Operator Manual RAM 48 CE / 966658601 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.
In order to implement improvements, specifications and designs can be altered without prior notification. 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. Do not modify or install non-standard equipment to the unit without consent from the manufacturer. Modifications to the unit may cause unsafe operations or damage the unit.
CONTENTS INTRODUCTION................................................................ 5 General........................................................................ 5 Driving and Transport on Public Roads....................... 5 Towing......................................................................... 5 Operating..................................................................... 5 Good Service............................................................... 6 Manufacturing Number..................
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.
INTRODUCTION Congratulations Towing Thank you for purchasing a Dixon ride-on mower. This machine is built for superior efficiency 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 valuable document. Read the contents carefully before using or servicing the machine. The following of instructions (use, service, maintenance, etc.
INTRODUCTION Good Service Dixon’s products are sold 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 certificate in the Service Journal in this operator’s manual. When you need spare parts or support in service questions, warranty issues, etc.
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! IMPORTANT INFORMATION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. 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.
SYMBOLS AND DECALS Read Operator’s Manual Whole body exposure to thrown objects Shut off engine and remove key before performing any maintenance or repair work Severing of fingers and toes Moving sharp blades under cover 8 Keep a safe distance from the machine Do not open or remove safety shields while engine is running Use on slopes no greater than 10° No passengers Careful backing up, watch for other people Careful going forward, watch for other people
SAFETY Safety Instructions These instructions are for your safety. Read them carefully. WARNING! WARNING! THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH. This symbol means that important safety instructions need to be emphasized. It concerns your safety. General Operation • Read, understand, and follow all instructions on the machine and in the manual before starting.
SAFETY • • • • • • • • • • • • 10 Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard. 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.
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. • • • • • • • Make sure that you have first aid equipment close at hand when using the machine. Never use the machine when barefoot.
SAFETY • • Do not try to stabilize the machine by putting a 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. WARNING! CHILDREN CAN BE INJURED BY THIS EQUIPMENT. The American Academy of Pediatrics recommends that children be a minimum of 16 years of age before operating a riding lawn mower.
SAFETY Safe Handling of Gasoline WARNING! The engine and the exhaust system become very hot during operation. There is risk for burns if touched. Allow engine and exhaust system to cool before refueling. To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes, and other sources of ignition. • Use only approved gasoline container.
SAFETY General Maintenance • • • • • • • • • • • • • • • • • 14 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. Clean oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing. If the machine strikes a foreign object, stop and inspect the machine.
SAFETY Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery. WARNING! Avoid electrical sparking and its consequences by the following routines: • • • • • • • • • • • • • • • Use protective goggles.
SAFETY Transport • • • • • • • The machine is heavy and can cause serious crushing injuries. Be extra cautious when it is loaded on or unloaded from a vehicle or trailer. Use an approved trailer to transport the machine. Activate the parking brake, turn off the fuel supply, and fasten the machine with approved fastening devices, such as bands, chains, or straps, when transporting. Do not operate this machine on public roadways.
CONTROLS This operator’s manual describes the Dixon Zero Turn Rider. The rider is fitted with a Briggs & Stratton Kohler four-stroke overhead valve engine. Transmission from the engine is made via belt-driven hydraulic pumps. Using the left and right steering controls, the flow is regulated and thereby the direction and speed. Control Locations 3 4 2 5 1 5 6 7 1. 2. 3. 4. 5. 6. 7.
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. When both controls are in the neutral position (N), the machine stands still.
CONTROLS Ignition Switch The ignition switch is placed on the control panel and is used to start and stop the engine. 8058-134 Ignition switch Throttle Control The throttle control regulates the engine speed and thereby the rate of rotation of the blades. In order to increase or decrease the engine speed, the control is moved forward or back respectively. Avoid idling the engine for long periods, as there is a risk of fouling the spark plugs.
CONTROLS Hour Meter The hour meter displays the total operating time. It will flash CHG OIL (Change Oil) at 50 hour intervals. The flash duration is one hour before and one hour after the interval. The CHG OIL icon will come on and shut off automatically. The hour meter cannot be manually reset. 8058-134 Hour meter Choke Control The choke control is used for cold starts in order to provide the engine with a richer fuel mixture. For cold starts the control should be pulled out.
CONTROLS Tracking Bolts If the mower is not tracking straight, check the air pressure in both rear tires. Recommended air pressure is 15 psi (103 kPa / 1 bar) for all tires. Tracking must be checked on a flat and level concrete or blacktop surface. Rotating the tracking bolts allows fine tuning adjustments so the machine tracks straight with the steering control levers in the full forward position. Rotate the knob bolt (as viewed from the operation position) to increase the speed on the left lever.
CONTROLS Fuel Tank Read the safety instructions before refueling. The machine has one fuel tank, just behind the console. The tank capacity is 3.5 gallons (13.2 liters). Regularly check the gas cap gasket for damage and keep the cap properly tightened. The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also Technical Data concerning ethanol fuel. Methanol fuel is not allowed. Do not use E85 alcohol based fuel.
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 Fuses Fuses are located under the seat of the machine. They are accessed by tilting the seat forward. They are flat pin fuses of the same type used in automobiles. There are two fuses with ratings and functions: 20 Amp Primary fuse 7.
OPERATION Read the Safety section and following pages, if you are unfamiliar with the machine. Training Due to unique steering capabilities, zero turn mowers are far more maneuverable than typical riding mowers. This section should be reviewed in its entirety prior to attempting to move the mower under its own power. When first operating the mower or until becoming comfortable with controls, use a reduced throttle speed and reduced ground speed.
OPERATION Before Starting 1. Read the sections on Safety and Controls before starting the machine. 2. Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). 3. Check that there is sufficient fuel in the fuel tank. 4. Adjust the seat to the desired position. 8058-034 Seat adjustment 5. Set the deck cutting height by inserting the lift pin into the desired cut height. Resecure the lift pin with the hairpin.
OPERATION Starting the Engine 1. Sit on the seat. 2. Raise the mower deck by pushing the release button on the top of the lifting lever. Pull the lifting lever backward to the locked (transport) position. 8058-019 Mower deck lifting lever 3. Activate the parking brake by pushing the release button in and pulling the lever upwards. 8058-191 Pull parking brake upwards to activate. 4. Disengage the mower blades by pressing the blade switch downwards.
OPERATION 5. Move the steering controls outward to the locked (outer) neutral position. 8058-190 Place controls in neutral position 6. Move the throttle to the middle position. 8058-148 Set the throttle 7. If the engine is cold, the choke control should be pulled up.
OPERATION 8. Press in and turn the ignition key to the start position. WARNING! 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. 9. When the engine starts, immediately release the ignition key back to the run position.
OPERATION 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 The 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 the mower to start other vehicles. If the battery is too weak to start the engine, it should be recharged. (See Battery in the Maintenance section.
OPERATION Running 1. Release the parking brake by pushing the button and 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. 2. Move the steering controls to the neutral position (N). 8058-191 Parking brake released 3. Push the release button on the cutting height lever and move lever to the pin, release the button.
OPERATION 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 to the outside of the unit and engage the parking brake. 8058-190 Place controls in neutral position • • • To restart movement, release the parking brake.
OPERATION Mowing Tips • • • • • • • • 32 Observe and flag rocks and other fixed objects to avoid collisions. Begin with a high cutting height and reduce it until the desired mowing result 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 healthier and better looking lawns, mow often after moderate growth. For best cutting performance, grass over 6" (15 cm) in height should be mowed twice.
OPERATION Stopping the Engine 1. Move the throttle to the minimum position (tortoise symbol). 2. Move the steering controls outward. 3. Disengage the mower deck by depressing the blade switch. 8058-173 Disengage the mower blades 4. Raise the mower deck by pressing the release button on the lever and pulling the lever upward to the transport position. 5. When the machine is standing still, activate the parking brake by pushing the lever release button and pulling the lever upward.
OPERATION Moving Machine By Hand ZT-2800 Bypass Linkages When pushing or pulling the mower, engage the ZT-2800 (Integrated Zeroturn Transaxle) bypass linkages. The ZT-2800 bypass linkages are located on the rear of the frame, below the rear engine guard. 1. Raise the deck into the highest cutting position. 1. Pull the ZT-2800 bypass linkages up and out of the keyhole slots. Release the levers with the head outside the frame and held in the bypass position. 1.
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. Read Maintenance in the Safety section.
MAINTENANCE Daily Maintenance Before After At least once each year Maintenance interval in hours 25 50 100 Check/adjust throttle cable ■ ■ Check the condition of belts, belt pulleys ♦ ♦ Change the engine oil ■ 1) ■ Replace the engine oil filter ■ ■ Clean/replace the spark plugs ■ ■ ● Check the caster wheels (every 200 hours) Check/adjust the mower deck Check the engine valve clearance 4) Perform the 300-hour service 4) Lubricate according to Lubrication Schedule 3,4) ● ♦ ♦ ● ● ●
MAINTENANCE Battery Your 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 terminals clean. • Keep battery bolts tight. • See chart for charging times Cleaning battery and terminals Corrosion and dirt on the battery and terminals can cause the battery to “leak” power. 1. Open the terminal access covers. 2.
MAINTENANCE 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 are in the outer, locked neutral position. 3. The parking brake is on. Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met. Change the conditions and try again.
MAINTENANCE 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 Deck Belt Removal 1. Park on a level surface. Apply parking brake. 2. Lower the deck into the lowest cutting position. 3. Remove bolts from belt shields and remove shields. 4.
MAINTENANCE Pump Belt Replacing pump belt Park the mower on a level surface. Engage the parking brake. 2 Belt removal 1. Remove the deck belt (see Deck Belt Removal in this section of the manual). 2. Relieve the spring tension after inserting a 3/8" rachet into the square opening in the idler arm. 3. The belt should now be able to be removed from the engine pulley and pump pulleys. Belt installation 1. Wrap the belt around the pulley 2. Route the belt around the inside of the idler pulley. 3.
MAINTENANCE Cutting Blades To attain the best mowing effect, it is important that blades are well sharpened and not damaged. Replace blades that have been bent or cracked when hitting obstacles. IMPORTANT INFORMATION The sharpening of blades should be carried out by an authorized service workshop. Let the service workshop decide whether a blade with large nicks can be repaired/ground or must be replaced. Balance the blades after sharpening. Check the blade mounts. Blade replacement 1.
MAINTENANCE Adjusting the Mower Deck Leveling deck Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Technical Data under Transmission. If tires are under or over inflated, the deck cannot be properly adjusted. The deck should be adjusted slightly higher in the rear. NOTE:To insure accuracy of leveling procedure, mower deck drive belt must be installed prior to leveling deck. 1. Wear heavy gloves.
MAINTENANCE 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 filled tires or solid tires will void the warranty. Removal and installation of caster wheel 1. Remove nut (1) and caster bolt (2). 2. Pull the wheel out of the fork and take care of the sleeve (3). 3. Reinstall in reverse order. Tighten caster bolt. 2 1 3 IMPORTANT INFORMATION DO NOT add any type of tire liner or foam fill material to the tires.
LUBRICATION 8050-832 * Change transmission filter 12/12 Every year 1/52 Every Week 1/365 Every day Lubricate with grease gun Oil change General Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be filled 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.
LUBRICATION Front Wheel Mount Lubricate with a grease gun, one zerk for each wheel mount. Use only good quality bearing grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. Front Wheel Bearings Lubricate with a grease gun, one zerk for each set of wheel bearings. Use only good quality bearing grease. 8050-009 Lubricating the wheel bearings Deck Spindle Lower the cutting deck completely.
LUBRICATION Transaxle 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 is performed with the transaxles installed in the mower and the mower on level ground. Apply the pump release valve for each transaxle and set the parking brake. 1. Remove the three ¼" filter guard screws and filter guard.
TROUBLESHOOTING Problem Engine will not start Starter does not turn the engine over Engine runs rough Engine seems weak Machine vibrates Cause • Blade switch is engaged. • Steering controls are not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line.
TROUBLESHOOTING Problem Engine overheats Battery not charging Machine moves slowly, unevenly, or not at all Mower deck not engaging Transaxle leaks oil Uneven mowing results 48 Cause • Clogged air intake or cooling fins • Engine overloaded • Poor ventilation around engine • Defective engine speed regulator • Too little or no oil in the engine • Contamination in the carburetor or fuel line.
STORAGE Winter Storage At the end of the mowing season (or if it will not be in use for more than 30 days), the machine should be readied for storage. 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 acceptable option as regards to the sticky residues that can occur during storage. Add stabilizer to the fuel in the tank or in the storage container.
WIRING DIAGRAM 8053-002 50
TECHNICAL DATA Torque Specifications Engine crankshaft bolt Deck pulley bolts Lug nuts Blade bolt Standard ¼" fasteners 50 ft/lb (67 Nm) 150 ft/lb (203 Nm) 75 ft/lb (100 Nm) 90 ft/lb (122 Nm) 9 ft/lb (12 Nm) Standard 5/16" fasteners Standard 3/8" fasteners Standard 7/16" fasteners Standard ½” fasteners 18 ft/lb (25 Nm) 33 ft/lb (44 Nm) 52 ft/lb (70 Nm) 80 ft/lb (110 Nm) HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specific torque values are not given. U.S.
TECHNICAL DATA Ram 48ZT 966658601 Engine Manufacturer Briggs & Stratton 1) Type Pro Power 26 hp 2) Lubrication Pressure with oil filter Fuel Min 87 octane unleaded (Maxethanol 5%, Max MTBE 15%) Fuel tank capacity 3.5 gallons / 13.2 liters Cooling Air cooled Air filter Standard Alternator 12V / 16A Starter Electric 12V Transmission Transmission ZT2800 Hydro Gear Speed and direction controls Dual levers, foam gripped Speed forward 0-6.5 mph / 0-10.5km/h Speed reverse 0-3.
TECHNICAL DATA Ram 48ZT 966658601 Frame Cutting Width 48" / 122cm Cutting Height 1½ - 4½" / 3.8 - 11.4 cm Uncut Circle 0 Number of Blades 3 Blade Length 16¼" / 41 cm Anti-scalp Rollers 3 Sprung Seat Standard Hinged Arm Rests Standard Hour Meter Standard Blade Engagement Electromagnetic clutch Deck Construction 11 gauge w/ 10 gauge skirts Productivity 2.
CONFORMITY CERTIFICATES Conformity Certificates For Model Listed Below: 966658601 / RAM 48 CE Zero Turn Rider 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.
SERVICE JOURNAL Action Date, mtr reading, stamp, sign Delivery Service r r r r r r r r r r Charge battery Adjust tire pressure of all wheels according to Technical Data Mount the steering controls in the normal position Connect the contact box to the cable for the seat’s safety switch Check that the right amount of oil is in the engine Adjust the position of the steering controls Fill with fuel and open the fuel shut off valve Start the engine Check that there is drive to both wheels Check the mower dec
SERVICE JOURNAL Action After the First 10 Hours Change engine oil 25-Hour Service Check the fuel pump’s air filter Check the hydraulic system’s oil level Check the tire pressures Lubricate the belt adjuster, mower deck Lubricate the belt adjuster, hydraulic pumps Check/clean the engine’s cooling air intake Clean air filter dust cap 56 Date, mtr reading, stamp, sign r r r r r r r r
SERVICE JOURNAL Action 50-Hour Service Perform the 25-hour service Clean/replace the air cleaner’s filter cartridge (paper filter) (shorter intervals for dusty operating conditions) Change engine oil Lubricate according to lubrication chart Check/adjust the parking brake 100-Hour Service Perform the 25-hour service Perform the 50-hour service Change the engine oil filter Clean/replace the spark plugs Replace the fuel filter Clean the cooling fins on the engine and transmission Check V-belts Check/tighten
SERVICE JOURNAL Action 300-Hour Service Perform the 25-hour service Perform the 50-hour service Perform the 100-hour service Check/adjust the mower deck Clean the combustion chamber and grind the valve seats Check the engine valve clearance Replace the air cleaner’s prefilter (foam) At Least Once Each Year Clean the engine’s cooling air intake (25 hours) Replace the air cleaner’s pre-filter (foam) (300 hours) Replace the air filter’s paper cartridge Change the engine oil (50 hours) Replace the engine oil
