Ferris Industries IS4000Z/KAV27 manual

22470 Rev. No. 04 Rev. Date: 9/2003 TP 100-7002-04-4Z-F IS4000Z Series Zero-T urn Riding Mower T ractor: Mower Deck: Models Description Models Description IS4000Z/D31 IS4000Z w/ 31 HP B&S,D Engine 4000/72 72” Mower Deck IS4000Z/KA V27 IS4000Z w/ 27 HP Kawasaki Engine 4000/61 61” Mower Deck Ferris Industries 5375 Nor th Main Street Munnsvill[...]

Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 www .f errisindustries.com © Cop yright 2003 Ferris Industries All Rights Reser ved. Printed in USA. FERRIS LIMITED W ARRANTY IMPORT ANT This warr anty shall apply ONL Y if the warranty registration f orm has been completed and retur ned to F erris Industr ies, Inc. within[...]

1 W ARNING Engine exhaust fr om this product contains chemicals known, in certain quantities, to cause cancer , birth defects, or other reproductive harm. T able of Contents T roub leshooting, Adjustments & Ser vice .......22 T roubleshooting the Rider .....................................22 T roubleshooting the Mower ..........................[...]

2 IDENTIFICA TION T A G LOCA TIONS Identification Numbers When contacting y our A uthoriz ed Dealer f or replacement par ts, service , or inf ormation Y OU MUST HA VE THESE NUMBERS. IDENTIFICA TION NUMBERS Record your model name/n umber , unit and mower deck, manuf acturer numbers and engine ser ial number in the space provided f or easy reference [...]

Read these saf ety rules and follow them closely . F ailure to obey these rules could result in loss of con- trol of the unit, se vere personal injury or death to you, or b ystanders, or damage to proper ty or equip- ment. This mowing dec k is capab le of amputating hands and feet and thr o wing objects. The trian- gle in te xt signifies impor tant[...]

4 Safety Rules & Information SLOPE OPERA TION Slopes are a major f actor related to loss-of-control and tip-ov er accidents, which can result in sev ere injur y or death. All slopes require e xtra caution. If y ou cannot back up the slope or if y ou feel uneasy on it, do not drive on it. Do • See your authorized dealer f or recommendations of[...]

5 Safety Rules & Information W ARNING BEW ARE OF PO WER DRIVEN P ARTS Decal - W arning P ar t No. 20337 SAFETY DECALS This unit has been designed and manuf actured to pro- vide you with the saf ety and reliability you would e xpect from an industr y leader in outdoor power equipment manuf actur ing. Reading this manual and the saf ety instr uct[...]

6 Features & Controls of the Zero T urn Rider A. Ground Speed Contr ol Lever s These le vers control the g round speed of the rider . The left le ver controls the left rear driv e wheel and the right le ver controls the right rear drive wheel. Moving a le ver f orward increases the FOR W ARD speed of the associated wheel, and pulling back on a [...]

7 Features & Controls SAFETY INTERLOCK SYSTEM This unit is equipped with saf ety interlock s witches and other saf ety devices . These safety systems are present f or your well being, do not attempt to b ypass safety s witches, and ne ver tamper with saf ety devices . Check their operation regularly . Operational SAFETY Checks Y our unit is equ[...]

Operating the Zero T urn Rider GENERAL OPERA TING SAFETY Bef ore first time operation: • Be sure to read all information in the Safety and Operation sections bef ore attempting to operate this tractor and mow er . • Become familiar with all of the controls and how to stop the unit. • Dr ive in an open area without mo wing to become accustomed[...]

9 W ARNING If you do not under stand how a specific control functions, or have not yet thoroughl y read the FEA TURES & CONTROLS section, do so now . Do NO T attempt to operate the tractor without first becoming familiar with the location and function of ALL controls. ST AR TING THE ENGINE 1. While sitting in the operators seat, engage the par [...]

10 Operating the Zero T urn Rider ZER O TURN DRIVING PRA CTICE The le ver controls of the Zero T ur n r ider are responsive , and learning to gain a smooth and efficient control of the rider’ s f orward, re verse , and tur ning movements will tak e some practice. Spending some time going through the maneuvers shown and becoming f amiliar with how[...]

11 AD V ANCED DRIVING Executing an End-Of-Ro w Zero T urn Y our Zero T ur n Rider’ s unique ability to tur n in place allows y ou to tur n around at the end of a cutting row rather than ha ving to stop and Y -turn before star ting a new ro w . F or example , to ex ecute a right end-of row Zero T ur n: 1. Slow down at the end of the row . 2. Move [...]

11. Drain fuel system completely or add a gasoline stabiliz- er to the fuel system. If you hav e chosen to use a fuel stabilizer and ha ve not dr ained the fuel system, follo w all saf ety instructions and storage precautions in this manual to pre vent the possibility of fire from the ignition of gasoline fumes. Remember , gasoline fumes can trav- [...]

13 Notes[...]

Regular Maintenance MAINTENANCE SCHEDULE & PROCEDURES The f ollowing schedule should be f ollowed f or nor mal care of your rider and mower . Y ou will need to k eep a record of your oper ating time. Deter mining operating time is easily accomplished by observing the hour meter . See Before Before Every Every Every Spring SAFETY ITEMS Page Firs[...]

CHECKING / ADDING FUEL T o add fuel: 1. Remove the fuel cap . 2. Fill the tank to the bottom of the fill tube. This will leav e room in the tank for fuel e xpansion. Refer to your engine man ual for specific fuel recommenda- tions. 3. Install and hand tighten the fuel cap. 4. Repeat same process for opposite tank. FUEL FIL TER The fuel filter is lo[...]

16 Regular Maintenance Figure 11A. Engine Coolant and Overflow (IS4000Z/D31) A. Coolant Ov erflow Reservoir B. Reservoir Cap CHECK ANTIFREEZE LEVEL The engine coolant le vel and quality should be chec ked bef ore each use, when the engine is cool and off . 1. Check the coolant in the ov erflow reservoir (A, Figures 11A & 11B). Coolant should be[...]

17 Regular Maintenance LUBRICA TION Lubricate the unit at the locations shown in FIgure 13 through 19 as well as the f ollowing lubrication points Grease: • front caster wheel axles • motion control pivots • suspension a-arms • rear deck mounts • deck lift piv ots • deck lift f oot pedal • blade spindles Use grease fittings when prese[...]

18 Regular Maintenance Figure 19. Rear Suspension Lubrication (Both upper & lower a-arms) RE-P A CK RE-P A CK BEARINGS BEARINGS ANU ALL Y ANU ALL Y RE-P A CK BEARINGS ANU ALL Y Figure 18. Front Caster & Wheel Figure 17. Gearbox Drive Idler Piv ot Figure 16. Control Handle Piv ots & Seat Pivots LUBRICA TION (CON’T .)[...]

19 B A TTER Y MAINTENANCE (Note: The tractor uses a standard BCI58 battery) Checking the Battery Fluid 1. Raise the seat plate to access batter y .. 2. Remove the battery filler cap (A, Figure 20). Fluid must be e ven with the split ring full mar k. If not, add distilled water . 3. Reinstall the filler cap. Cleaning the Battery and Cables 1. Discon[...]

20 Regular Maintenance LOOSEN A B TIGHTEN Figure 21. Removing the Blade Figure 22. Balancing The Blade Figure 23. Installing The Blade A. 4x4 W ood Block B. Flat W asher C . Blade Bolt Nail SER VICING THE MO WER BLADES 1. Blades should be shar p and free of nicks and dents. If not, shar pen blades as described in f ollowing steps. 2. T o remove b l[...]

21 Notes[...]

22 T roubleshooting Adjustments & Service TR OUBLESHOO TING While normal care and regular maintenance will extend the lif e of your equipment, prolonged or constant use ma y ev entually require that ser vice be performed to allow it to continue oper ating properly . The troubleshooting guide belo w lists the most common problems , their causes [...]

23 Rider Troubleshooting Continued. PROBLEM CA USE REMED Y Engine runs, b ut rider will 1. Hydraulic dump valv e(s) 1. T urn dump valve(s) cloc kwise to close. not drive. in “open” position. 2. Belt is broken. 2. See Dr ive Belt Replacement. 3. Dr ive belt slips . 3. See problem and cause below . 4. Brake is not fully released. 4. See author iz[...]

24 SEA T ADJUSTMENT See Figure 24. The seat can be adjusted f orward and back. Mov e the le ver f orward, position the seat as desired, and release the le ver to loc k the seat into posi- tion. GR OUND SPEED CONTROL LEVER ADJUSTMENT The control le vers can be adjusted in three w a ys. The alignment of the control le vers , the placement of the le v[...]

25 T roubleshooting, Adjustment & Service FR ONT Figure 27. Parking Brake Adjustment A. Upper Brake Spring A Figure 28. Parking Brake Adjustment A. Lower Brak e Spring B. Adjustment Nuts C . Adjustment Link A C B P ARKING BRAKE ADJUSTMENT 1. Disengage the PTO , stop the engine, b lock the front wheels, remo ve the ignition k ey , and engage the[...]

T roubleshooting, Adjustment & Service 26 SUSPENSION HEIGHT ADJUSTMENT If the rider tilts either side-to-side or front-to-rear , this adjustment will le vel the fr ame with the ground. Although this adjustment ma y not be necessar y , it may be required if additional weight (ie. a grass catcher) is added to the frame or a drive tire is replaced[...]

MO WER DECK LEVELING ADJUSTMENT 1. Place the cutting height quick pin in the 4” setting. 2. Measure the front and back edges of the mower deck. It should measure 4-1/2” (11,4cm) from the ground to the front low er edge of the mower dec k and 3-5/8” (9,2cm) from the back low er edge to the ground. These measurements should be made par- allel t[...]

28 T roubleshooting, Adjustment & Service W ARNING T o av oid serious injury , perform adjustments onl y with engine stopped, key removed and tractor on level gr ound. C A B B B A B Figure 35. PT O Clutch Adjustment A. Adjustment Windo w (Qty . 3, one shown) B. Adjustment Nut Figure 36. Adjust PT O Clutch A. Window B. Adjustment Nut C . .016”[...]

29 Figure 37. Neutral Adjustment (Left-hand side shown) A. Control Linkage B. Jam Nut NEUTRAL ADJUSTMENT If the tractor “creeps” while the ground speed control le vers are loc ked in NEUTRAL, then it may be neces- sar y to adjust the control linkage. NO TE: P erform this adjustment on a hard, lev el surface such as a concrete floor . 1. Disenga[...]

30 T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Mower Drive Belt Remo val & Replacement 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PT O , engage the parking brake , tur n off the engine, and remov e the ignition ke y . 2. Remove the hairpin clip and clevis pin and r[...]

31 Clutch Belt Remo val 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PT O , engage the parking brake , tur n off the engine, and remov e the ignition ke y . 2. Remove the rear skid plate b y removing the bolts that f asten the skid plate to the bumper and slide the plate f orward until it drops from the [...]

32 Pump Drive Belt Remov al 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PT O , engage the parking brake , tur n off the engine, and remov e the ignition ke y . 2. Remove the clutch belts (see CLUTCH BEL T REMO V AL f or instructions). 3. Using a 1/2” breaker bar , place the square end in the square ho[...]

33 To p Front Figure 43. Gearbox Oil Le vel A. Fill Plug B. Drain Plug A B GEARBO X MAINTENANCE Check Gearbo x Oil Level 1. Remove fill plug (A, Figure 43) on gearbo x. 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 star ts to seep from hole, then replace fill plug[...]

34 T roubleshooting, Adjustment & Service B A TTER Y SER VICE Checking Battery V oltage A voltmeter can be used to determine condition of bat- ter y . When engine is off, the v oltmeter shows batter y voltage , which should be 12 volts. When engine is run- ning, the voltmeter sho ws voltage of charging circuit which nor mally is 13 to 14 v olts[...]

35 To Starter Switch Starting V ehicle Battery T o Ground To Starter Switch Dischar ged V ehicle Battery Engine Block THIS HOOK-UP FOR NEGA TIVE GROUND VEHICLES MAKE CERT AIN VEHICLES DO NO T T OUCH Jumper Cab le Jumper Cab le W ARNING Any pr ocedure other than the preceding could result in: (1) personal injury caused by electr olyte squirting out [...]

Lawn Care & Mowing Information TYPES OF GRASS, CLIMA TE AND CONDITIONS A variety of grasses are commonly grown in household lawns, but two main groups known as cool-season grasses (varieties of bluegrass, ryegrass, and fescue), and warm-season grasses (typically bermuda, buffalo grass, and zoysia varieties) are the most common. The cool-season [...]

LC-2 Lawn Care & Mowing Information HO W HIGH T O MO W THE GRASS Often cutting height is a matter of personal prefer- ence. Typically, you should mow the grass when it is is between three and five inches high. The proper cutting height range for a specific lawn will depend upon several factors, including the type of grass, the amount of rainfal[...]

LC-3 Lawn Care & Mowing Information Where possible, make one or two passes around the outside of the area discharging the grass INTO the lawn to keep the cut grass off fences and walks. WHEN AND HO W OFTEN T O MO W The time of day and condition of the grass greatly affect the results you’ll get when mowing. For the best results, follow these [...]

LC-4 Lawn Care & Mowing Information MO WING METHODS Proper Br oadcast Mowing Broadcasting, or side-discharging, disperses fine clip- pings evenly over the entire lawn. Many golf courses use this method. Your mower has a deep dish deck to allow freer circulation of clippings so they are broadcast evenly over the lawn. ENGINE SPEED & GROUND S[...]

LC-5 Lawn Care & Mowing Information TIPS On Dealing With Clippings Clippings are beneficial to your lawn. A common mis- conception about clippings is that they automatically lead to thatch—this is untrue. Short clippings produced by broadcasting and clippings produced by mulching methods actually contribute to a healthy lawn because they: •[...]

LC-6 Lawn Care & Mowing Information Stepped Cutting Stepped cutting is sharp ridges or uneven levels left in the lawn surface. Stepped cutting is usually caused by mower deck damage or misadjustment, or damage to mower blades. CAUSE SOLUTION Deck is not leveled correctly Level the deck correctly Tires are not properly inflated Check and inflate[...]

LC-7 Lawn Care & Mowing Information Stingers Stingers are sparse patches of uncut grass left behind the mower. Stingers are usually caused by operator error or poor blade maintenance. CAUSE SOLUTION Blades are not sharp or are nicked Sharpen your blades Blades are worn down too far Replace your blades Engine speed is too slow Always mow at full[...]

LC-8 Common International Symbols T echnical Manuals Additional T echnical Literature A vailab le Operators Manuals Additional copies of this manual are available, (and as part of our product support commitment, we maintain a stock of printed operators manuals going back many years!) Parts Manuals Fully illustrated parts manuals are also available [...]

LC-9 Notes[...]