...]

  44 General Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be lled with engine oil. When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulphide grease. For daily use, the machine should be lubricated twice[...]

  45 Front Wheel Mount Lubricate with a grease gun, one zerk for each wheel mount, until the grease is for ced out. Use only good quality bearing grease. Grease fr om well-known brand names (petrochemical companies, etc.) usually maintains a good quality . Front Wheel Bearings Lubricate with a grease gun, one zerk f[...]

  46 2 3 1 Purging Due to the effects air has on efciency in hydr ostatic drive applications, it is critical that it is purged from the system. These purge procedur es should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. [...]

 47 Problem Cause The engine will not start. Blade lever is engaged. • Steering controls ar e not locked in neutral • position. Driver is not sitting in driver’s seat. • Parking brake is not activated. • Battery is dead. • Contamination in carburetor or fuel line. • Fuel supply is closed or[...]

 48 Problem Cause The engine seems weak. Clogged air lter . • Fouled spark plugs. • Carburetor incorr ectly adjusted. • The engine overheats. Clogged air intake or cooling ns. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator . • Soot in the com[...]

  49 Winter Storage At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for longer than 30 days). Fuel allowed to stand for long periods of time (30 days or more) can leave sticky residues that can plug the carbur etor and disrupt engine function. Fuel stabilizers are an accep[...]

50   8053-002[...]

    51 HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specic tor que values are not given. U.S. Standard Hardware Grade SAE Grade 5 SAE Grade 8 Flangelock Screw w/Flangelock Nut Shank Size (Diameter in inches, ne or coarse thread) ft./lbs ft./lbs Nm ft./lbs Nm f[...]

    52 *The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standar d J1349/ISO1585. Mass production engines may dif fer from this value. Actual power output for the engine installed in the nal m[...]

    53 966985401, 966985402 Equipment Cutting width 61" / 155cm Cutting height 1½ - 4½" / 3.8 - 11.4 cm Number of blades 3 Blade length 21" / 43 cm Nose Rollers Y es Sprung seat Standard Hinged armrests Y es Hour Meter Standard Blade engagement Electromagnetic clutch Deck construction 11 ga[...]

54    USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requir ements. This is also applicable to special requir ements for any of the states, (Califor nia emission rules etc.). Do not remove any of these l[...]

55   DIXON WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MA TERIAL AND WORKMANSHIP FOR THE PERIODS SET FORTH BELOW . THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT OR REP AIR OF P ARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMIT A TIONS: 1. COMMERCIAL WARRANTY (use other than, or [...]

56   Action Date, mtr reading, stamp, sign Delivery Service 1. Charge battery . 2. Adjust tire pr essure of all wheels according to T echnical Data. 3. Mount the steering controls in the normal position. 4. Connect the contact box to the cable for the seat’s safety switch. 5. Check that the right amoun[...]

57   Action Date, mtr reading, stamp, sign After the First 10 Hours 1. Change engine oil. 25-Hour Service 1. Check the fuel pump’s air lter . 2. Check the hydraulic system’s oil level. 3. Check the tire pr essures. 4. Lubricate the belt adjuster , mower deck. 5. Lubricate the belt adjuster , hydra[...]

58   Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perfor m the 25-hour service. 2. Clean/replace the air cleaner’s lter cartridge (paper lter) (shorter intervals for dusty operating conditions). 3. Change engine oil. 4. Lubricate according to lubrication chart. 5. Check/adjust the par[...]

59   Action Date, mtr reading, stamp, sign At Least Once Each Y ear 1. Clean the engine’s cooling air intake (25 hours). 2. Replace the air cleaner’s pre-lter (foam) (300 hours). 3. Replace the air lter’s paper cartridge. 4. Change the engine oil (50 hours). 5. Replace the engine oil lter [...]

60   Action Date, mtr reading, stamp, sign[...]

61   Action Date, mtr reading, stamp, sign[...]

62   Action Date, mtr reading, stamp, sign[...]

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P/N 115 354727R1 01/06/10[...]