Ferris Industries 5900592 manual

5102954 Rev A IS5100Z Series Zero-Turn Riding Mower OPERATOR’S MANUAL 61” Model: Model Description 5901013 33HP Caterpillar Diesel w/ 61” Mower Deck & ROPS (IS5100ZC33D) 72” Models: Tractor 5901011 33HP Caterpillar Diesel w/ ROPS (IS5100ZC33D) Mower Deck 5900591 72” Side Discharge Mower Deck (5100/72) 5900592 72” Rear Discharge Mowe[...]

Thank you for purchasing this quality-built FERRIS product. We’re pleased that you’ve placed your confidence in the FERRIS brand. When operated and maintained according to the instructions in this manual, your FERRIS product will provide many years of dependable service. This manual contains safety information to make you aware of the hazards a[...]

1 Table of Contents Operator Safety .................................................. 2 Identification Numbers ..........................................11 Safety Decals ........................................................12 Safety Icons ..........................................................14 Safety Interlock System ......................[...]

2 Operator Safety Operating Safety Congratulations on purchasing a superior-quality piece of lawn and garden equipment. Our products are designed and manufactured to meet or exceed all industry standards for safety. Do not operate this machine unless you have been trained. Reading and understanding this operator’s manual is a way to train yoursel[...]

3 Operator Safety Slope Operation Operation on slopes can be dangerous. Using the unit on a slope that is too steep where you do not have adequate wheel traction (and control) can cause sliding, loss of steering, control, and possible rollover. You should not operate on a slope greater than a 5.4 foot rise over a 20 foot length (15 degrees). Always[...]

4 Roll Bar Use Keep the roll bar in the raised position and fasten the seat belt. There is no roll over protection when the roll bar is down! Do not jump off if the mower tips (it is safer to be secured by the seat belt with the roll bar raised.) Lower the roll bar only when necessary (such as to temporarily clear a low overhanging obstacle) and NE[...]

5 Operator Safety Enclosed Areas Only operate this unit outdoors and away from unventilated areas such as inside garages or enclosed trailers. The engine emits poisonous carbon monoxide gas and prolonged exposure in an enclosed area can result in serious injury or death. Fuel and Maintenance Always disengage all drives, shutoff the engine, and remo[...]

6 2. Mow only in the daylight or with good artificial light, keeping away from holes and hidden hazards. 3. Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided. 4. Be sure of your footing while using pedestrian controlled equipment, espec[...]

7 Operator Safety 23. Use care when approaching blind corners, shrubs, trees or other objects that may obscure vision. 24. To reduce fire hazard, keep unit free of grass, leaves & excess oil. Do not stop or park over dry leaves, grass or combustible materials. 25. OSHA regulations may require the use of hearing protection when exposed to sound [...]

8 Operator Safety EMISSIONS 1. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. 2. Look for the relevant Emissions Durability Period and Air Index information on the engine emissions label. IGNITION SYSTEM (GASOLINE MODELS) 1. This spark ignition system com[...]

9 Operator Safety ROLL BAR INSTRUCTIONS For models equipped with factory-installed Roll Over Protection System (ROPS). OPERATIONAL WARNINGS • Always use the seat belt when the roll bar is in the raised position. • Never use the seat belt when the roll bar is in the down position. • Remember there is no roll over protection when the roll bar i[...]

10 INSPECT BUCKLE & LA TCH INSPECT WEBBING Operator Safety WARNING Failure to properly inspect and maintain the seat belt can cause serious injury or death. INSPECTION AND MAINTENANCE OF THE ROLL BAR SEAT BELT • The seat belt like the ROLL BAR, needs to be periodically inspected to verify that the integrity has not been compromised through no[...]

11 North American Models SAMPLE SAMPLE When contacting your authorized dealer for replacement parts, service, or information you MUST have these numbers. Record your model/serial number and engine serial numbers on the space provided for easy access. These numbers can be found in the locations shown. NOTE: For location of engine identification numb[...]

12 www.ferrisindustries.com Operator Safety SAFETY DECALS This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing. Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowle[...]

13 1 2 3 4 5 6 7 8 9 10 Operator Safety Not for Reproduction[...]

14 www.ferrisindustries.com Operator Safety NORTH AMERICAN SAFETY ICONS DANGER This indicates a hazard which, if not avoided, will result in serious injury or death. WARNING This indicates a hazard which, if not avoided, could result in serial injury or death. CAUTION This indicates a hazard which, if not avoided, might result in minor or moderate [...]

15 SAFETY INTERLOCK SYSTEM This unit is equipped with safety interlock switches. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with safety devices. Check their operation regularly. Operational SAFETY Checks Test 1 — Engine should NOT crank if: • PTO switch is engaged, OR • Parking[...]

16 www.ferrisindustries.com Deck Lift Pedal The deck lift pedal can be depressed during operation to briefly raise the mower deck while mowing around obstacles. Parking Brake DISENGAGE Releases the parking brake. ENGAGE Locks the parking brake. Pull the parking brake lever back to engage the parking brake. Move the lever fully forward to disengage [...]

17 Glow Plug Indicator Lamp that indicates that the glow plugs are heating. Hold the ignition key in the “HEAT” position until indicator lamp turns off, then turn the key to start. Voltage Gauge Gauge measures the output voltage of the engine charging system. Oil Pressure Indicator Lamp that indicates a low oil pressure condition. If the indica[...]

18 www.ferrisindustries.com GENERAL OPERATING SAFETY Before first time operation: • Be sure to read all information in the Safety and Operation sections before attempting to operate this tractor and mower. • Become familiar with all of the controls and how to stop the unit. • Drive in an open area without mowing to become accustomed to the un[...]

19 PRIMING THE FUEL SYSTEM Priming the fuel system fills the fuel filters and removes any air bubbles from the fuel system. This must be performed before the first use, after any fuel filter maintenance or if the fuel system is run dry. To prime the fuel system: On the water separator: 1. Using a 1/2” wrench, loosen the vent screw (A, Figure 2) o[...]

20 www.ferrisindustries.com Operation STARTING THE ENGINE 1. While sitting in the operators seat, engage the parking brake and make sure the PTO switch is disengaged and the ground speed control levers are locked in the neutral position. 2. Set the throttle to middle position (set throttle to FULL when starting in cold weather) 3. Turn the key to t[...]

21 Figure 3. Hydraulic Release Valve Location A. Hydraulic Release Valve (Right-hand side shown) A PUSHING THE RIDER BY HAND 1. Refer to Figure 3 for hydraulic release valve location. 2. To open the dump valves, turn the right-hand release valve, which is located on top of the right- hand pump, counter-clockwise 2 full turns MAX. Then turn the left[...]

22 www.ferrisindustries.com Operation ZERO TURN DRIVING PRACTICE The lever controls of the Zero Turn rider are responsive, and learning to gain a smooth and efficient control of the rider’s forward, reverse, and turning movements will take some practice. Spending some time going through the maneuvers shown and becoming familiar with how the unit [...]

23 ADVANCED DRIVING Executing an End-Of-Row Zero Turn Your Zero Turn Rider’s unique ability to turn in place allows you to turn around at the end of a cutting row rather than having to stop and Y-turn before starting a new row. For example, to execute a right end-of-row Zero Turn: 1. Slow down at the end of the row. 2. Move the LEFT ground speed [...]

24 www.ferrisindustries.com MOWING 1. Engage the parking brake. Make sure the PTO switch is disengaged, the motion control levers are locked in the NEUTRAL position and the operator is on the seat. 2. Start the engine (see STARTING THE ENGINE). 3. Set the mower cutting height. 4. Set the throttle to FULL. 5. Engage the PTO by pulling up on the PTO [...]

25 When and How Often to Mow The time of day and condition of the grass greatly affect the results you’ll get when mowing. For the best results, follow these guidelines: 1. Mow when the grass is between three and five inches high. 2. Mow with sharp blades. Short clippings of grass one inch or shorter decompose more quickly than longer blades. Sha[...]

26 www.ferrisindustries.com Operation Proper Mulching Mulching consists of a mower deck which cuts and recuts clippings into tiny particles and which then blows them down INTO the lawn. These tiny particles decompose rapidly into by-products your lawn can use. UNDER PROPER CONDITIONS, your mulching mower will virtually eliminate noticeable clipping[...]

27 WARNING AVOID SERIOUS INJURY OR DEATH FROM ROLL OVER: Keep roll bar in the raised position and use seat belt. THERE IS NO ROLL OVER PROTECTION WHEN THE ROLL BAR IS DOWN Lower the roll bar only when necessary and NEVER remove it. Do NOT use seat belt when the roll bar is down. Raise the roll bar as soon as clearance permits. Do NOT jump off if mo[...]

28 www.ferrisindustries.com WARNING Never store the unit, with diesel fuel in engine or fuel tank, in a heated shelter or in enclosed, poorly ventilated enclosures. Diesel fumes may reach an open flame, spark or pilot light (such as a furnace, water heater, clothes dryer, etc.) and cause an explosion. Handle diesel fuel carefully. It is highly flam[...]

29 Figure 12. Checking Tire Pressure CHECK TIRE PRESSURES Tire Pressure should be checked periodically, and maintained at the levels shown in the chart. Note that these pressures may differ slightly from the “Max Inflation” stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire l[...]

30 www.ferrisindustries.com Regular Maintenance CHECKING / ADDING FUEL To add fuel: 1. Remove the fuel cap (A, Figure 13). 2. Fill the tank to the bottom of the fill tube. This will leave room in the tank for fuel expansion. Refer to your engine manual for specific fuel recommendations. 3. Install and hand tighten the fuel cap. 4. Repeat same proce[...]

31 CHECK / ADD ENGINE OIL Refer to Figure 15 for dipstick and oil fill locations. Refer to the engine owners manual for specific engine oil check and fill procedures. Also refer to the engine owners manual for specific engine oil and filter change procedures. CHECK / CHANGE AIR FILTER Refer to the engine owners manual for specific air filter servic[...]

32 www.ferrisindustries.com Regular Maintenance CHECK ENGINE COOLANT LEVEL The engine coolant level and quality should be checked before each use, when the engine is cool and off. 1. Remove the radiator pressure cap (A, Figure 18) to check the fluid level. 2. Coolant level should be 1/2” (13mm) below the bottom of the filler tube. If coolant leve[...]

33 LUBRICATION Lubricate the unit at the locations shown in Figure 20 through 24. Grease: Use grease fittings when present. Disassemble parts to apply grease to moving parts when grease fittings are not installed. Not all greases are compatible. Red Grease (P/N 5022285) is recommended, automotive-type high- temperature, lithium grease may be used w[...]

34 www.ferrisindustries.com Regular Maintenance CLEANING THE BATTERY AND CABLES (Note: The tractor equipped with a maintenance-free BCI58 battery) 1. Disconnect the cables from the battery, negative cable first (B, Figure 25). 2. Remove the battery and clean the compartment with a solution of baking soda and water. 3. Clean the battery terminals an[...]

35 SERVICING THE MOWER BLADES 1. Blades should be sharp and free of nicks and dents. If not, sharpen blades as described in following steps. 2. To remove blade for sharpening, use a 1” wrench on the flats of the spindle shaft while removing the blade mounting bolt with a 15/16” wrench (Figure 26). 3. Use a file to sharpen blade to fine edge. Re[...]

36 www.ferrisindustries.com Troubleshooting, Adjustment & Repair TROUBLESHOOTING While normal care and regular maintenance will extend the life of your equipment, prolonged or constant use may eventually require that service be performed to allow it to continue operating properly. The troubleshooting guide below lists the most common problems, [...]

37 Troubleshooting, Adjustment & Repair Troubleshooting the Rider Continued PROBLEM CAUSE REMEDY Engine runs, but rider will not drive. Hydraulic dump valve(s) in “open” position. Turn dump valve(s) clockwise to close. Torque to 80-120 in.lbs. (9-13.5 Nm) Belt is broken. See Belt Removal and Replacement. Drive belt slips. See problem and ca[...]

38 www.ferrisindustries.com TROUBLESHOOTING COMMON CUTTING PROBLEMS PROBLEM CAUSE REMEDY Streaking Blades are not shar p . Shar pen your b lades. Blades are worn down to f ar . Replace your b lades. Engine speed is too slow . Alwa ys mow at full throttle. Ground speed is too f ast. Slow do wn. Deck is plugged with g rass Clean out the mo wer . Not [...]

39 SEAT ADJUSTMENT See Figure 29. The seat can be adjusted fore and aft. Move the lever forward, position the seat as desired, and release the lever to lock the seat into position. GROUND SPEED LEVER ADJUSTMENT The control levers can be adjusted in three ways. The alignment of the control levers, the placement of the levers (how close the ends are [...]

40 www.ferrisindustries.com Troubleshooting, Adjustment & Repair NEUTRAL ADJUSTMENT If the tractor “creeps” while the ground speed control levers are locked in NEUTRAL, then it may be necessary to adjust the control linkage. NOTE: Perform this adjustment on a hard, level surface such as a concrete floor. 1. Disengage the PTO, engage the par[...]

41 Troubleshooting, Adjustment & Repair PARKING BRAKE ADJUSTMENT 1. Disengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. 2. Locate the upper brake spring (A, Figure 34) through the opening under the fuel tanks. 3. With the parking brake engaged, measure the compressed spring length. [...]

42 www.ferrisindustries.com Troubleshooting, Adjustment & Repair REAR TIRE CAMBER ADJUSTMENT The rubber bushings in the cast A-arms may stretch and wear with time and adversely affect the angle that the rear tire runs against the ground. To evaluate if the rear tire camber should be adjusted, park the machine on a flat and level surface and vie[...]

43 WARNING Use two hands when adjusting the shock springs. This will prevent the wrench from slipping while pressure is being applied. SUSPENSION ADJUSTMENT The shock assembly can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to maintain the ride height. Use less pre-load for light weight operators. Use[...]

44 www.ferrisindustries.com DECK LIFT ROD TIMING ADJUSTMENT 1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72 bar). 2. To check the inner lift rod timing, measure and record the distance between the inner lift pivot[...]

45 Troubleshooting, Adjustment & Repair DECK LEVELING ADJUSTMENT NOTE: Before adjusting the deck level, the deck lift rod timing must be checked and/or adjusted. 1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72[...]

46 www.ferrisindustries.com Figure 45. Mower PTO Belt A. Spring-loaded Idler Pulley B. Idler Spring C. Stationary Idler Pulley B A C Troubleshooting, Adjustment & Repair A B C 61” Side Discharge Model 72” Side Discharge Model Adjusting the Mower Belt Spring Length 1. Loosen the jam nut (C) on the anchor eyebolt (B). 2. Turn the adjustment n[...]

47 Troubleshooting, Adjustment & Repair Clutch Belt Removal 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Release the hood latch and raise the hood until it locks in place. 3. Remove the rear belt shield. 4. Remove the 5/[...]

48 www.ferrisindustries.com Pump Drive Belt Removal 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the PTO drive belt from the clutch (see CLUTCH BELT REMOVAL for instructions). 3. Using a 1/2” breaker bar, place the [...]

49 Troubleshooting, Adjustment & Repair To p Front Figure 49. Gearbox Oil Level A. Fill Plug B. Drain Plug A B GEARBOX MAINTENANCE Check Gearbox Oil Level 1. Remove fill plug (A, Figure 49) on gearbox. 2. Once plug is removed, oil should seep out of fill plug hole. If no oil drains out, fill with SAE 80-90 weight gear oil until oil starts to se[...]

50 www.ferrisindustries.com BATTERY SERVICE Checking Battery Voltage A voltmeter can be used to determine condition of battery. When engine is off, the voltmeter shows battery voltage, which should be 12 volts. When engine is running, the voltmeter shows voltage of charging circuit which normally is 13 to 14 volts. A dead battery or one too weak to[...]

51 Troubleshooting, Adjustment & Repair WARNING Any procedure other than the preceding could result in: (1) personal injury caused by electrolyte squirting out the battery vents, (2) personal injury or property damage due to battery explosion, (3) damage to the charging system of the booster vehicle or of the immobilized vehicle. Do not attempt[...]

52 www.ferrisindustries.com Specifications SPECIFICATIONS NOTE: Specifications are correct at time of printing and are subject to change without notice. * Actual sustained equipment horsepower will likely be lower due to operating limitations and environmental factors. ENGINE: 33 HP* CATERPILLAR Make Caterpillar Model 3013E Horsepower 33 @ 3600 rpm[...]

Thank you for purchasing Ferris commercial mowing equipment. Please take a few minutes to read this limited warranty information. It contains all the information you will need to have your Ferris mower repaired in the unlikely event that a breakdown covered by this limited warranty should occur. Owner’s Responsibilities - As a condition to our ob[...]

IS5100Z Series Zero-Turn Riding Mower OPERATOR’S MANUAL Not for Reproduction[...]