Dixon 968999724, Operator'S Manual

Page 1: ...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 s...

Page 2: ...2008 HTC All rights reserved Beatrice NE Printed in U S A...

Page 3: ...29 Operating On Hills 30 Mowing Tips 31 Stopping the Engine 32 Moving by Hand 33 Maintenance 34 Maintenance Schedule 34 Battery 36 Ignition System 37 Safety System 37 Engine Cooling Air Intake 38 Thr...

Page 4: ...d and body and must not be under the influence of any mind altering substance WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the Stat...

Page 5: ...d traffic regulations before transporting on public roads If the machine is transported you must always use approved fastening equipment and ensure that the machine is well anchored DO NOT operate thi...

Page 6: ...ing Number The machine s manufacturing number can be found on the printed plate affixed to the left in the engine compartment Stated on the plate from the top are The machine s type designation I D Th...

Page 7: ...al for misuse or misassembly WARNING Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx xx xxxxxxxx xxxx xxxxxx IMPORTANT INFORMATION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx xx xxxxxxxx xxxx...

Page 8: ...rom 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 exposure to and toes remove safety wa...

Page 9: ...achine is only intended for use by one person Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing Never direct discharged material toward anyone Avoi...

Page 10: ...eye protection when operating machine Data indicates that operators age 60 years and above are involved in a large percentage of riding mower related injuries These operators should evaluate their abi...

Page 11: ...e clothing that can get caught in moving parts Use ear protectors to avoid damage to hearing Slope Operation Slopes are a major factor related to loss of control and tip over accidents which can resul...

Page 12: ...ing activity Never assume that children will remain where you last saw them Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator Be alert and tu...

Page 13: ...e ground If this is not possible refuel such equipment with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or container open...

Page 14: ...eplace with manufacturer s recommended parts when necessary Mower blades are sharp Wrap the blade or wear gloves and use extra caution when servicing them Check brake operation frequently Adjust and s...

Page 15: ...otective goggles Ensure that the fuel filler cap is mounted tightly and no flammable substances are stored in an open vessel Never work with the starter circuit if there is spilled fuel Disconnect the...

Page 16: ...r debris that may have accumulated on the machine Allow the machine to cool before putting it in storage Regularly clean deck and underside of deck avoid spraying engine and electrical components with...

Page 17: ...ly no jerky turns starts or stops When mower is stopped set brakes securely and use park brake If any part of ROPS is damaged the entire ROPS must be replaced Check all bolts including seat belt for c...

Page 18: ...rol levers 1 Parking brake 2 Throttle control 3 Blade switch 4 Ignition switch 5 Choke control 6 1 2 6 10 9 8 4 5 12 7 3 11 Fuses 7 Fuel tank cap 8 Fuel shut off valve 9 Deck lift 10 Seat adjustment l...

Page 19: ...In order for example to turn right while moving forward move the right control towards the neutral position The rotation of the right wheel is reduced and the machine turns to the right Zero turn can...

Page 20: ...The throttle control regulates the engine speed and thereby the rate of rotation of the blades assuming the blade switch is pulled out see Engaging the Mower Deck In order to increase or decrease the...

Page 21: ...lat pin fuses of the same type used in automobiles There are two fuses with ratings and functions 20 A Primary fuse 7 5 A Mower deck coupling 8061 017 Ignition switch 8061 017 Choke control Choke Cont...

Page 22: ...system to cool at least two 2 minutes before refueling WARNING Fill to bottom of filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame Whe...

Page 23: ...pedal and allow it to pivot while the lift arm rotates to the rear of the unit To stop in the desired cutting position rotate the foot pedal down into the notch in the height plate The cutting height...

Page 24: ...ich the seat can be moved backward or forward 8011 441 Lengthways adjustment Hour Meter The hour meter displays the total operating time It will flash CHG OIL Change Oil at 50 hour intervals The flash...

Page 25: ...uld push mower see Moving by Hand in the Operation section to an open flat area without other people or vehicles obstacles nearby In order to move unit under its own power the operator must be in the...

Page 26: ...be fulfilled before the engine can be started The driver must be seated on the seat The blade switch for engaging the mower blades must be depressed The parking brake must be on Both steering control...

Page 27: ...e choke lever should be pushed to the ON position 8061 004 Set the choke control WARNING Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer birth defect...

Page 28: ...o weak to start the engine it should be recharged See Battery in the Maintenance Section If jumper cables are used for emergency starting follow this procedure Jumper cables Connect each end of the RE...

Page 29: ...r deck by pulling out the 5 blade switch Move throttle control to full throttle 6 The machine s speed and direction are 7 continuously variable using the two steering controls When both controls are i...

Page 30: ...to the outside of the unit and engage the parking brake To restart movement release the parking brake Pull the control levers back to the center of the mower and press forward to regain forward motion...

Page 31: ...est with a high engine speed the blades rotate rapidly and low speed the rider moves slowly If the grass is not too long and dense the driving speed can be increased without negatively affecting the m...

Page 32: ...age the mower deck by depressing the blade switch 8061 017 Disengage the mower deck and move throttle to minimum Raise the mower deck by pressing the foot pedal forward to the transport position When...

Page 33: ...t and rear of the pump They are used to release the system so the machine may be moved by hand when not running Tilt seat forward to gain access to the pump The rear bypass valve sits directly opposit...

Page 34: ...e weekly 4 Performed by authorized service workshop Described in this manual Not described in this manual Maintenance Before After Daily Weekly At least once each year Maintenance interval in hours 25...

Page 35: ...brication Schedule Check hydraulic oil at reservoir Change hydraulic oil filter 200 hours 1 First change after 5 8 hours When operating with a heavy load or at high ambient temperatures replace every...

Page 36: ...battery cable 4 Using a 7 16 wrench remove the bolts on either side of the terminal guard and lift off guard 5 Carefully remove the battery from the mower 6 Install new battery with terminals in the...

Page 37: ...plugs can cause overheating and damage the engine Tightening the spark plugs too hard can damage the threads in the cylinder head 8011 054 Measure the electrode gap Safety System The machine is equip...

Page 38: ...position 2 Check that the throttle cable is mounted in the correct hole in the lower lever see illustration 3 Push the throttle cable s outer casing as far to the right as possible and tighten the cl...

Page 39: ...urs Open the door on the blower housing 1 to access the air cleaner element and precleaner Unhook the latch and remove the precleaner 2 from the air cleaner element or remove as an assembly for servic...

Page 40: ...the hose ends Position the filter with the FLOW arrow pointing up toward the fuel pump If necessary a soap solution can be applied to the filter ends to ease mounting 4 Move the hose clamps back towar...

Page 41: ...king ability and can cause an accident 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...

Page 42: ...ated on the engine shaft Route the belt forward between the EZT 2 E Series Zeroturn Transaxles and up onto the deck Place belt around spring loaded idler pulley 3 Wrap the belt around the stationary i...

Page 43: ...rvice workshop 8011 604 Check the blades 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 1 Removal in this sect...

Page 44: ...with star on cutter housing Install new or resharpened blade with stamped GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing Install and tighten blade bolt secu...

Page 45: ...es to align front to back 4 Set the cutting height to 4 10cm 5 Measure front blade tip It should be 4 from ground If not turn locknut on top of front L bolt until measurement is achieved Check blade t...

Page 46: ...ons IMPORTANT INFORMATION Adjust anti scalp rollers with the mower on a flat level surface IMPORTANT INFORMATION The anti scalp rollers must not be used for gauge wheels or the roller and deck may be...

Page 47: ...shing Foam filled tires or solid tires will void the warranty Removal and installation of caster wheel Remove nut and caster bolt Pull the wheel out of the fork and take care of the sleeve Install in...

Page 48: ...ry year 1 52 Every Week 1 365 Every day Lubricate with grease gun Oil change Filter change Lubricate with oil can Level check Change transaxles transmission filters 8011 672 6 Wipe away excess grease...

Page 49: ...e cable it must be replaced Front Wheel Mount Lubricate with a grease gun one zerk for each wheel mount until the grease is forced out Use only good quality bearing grease Grease from well known brand...

Page 50: ...r Drain the engine oil in accordance with the work description under the heading Engine Oil Change Engine Oil Remove the oil filter If necessary use a filter remover Wipe new clean engine oil onto the...

Page 51: ...AE 30 must be used The engine holds 0 88 qt 1 0 liters of oil excluding the filter including filter 2 qt 1 9 liters 8011 500 Remove the dipstick The dipstick markings 8009 159 Changing the Engine Oil...

Page 52: ...containers and dispose of it in accordance with laws in your area Remove the cap from the pump s 5 expansion tank located on the vehicle frame Fill reservoir with SAE 10W30 oil to just 6 above the MIN...

Page 53: ...Dead battery Poor contact of the battery terminal cable connections Fuse blown Fault in the starter safety circuit See Checking the Safety System in the Maintenance Section The engine runs rough Faul...

Page 54: ...c coupling has loosened The blade switch is faulty or has come loose from the cable contact The fuse has blown Transaxle leaks oil Damaged seals housing or gaskets Air trapped in hydraulic system Clog...

Page 55: ...er outdoors and far away from open flame Never use gasoline for cleaning Use a degreaser and warm water instead To ready the machine for storage Thoroughly clean the machine especially 1 under the mow...

Page 56: ...SEAT SW 1 SEAT UNOCCUPIED 2 BRAKE SWITCH IN OFF POSITION 3 MOTION CONTROl lEVERS OUT 4 PTO IN OFF POSITION SOlENOID BlU BRN RED BlK BlK yEl yEl PUR GRN PUR WHT ENGINE PIGTAIl NOTES B S A1 A2 l M G 7 5...

Page 57: ...tane unleaded Max ethanol 10 Max MTBE 15 5 2 gallons 19 7 liters Champion RCY12YC 030 0 75 mm Air cooled Standard 12V Electric Hydraulic pump Dual levers foam gripped 8 mph 12 9 km h 4 mph 6 45 km h M...

Page 58: ...chine Width Overall Width Chute Up Overall Width Chute Down 968999722 968999725 52 127cm 1 5 4 5 3 8 11 4 cm 0 3 17 435 mm Yes Standard Yes Standard Electromagnetic clutch 11 gauge fabricated 4 0 acre...

Page 59: ...es smooth tread Rear tires turf pneumatic Tire pressure front Tire pressure rear 968999724 968999773 Kohler Courage Pro 27 hp Pressure with oil filter 1 6 qt 1 7 liter 1 7 qt 1 9 liter 10W30 5W30 SG S...

Page 60: ...ivity Overall Dimensions Weight Base Machine Length Base Machine Height ROPS up Base Machine Height ROPS dwn Base Machine Width Overall Width Chute Up Overall Width Chute Down 968999724 968999773 72 1...

Page 61: ...lb 110 Nm When this product is worn out and no longer used it should be returned to the reseller or other party for recycling In order to implement improvements specifications and designs can be alte...

Page 62: ...ements 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 Take care of...

Page 63: ...he mower deck adjustment 11 Check The safety switch for the parking brake The safety switch for the mower deck The safety switch in the seat The safety switch in the steering controls Parking brake fu...

Page 64: ...64 Dixon SERVICE JOURNAL After the First 5 8 Hours 1 Change engine oil Action Date mtr reading stamp sign...

Page 65: ...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 en...

Page 66: ...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 c...

Page 67: ...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 ho...

Page 68: ...ur 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...

Page 69: ...air cleaner s pre filter foam 300 hours 3 Replace the air filter s paper cartridge 4 Change the engine oil 50 hours 5 Replace the engine oil filter 100 hours 6 Check adjust the cutting height 7 Check...

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