Dixon Ram Ultra 50 Operator's Manual
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Dixon Ram Ultra 50 Operator's Manual

Dixon Ram Ultra 50 Operator's Manual

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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.

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  • Page 1 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...
  • Page 2 ©2008 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A.

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION ............... 5 Safety System............37 General ............... 5 Engine Cooling Air Intake ......... 38 Driving and Transport on Public Roads ...... 5 Throttle Cable ............38 Towing................. 5 Choke Cable ............38 Operating ..............5 Air Filter ..............39 Good Service ..............
  • Page 4 WARNING! 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 influence of any mind altering substance.

  • Page 5: Introduction

    INTRODUCTION Congratulations Towing Thank you for purchasing a Dixon ride-on mower. This Do not tow this machine, it may cause damage to the machine is built for superior efficiency to rapidly mow drive system. primarily large areas. A control panel easily accessible Do not tow any trailers with this mower.

  • Page 6: Good Service

    INTRODUCTION 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.

  • Page 7: Symbols And Decals

    SyMBOlS AND DECAlS These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. WARNING! Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. 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.
  • Page 8 SyMBOlS AND DECAlS 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 fingers Do not open or Careful backing up, Careful going...

  • Page 9: Safety

    SAFETy Safety Instructions These instructions are for your safety. Read them carefully. WARNING! This symbol means that important safety instructions need to be emphasized. It concerns your safety. IMPORTANT: THIS CUTTING MACHINE IS CAPABlE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS.
  • Page 10 SAFETy • Operate machine only in daylight or good artificial light. • Do not operate the machine while under the influence of alcohol or drugs. • Watch for traffic when operating near or crossing roadways. • Use extra care when loading or unloading the machine into a trailer or truck.

  • Page 11: Personal Safety Equipment

    SAFETy Personal Safety Equipment WARNING! 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.
  • Page 12 SAFETy • 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 suddenly roll over if a wheel is over the edge or if the edge caves in.

  • Page 13: Safe Handling Of Gasoline

    SAFETy WARNING! The engine must not be started when the driver’s floor plate or any protective plate for the mower deck’s drive belt is removed. Safe Handling of Gasoline To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

  • Page 14: General Maintenance

    SAFETy 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 regularly. • Keep machine free of grass, leaves, or other debris buildup.
  • Page 15 SAFETy • 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, protective cowlings, safety switches, or other protective...

  • Page 16: Transport

    SAFETy • The blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them. • Check the parking brake’s functionality regularly. Adjust and service as necessary. • The mulch blades should only be used in familiar areas when higher quality mowing is desired.

  • Page 17: Roll Over Protection System (Rops)

    SAFETy Roll over Protection system (ROPS) WARNING! The ROPS increases the basic weight of the unit by 42 lbs/19 kg. The ROPS is an accessory. The rollover protection system's capabilities may • Do not use ROPS as a lifting, attaching or anchoring point.

  • Page 18: Controls

    CONTROlS This operator’s manual describes the Dixon Zero Transmission from the engine is made via a belt-driven Turn Rider. The rider is fitted with a Kohler four- hydraulic pumps. Using the left and right steering stroke overhead valve engine developing 25-27 horse controls, the flow is regulated and thereby the direction power*.

  • Page 19: Steering Control Levers

    CONTROlS 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 neutral position. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.

  • Page 20: Parking Brake

    CONTROlS Parking Brake IMPORTANT INFORMATION 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. The parking brake is found on the left of the machine. Pull the lever backward to activate the brake and forward to release it.

  • Page 21: Ignition Switch

    CONTROlS Ignition Switch The ignition key is placed on the control panel and is used to start and stop the engine. BLADES THROTTLE CHOKE 8061-017 Ignition switch Choke Control The choke control is used for cold starts in order to provide the engine with a richer fuel mixture.

  • Page 22: Fuel Tank

    CONTROlS Fuel Tank 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).

  • Page 23: Fuel Shut Off Valve

    CONTROlS Fuel Shut Off Valve The fuel shut off valve is located at the left rear of the seat. The valve is off when the handle tab is turned perpendicular to the fuel line. 8011-419 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.

  • Page 24: Hour Meter

    CONTROlS 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.

  • Page 25: Operation

    OPERATION Read “Safety Instructions” section and following Steering pages, if you are unfamiliar with the machine. To move forward and backward Training The direction and speed of the mower’s movements is effected by the movement of the control lever(s) Zero turn mowers are far more maneuverable than on each side of mower.

  • Page 26: Before Starting

    OPERATION 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 sufficient fuel in the fuel tank. •...
  • Page 27 OPERATION Move the steering controls outward to the locked (outer) neutral position. 8061-012 Place controls in neutral position Move the throttle to the middle position. WARNING! Engine exhaust and certain BLADES vehicle components contain or emit chemicals considered THROTTLE to cause cancer, birth defects or other reproductive system damage.

  • Page 28: Starting With A Weak Battery

    OPERATION Starting the engine with a weak battery WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. IMPORTANT INFORMATION Your mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system.

  • Page 29: Running

    OPERATION Running Release the parking brake by moving the 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 first setting the parking brake will shut off the engine.

  • Page 30: Operating On Hills

    OPERATION Operating On Hills Read the Safety Instructions “Driving on Slopes” in the “Safety Instructions”. WARNING! Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes. • The slowest speed possible should be used before starting up or down hills.

  • Page 31: Mowing Tips

    OPERATION Mowing Tips WARNING! • Observe and flag rocks and other fixed objects to avoid collisions. Clear the lawn of stones and other objects that can be thrown • Begin with a high cutting height and reduce it until the desired mowing result is attained. out by the blades.

  • Page 32: Stopping The Engine

    OPERATION 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 idling the engine for longer periods, as there is a risk of the spark plugs BLADES fouling.

  • Page 33: Moving By Hand

    OPERATION Moving by Hand IMPORTANT INFORMATION Tighten the valve moderately. Do not overtighten the valve when closing. That can damage the valve seat. 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 be moved by hand when not running.

  • Page 34: Maintenance

    MAINTENANCE 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 condition and to ensure safe operation.
  • Page 35 MAINTENANCE Daily Weekly Maintenance interval least in hours once each Maintenance Before After year 100 300 Check/adjust throttle and choke cables  Check the condition of belts, belt pulleys   Change the engine oil   Replace the engine oil filter ...

  • Page 36: Battery

    MAINTENANCE Battery your mower is equipped with a maintenance free Always use protective glasses battery and does not need servicing. However, when handling the battery. periodic charging of the battery with an automotive type battery charger will extend its life. •...

  • Page 37: Ignition System

    MAINTENANCE Ignition System IMPORTANT INFORMATION The engine is equipped with an electronic ignition Fitting the wrong spark plug type can system. Only the spark plugs require maintenance. damage the engine. For recommended spark plugs, see Technical Data. 1. Remove the ignition cable boot and clean around Inadequately tightened spark plugs can the spark plug.

  • Page 38: Engine Cooling Air Intake

    MAINTENANCE 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.

  • Page 39: Air Filter

    MAINTENANCE Air Filter If the engine seems weak or runs unevenly, the air Servicing Precleaner filter may be clogged. If running with a dirty air filter, Wash and re-oil the precleaner every 25 hours of the spark plugs can become fouled. operation (more often under extremely dusty or dirty For this reason, it is important to replace the air filter conditions).

  • Page 40: Fuel Filter

    MAINTENANCE Fuel Filter Replace the line-mounted fuel filter every 100 hours (once per season) or more regularly if it is clogged. Replace the filter as follows: 1. Move the hose clamps away from the filter. Use flat-nosed pliers. 2. Pull the filter loose from the hose ends. 3.

  • Page 41: Tire Pressures

    MAINTENANCE Tire Pressures Rear tires should have a pressure of 10 psi / 69 kPa /.7 bar. Front tires should be at 15 psi / 103 kPa / 1 bar. 8011-564 Tire pressures Parking Brake Visually check that no damage is found on the lever, cables, or switch belonging to the parking brake.

  • Page 42: Deck Belt

    MAINTENANCE Deck Belt Park on a level surface. Apply parking brake. lower the deck into the lowest cutting position. Remove bolts from belt shields and remove shields. Remove any dirt or grass that may have Belt Shields accumulated around the cutter housings and entire deck surface.

  • Page 43: Pump Belt

    MAINTENANCE Pump Belt Replacing pump belt Park the mower on a level surface. Engage the parking brake. Belt removal Remove the deck belt (see Deck Belt Removal in this section of the manual). Remove clutch stop to access the belt. Disconnect clutch wire.

  • Page 44: Blade Replacement

    MAINTENANCE Blade replacement 50" / 60" WARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. • Remove blade bolt by turning counterclockwise. IMPORTANT INFORMATION To ensure proper assembly, center hole 72" in blade must align with star on cutter 1.

  • Page 45: Adjusting The Mower Deck

    MAINTENANCE Adjusting the Mower Deck WARNING! Before performing any service or adjustment checklist: 1. Engage the parking brake. 2. Place the Blade switch in the disengaged position. 3. Turn ignition switch to “OFF” position and remove the key. 4. Make sure the blades and all moving parts have completely stopped. 5.

  • Page 46: Anti-Scalp Rollers

    MAINTENANCE 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.

  • Page 47: Cleaning And Washing

    MAINTENANCE Cleaning and Washing 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 deck.

  • Page 48: Lubrication

    lUBRICATION 8011-672-6 12/12 Every year lubricate with grease gun lubricate with oil can 1/52 Every Week Oil change level check 1/365 Every day Filter change *Change transaxles (transmission) filters. General Remove the ignition key to prevent unintentional Wipe away excess grease after lubrication. movements during lubrication.

  • Page 49: Lubricating The Cables

    lUBRICATION Lubricating the Cables If possible, grease both ends of the cables and move the controls to end stop positions when lubricating. Refit the rubber covers on the cables after lubrication. Cables with sheaths will bind if they are not lubricated regularly.

  • Page 50: Deck Outer Spindle

    lUBRICATION Deck outer spindle lubricate using a grease gun, one zerk, each side 2-3 strokes. Use only good quality bearing grease. 8011-733 Deck outer spindle (with belt shield removed) WARNING! Engine oil can be very hot if it is drained directly after stopping the engine.

  • Page 51: Changing The Engine Oil

    lUBRICATION WARNING! Engine oil can be very hot if it is drained directly after stopping the engine. Allow the engine to cool to a safe temperature first. Changing the Engine Oil The engine oil should be changed for the first time after 5-8 hours of operation.

  • Page 52: Hydraulic Pump

    lUBRICATION *Hydraulic Pump Fluid Change This transaxle is designed with an external filter for ease of maintenance. To ensure constant fluid quality levels and longer life an oil filter change interval of every 200 hours is recommended. The following procedure can be performed with the pump installed in the vehicle, and the vehicle on level ground.

  • Page 53: Troubleshooting

    TROUBlESHOOTING 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. •...
  • Page 54 TROUBlESHOOTING Cause Problem The engine overheats. • Clogged air intake or cooling fins. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator. • Too little or no oil in the engine. • Fouled spark plugs. Battery not charging. •...

  • Page 55: Storage

    STORAGE Winter Storage To ready the machine for storage: At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for Thoroughly clean the machine, especially longer than 30 days). Fuel allowed to stand for long under the mower deck.

  • Page 56: Schematics

    SCHEMATICS NOTES: 1. SEAT UNOCCUPIED 2. BRAKE SWITCH IN OFF POSITION 3. MOTION CONTROl lEVERS OUT SOlENOID 4. PTO IN OFF POSITION RED/BlK BRAKE RED/BlK SWITCH 20 AMP ENGINE PIGTAIl RIGHT MOTION CONTROl lEVER lEFT MOTION CONTROl lEVER yEl/RED HOURMETER SEAT 7.5 AMP SWITCH...

  • Page 57: Technical Data

    TECHNICAl DATA 968999722 968999723 968999726 968999726 Engine Kohler Kohler Manufacturer Courage Pro Courage Pro Type 25 hp* 25 hp* Power Pressure with oil filter Pressure with oil filter lubrication 1.6 qt / 1.7 liter 1.6 qt / 1.5 liter Oil capacity excluding filter 1.7 qt / 1.9 liter 1.7 qt / 1.6 liter Oil capacity including filter...
  • Page 58 TECHNICAl DATA 968999722 968999723 968999725 968999726 Cutting Width 52" / 127cm 60" / 152cm 1.5 - 4.5" / 3.8 - 11.4 cm 1.5 - 4.5" / 3.8 - 11.4 cm Cutting Height Uncut Circle Number of Blades 17" / 435 mm 20"...
  • Page 59 TECHNICAl DATA 968999724 968999773 Engine Kohler Manufacturer Courage Pro Type 27 hp* Power Pressure with oil filter lubrication 1.6 qt / 1.7 liter Oil capacity excluding filter 1.7 qt / 1.9 liter Oil capacity including filter 10W30, 5W30 Engine oil SG, SH, SJ (See viscosity diagram) Min 87 octane unleaded (Max...
  • Page 60 TECHNICAl DATA 968999724 968999773 Cutting Width 72" / 183cm 1.5 - 4.5" / 3.8 - 11.4 cm Cutting Height Uncut Circle Number of Blades 25" / 635 mm Blade length Nose Rollers Sprung Seat Standard Hinged Arm Rests Hour Meter Standard Blade Engagement Electromagnetic clutch...

  • Page 61: Accessories

    TECHNICAl DATA Accessories Collection system Torque Specifications • 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) •...

  • Page 62: Conformity Certificates

    CONFORMITy CERTIFICATES USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill 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. Certificates can also be supplied with the machine at delivery or written in the Engine manual.

  • Page 63: Service Journal

    SERVICE 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.
  • Page 64 SERVICE JOURNAl Action Date, mtr reading, stamp, sign After the First 5-8 Hours 1. Change engine oil. -Dixon...
  • Page 65 SERVICE JOURNAl Action Date, mtr reading, stamp, sign 25-Hour Service 1. Check the engine air filter. 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.
  • Page 66 SERVICE JOURNAl Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perform the 25-hour service. 2. Clean/replace the air cleaner’s filter cartridge (paper filter) (shorter intervals for dusty operating conditions). 3. Change engine oil. 4. lubricate according to lubrication chart. 5.
  • Page 67 SERVICE 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 filter. 4. Clean/replace the spark plugs. 5. Replace the fuel filter. 6. Check V-belts. 7. Check tighten caster wheel axle bolts (every 200 hours). 8.
  • Page 68 SERVICE 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.
  • Page 69 SERVICE JOURNAl Action Date, mtr reading, stamp, sign At Least Once Each Year 1. Clean the engine’s cooling air intake (25 hours). 2. Replace the air cleaner’s pre-filter (foam) (300 hours). 3. Replace the air filter’s paper cartridge. 4. Change the engine oil (50 hours). 5.
  • Page 72 P/N 539 132404 R02 04/01/08...

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