Dixon Ram Ultra 27 manual

Operator ’ s Manual Ram Ultra 50, 25 KOH / 968999722 Ram Ultra 60, 25 KOH / 968999723 Ram Ultra 72, 27 KOH / 968999724 Ram Ultra 50, 25 KOH BF / 968999725 Ram Ultra 60, 25 KOH BF / 968999726 Ram Ultra 72, 27 KOH BF / 968999773 Please read the operator ’s manual carefully and make sure you understand the instructions before using the machine.[...]

©2008 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A.[...]

CONTENTS English - 3 INTRODUCTION ............................................................... 5 General ....................................................................... 5 Driving and T ransport on Public Roads ...................... 5 T owing......................................................................... 5 Operating ...........[...]

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[...]

INTRODUCTION Dixon- 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 control panel easily accessible to the operator and a hydrostatic transmission regulated by steering controls both contribute to the machine’s performance. This manual is a v[...]

INTRODUCTION 6 -Dixon Good Service Dixon’s products are sold all over the world and only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer . See the certica[...]

SYMBOLS AND DECALS Dixon- 7 These symbols are found on the machine and in the operator ’s manual. Study them carefully so that you know what they mean. Used in this publication to notify the reader of a risk of personal injury or death , particularly if the reader should neglect to follow instructions given in the manual. Used in this publication[...]

SYMBOLS AND DECALS 8 -Dixon Read Shut off engine and Keep a safe Use on slopes No passengers Operator ’s remove key before distance from no greater Manual performing 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 toes remove safety watch for oth[...]

SAFETY Dixon- 9 Safety Instructions These instructions are for your safety . Read them carefully . IMPORT ANT : THIS CUTTING MACHINE IS CAP ABLE OF AMPUT A TING HANDS AND FEET AND THROWING OBJECTS. F AILURE T O OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESUL T IN SERIOUS INJURY OR DEA TH. General Operation Read, understand, and follow all ins[...]

SAFETY 10 -Dixon W ARNING! Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer , birth defects, or other reproductive system damage. The engine exhaust contains carbon monoxide, which is a odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces. 801 1-520 Never take passengers Ope[...]

SAFETY Dixon- 11 W ARNING! When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. Ask your retailer for help in choosing the right equipment. Personal Safety Equipment [...]

SAFETY 12 -Dixon 801 1-509 Be extra cautious when driving on slopes 801 1-517 Never allow children to operate the machine 801 1-518 Keep children away from work area Do not use on steep slopes. • Do not try to stabilize the machine by putting • your foot on the ground. Do not mow near drop-offs, ditches, or • embankments. The machine could su[...]

SAFETY Dixon- 13 Safe Handling of Gasoline T o avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely ammable and the vapors are explosive. Extinguish all cigarettes, cigars, pipes, and • other sources of ignition. Use only approved gasoline container . • Never remove gas cap or add fuel with t[...]

SAFETY 14 -Dixon 801 1-515 Never drive the machine in an enclosed space W ARNING! The battery contains lead and lead compounds, chemicals that are considered to cause cancer , birth defects, and other reproductive system damage. W ash your hands after handling the battery . Use protective glasses for maintenance work. General Maintenance Never oper[...]

SAFETY Dixon- 15 Ensure that nuts and bolts, especially the • fastening bolts for the blade attachments, are properly tightened, torqued and that the equipment is in good condition. Do not modify safety equipment. Check • regularly to be sure it works properly . The machine must not be driven with defective or unmounted protective plates, prote[...]

SAFETY 16 -Dixon W ARNING! Escaping hydraulic oil under pressure can have sufcient force to penetrate the skin, causing serious injury . If injured by escaping uid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately . IMPORT ANT INFORMA TION The parking brake is not suf?[...]

SAFETY Dixon- 17 Roll over Protection system (ROPS) The ROPS increases the basic weight of the unit by 42 lbs/19 kg. The ROPS is an accessory . Do not use ROPS as a lifting, attaching or • anchoring point. Do not use ROPS for wrecking or towing. • Do not exceed Max GVW: 2822 lbs/1283 kg. • Read machine operator´s manual before • each use. [...]

CONTROLS 18 -Dixon This operator ’s manual describes the Dixon Zero T urn Rider . The rider is tted with a Kohler four- stroke overhead valve engine developing 25-27 horse power*. T H R O T T L E C H O K E O F F B L A D E S Control Locations Motion control levers 1. Parking brake 2. Throttle control 3. Blade switch 4. Ignition switch 5. Choke [...]

CONTROLS Dixon- 19 801 1-789 Steering controls W ARNING! The machine can turn very rapidly if one steering control is moved much further forward than the other . Steering Control Levers The machine’s speed and direction are continuously variable using the two steering controls. The steering controls can be moved forward or backward about a neutra[...]

CONTROLS 20 -Dixon Parking Brake 8061-019 Parking brake not activated IMPORT ANT INFORMA TION The machine must stand absolutely still when applying the parking brake. Always set the parking brake before dismounting. Release the parking brake before moving the mower . Blade Switch In order to engage the mower deck, pull the knob out; the mower blade[...]

CONTROLS Dixon- 21 Ignition Switch The ignition key is placed on the control panel and is used to start and stop the engine. Fuses Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They are at pin fuses of the same type used in automobiles. There are two fuses with ratings and functions: 20 A,[...]

CONTROLS 22 -Dixon Fuel T ank Read the safety instructions before refueling. 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 properly tightened and the cap gasket is not damaged. The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally [...]

CONTROLS Dixon- 23 Fuel Shut Off V alve The fuel shut off valve is located at the left rear of the seat. The valve is of f when the handle tab is turned perpendicular to the fuel line. 801 1-419 Fuel shut off valve in the CLOSED position Cutting Height Adjuster The deck cutting height is obtained by pressing the foot pedal forward to lift the deck.[...]

CONTROLS 24 -Dixon 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. 801 1-441 Lengthways adjustment Hour Meter The hour meter displays the total operating time[...]

OPERA TION Dixon- 25 Read “Safety Instructions” section and following pages, if you are unfamiliar with the machine. T raining Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be reviewed in its entirety prior to attempting to move the mower under its o[...]

OPERA TION 26 -Dixon 8061-019 Parking brake not activated Before Starting Read the sections Safety Instructions and • Controls before starting the machine. Perform 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 the desir[...]

OPERA TION Dixon- 27 Move the steering controls outward to the locked (outer) neutral position. Move the throttle to the middle position. 8061-001 Set the throttle 8061-012 Place controls in neutral position If the engine is cold, the choke lever should be pushed to the ON position. 8061-004 Set the choke control W ARNING! Engine exhaust and certai[...]

OPERA TION 28 -Dixon 801 1-642 Jumper cable connection W ARNING! Lead-acid batteries generate explosive gases. Keep sparks, ame and smoking materials away from batteries. Always wear eye protection when around batteries. IMPORT ANT INFORMA TION Y our mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-v[...]

OPERA TION Dixon- 29 THROTTLE CHOKE ON OF F BLADE S Running Release the parking brake by moving the 1. lever 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 brake will shut off the engine. Move the steering controls t[...]

OPERA TION 30 -Dixon Operating On Hills Read the Safety Instructions “Driving on Slopes” in the “Safety Instructions”. The slowest speed possible should be used • before starting up or down hills. Avoid stopping or changing speed on hills. • If stopping is absolutely necessary , pull drive • levers into the neutral position and push t[...]

OPERA TION Dixon- 31 W ARNING! Clear the lawn of stones and other objects that can be thrown out by the blades. W ARNING! Never drive the rider on terrain that slopes more than 10 degrees. Mow slopes up and down, never side to side. Avoid sudden directional changes. Mowing pattern 801 1-603 Mowing Tips Observe and ag rocks and other xed • o[...]

OPERA TION 32 -Dixon IMPORT ANT INFORMA TION Leaving the ignition switch in any other position than “OFF” will cause the battery to be discharged and the hour meter to accumulate hours. 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. Avoid idli[...]

OPERA TION Dixon- 33 English - 33 Moving by Hand IMPORT ANT INFORMA TION Tighten the valve moderately . Do not overtighten the valve when closing. That can damage the valve seat. 801 1-507 Pump release valve Pump release valves Pump release valves are located at the front and rear of the pump. They are used to release the system so the machine may [...]

MAINTENANCE 34 -Dixon Maintenance Schedule The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible conditio[...]

MAINTENANCE Dixon- 35 Maintenance Before After Daily W eekly At least once each year Maintenance interval in hours 25 50 100 300 Check/adjust throttle and choke cables Check the condition of belts, belt pulleys Change the engine oil 1) Replace the engine oil lter Clean/replace the spark plugs Replace the fuel lter Replace the air lter (pap[...]

MAINTENANCE 36 -Dixon Battery Y our mower is equipped with a maintenance free battery and does not need servicing. However , periodic charging of the battery with an automotive type battery charger will extend its life. • Keep battery and terminals clean. • Keep battery bolts tight. • Recharge at 6-10 amperes for 1 hour T o clean bat[...]

MAINTENANCE Dixon- 37 Ignition System The engine is equipped with an electronic ignition system. Only the spark plugs require maintenance. For recommended spark plugs, see T echnical Data. 1. Remove the ignition cable boot and clean around the spark plug. 2. Remove the spark plug with a spark plug socket wrench. 3. Check the spark plug. Replace the[...]

MAINTENANCE 38 -Dixon Engine Cooling Air Intake Check that the engine’s cooling air intake is free from leaves, grass, and dirt. If the cooling air intake is clogged, engine cooling deteriorates, which can lead to engine damage. The cooling air intakes rotates when the engine is running. Mind your ngers. Throttle Cable Check that the engine re[...]

MAINTENANCE Dixon- 39 Replacing Air Filter The engine is equipped with a replaceable, high density paper air cleaner element and an oiled, foam precleaner which surrounds the paper element. Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also chec[...]

MAINTENANCE 40 -Dixon Fuel Filter Replace the line-mounted fuel lter every 100 hours (once per season) or more regularly if it is clogged. Replace the lter as follows: 1. Move the hose clamps away from the lter . Use at-nosed pliers. 2. Pull the lter loose from the hose ends. 3. Push the new lter into the hose ends. Position the ?[...]

MAINTENANCE Dixon- 41 Parking Brake Visually check that no damage is found on the lever , cables, or switch belonging to the parking brake. Perform a standstill test and check that there is sufcient braking action. T o adjust the parking brake, contact the Dixon service workshop. W ARNING! Faulty adjustment will result in reduced braking ability[...]

MAINTENANCE 42 -Dixon Deck Belt Park on a level surface. Apply parking brake. 1. Lower the deck into the lowest cutting 2. position. Remove bolts from belt shields and remove 3. shields. Remove any dirt or grass that may have 4. accumulated around the cutter housings and entire deck surface. Carefully roll the belt over the top of the 5. cutter hou[...]

MAINTENANCE Dixon- 43 Cutting Blades In order to attain the best mowing effect, it is important that the blades are well sharpened and not damaged. W ARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. Bent or cracked blades or blades with large nicks should be replaced. Damaged blades shoul[...]

MAINTENANCE 44 -Dixon Blade replacement W ARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. • Remove blade bolt by turning counterclockwise. IMPORT ANT INFORMA TION T o ensure proper assembly , center hole in blade must align with star on cutter housing. • Install new or resharpe[...]

MAINTENANCE Dixon- 45 Adjusting the Mower Deck W ARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. 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” posit[...]

MAINTENANCE 46 -Dixon Anti-scalp rollers Anti-scalp rollers are properly adjusted when they are just slightly off 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 INFORMA TION Adjust ant[...]

MAINTENANCE Dixon- 47 Cleaning and W ashing Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span. Make it a habit to clean the machine directly after use (after it is cooled), before the dirt sticks. Do not spray water on the top of the mower deck. Use compressed air to clean the top side of mower d[...]

LUBRICA TION 48 -Dixon 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 weekly . 12/12[...]

LUBRICA TION Dixon- 49 Lubricating the Cables If possible, grease both ends of the cables and move the controls to end stop positions when lubricating. Ret the rubber covers on the cables after lubrication. Cables with sheaths will bind if they are not lubricated regularly . If a cable binds, it can disrupt operation. If a cable binds, remove th[...]

LUBRICA TION 50 -Dixon IMPORT ANT INFORMA TION Used engine oil is a health hazard and must not be disposed of on the ground or in nature; it should always be disposed of at a workshop or appropriate disposal location. A void skin contact; wash with soap and water in case of spills. W ARNING! Engine oil can be very hot if it is drained directly afte[...]

LUBRICA TION Dixon- 51 Engine Oil Levels Check the oil level in the engine when the machine is standing level and the engine is stopped. Remove the dipstick, wipe it clean, and then replace it. The dipstick should be screwed into place. T ake the dipstick out again and read the oil level. The oil level should lie between the markings on the dipstic[...]

LUBRICA TION 52 -Dixon Purging Due to the effects air has on efciency in hydrostatic drive applications, it is critical that it is purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. The resulting symptoms [...]

TROUBLESHOOTING Dixon- 53 Problem Cause The engine will not start. • The blade switch is engaged. • The steering controls are not locked in the neutral position. • The driver is not sitting in the driver ’s seat. • The parking brake is not activated. • The battery is dead. • Contamination in the carburetor or fuel line. • The fuel s[...]

TROUBLESHOOTING 54 -Dixon The engine overheats. Battery not charging. • Poor contact with battery terminal cable connectors. • Charging lead is disconnected. The machine moves slowly , unevenly , or not at all. • Parking brake on. • Bypass valve on pump open. • Drive belt for the transmission slack or has come off. • Air trapped in hydr[...]

Dixon- 55 ST ORAGE Dixon- 55 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 carburetor and disrupt engine function. Fuel stabilizers are an acc[...]

SCHEMA TICS 56 -Dixon 20 AMP ELECTRIC CLUTCH ACCESSORY OUTLE T ENGINE GROUND WH T GRN WH T BL K RED/BL K RED/BL K YEL YEL BR N GRY BR N GRN GRN BR N YEL/RED BR N RIGHT MOTION CONTROL LEVER LEFT MOTION CONTROL LEVER BRAKE SWITCH SEAT SW . 1. SEAT UNOCCUPIED 2. BRAKE SWITCH IN OFF POSITION 3. MOTION CONTROL LEVERS OUT 4. PTO IN OFF POSITION SOLENOI D[...]

TECHNICAL DA T A Dixon- 57 Engine Manufacturer T ype Power Lubrication Oil capacity excluding lter Oil capacity including lter Engine oil (See viscosity diagram) Fuel Fuel tank capacity Spark plugs / gap Cooling Air lter Alternator Starter T ransmission T ransmission Speed and direction controls Speed forward Speed reverse Brakes Front cas[...]

TECHNICAL DA T A 58 -Dixon Cutting Width Cutting Height Uncut Circle Number of Blades Blade Length Nose Rollers Sprung Seat Hinged Arm Rests Hour Meter Blade Engagement Deck Construction Productivity Productivity Overall Dimensions Weight Base Machine Length Base Machine Height (ROPS up) Base Machine Height (ROPS dwn) Base Machine Width Overall Wid[...]

TECHNICAL DA T A Dixon- 59 Engine Manufacturer T ype Power Lubrication Oil capacity excluding lter Oil capacity including lter Engine oil (See viscosity diagram) Fuel Fuel tank capacity Spark plugs / gap Cooling Air lter Alternator Starter T ransmission T ransmission Speed and direction controls Speed forward Speed reverse Brakes Front cas[...]

TECHNICAL DA T A 60 -Dixon Cutting Width Cutting Height Uncut Circle Number of Blades Blade Length Nose Rollers Sprung Seat Hinged Arm Rests Hour Meter Blade Engagement Deck Construction Productivity Productivity Overall Dimensions Weight Base Machine Length Base Machine Height (ROPS up) Base Machine Height (ROPS dwn) Base Machine Width Overall Wid[...]

TECHNICAL DA T A Dixon- 61 Accessories Collection system T orque Specications Engine crankshaft bolt 50 ft/lb (67 Nm) • Deck pulley bolts 45 ft/lb (61 Nm) • Lug nuts 75 ft/lb (100 Nm) • Blade bolt 45-55 ft/lb (60-75 Nm) • Standard ¼" fasteners 9 ft/lb (12 Nm) • Standard • 5 / 16 " fasteners 18 ft/lb (25 Nm) Standard • 3 [...]

62 -Dixon CONFORMITY CER TIFICA TES USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.). Do not remove any of these labels. Certicates can also be supplied [...]

Dixon- 63 SER VICE JOURNAL Action Date, mtr reading, stamp, sign Delivery Service 1. Charge the battery . 2. Adjust the tire pressure of all wheels to 15 PSI (1 bar). 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 amount of oil is in the engine. [...]

64 -Dixon SER VICE JOURNAL After the First 5-8 Hours 1. Change engine oil. Action Date, mtr reading, stamp, sign[...]

Dixon- 65 SER VICE JOURNAL Action Date, mtr reading, stamp, sign 25-Hour Service 1. Check the engine air lter . 2. Sharpen/Replace mower blades if required. 3. Check the tire pressures. 4. Check battery with cables. 5. Lubricate according to lubrication chart. 6. Check/clean the engine’s cooling air intake. 7. Clean the air cleaner ’s pre[...]

66 -Dixon SER VICE JOURNAL Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perform 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 parking brake. 6. Change h[...]

Dixon- 67 SER VICE JOURNAL Action Date, mtr reading, stamp, sign 100-Hour Service 1. Perform the 25-hour service. 2. Perform the 50-hour service. 3. Change the engine oil lter . 4. Clean/replace the spark plugs. 5. Replace the fuel lter . 6. Check V -belts. 7. Check tighten caster wheel axle bolts (every 200 hours). 8. Change the air lter [...]

68 -Dixon SER VICE JOURNAL Action Date, mtr reading, stamp, sign 300-Hour Service 1. Perform the 25-hour service. 2. Perform the 50-hour service. 3. Perform the 100-hour service. 4. Check/adjust the mower deck. 5. Clean the combustion chamber and grind the valve seats. 6. Check the engine valve clearance. 7. Replace the air cleaner ’s prelter [...]

Dixon- 69 SER VICE JOURNAL 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 (100 hours). 6. Check[...]

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P/N 539 132404 R02 04/01/08[...]