Ferris Industries IS4500ZBL3561 manual

23469 Revision 02 Rev. Date: 4/2005 TP 100-7174-02-45-F IS4500Z Series Zero-T urn Riding Mower Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 OPERA TOR’S MANUAL Models: IS4500ZC28D61 IS4500ZC28D61CE IS4500ZBL3561[...]

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1 W ARNING Engine exhaust fr om this product contains chemicals known, in certain quantities, to cause cancer , bir th defects, or other reproductive harm. T able of Contents T roubleshooting, Adjustments & Service .......26 T roub leshooting the Rider .....................................26 T roub leshooting the Mower .........................[...]

2 TP 600-7124-03-UV-F OPERA TION 1. Ne ver run an engine in an enclosed area. 2. Mow only in the da ylight or with good ar tificial light, keeping a way from holes and hidden hazards . 3. Be sure all drives are in neutral and parking brak e is engaged bef ore star ting engine. Only star t engine from the operator’ s position. Use seat belts if pr[...]

Safety Rules & Information 23. Use care when approaching blind cor ners , shrubs, trees or other objects that ma y obscure vision. 24. T o reduce fire hazard, keep unit free of gr ass, lea ves & e xcess oil. Do not stop or par k ov er dr y leav es, grass or comb ustible materials. 25. The engine in this unit is not factory equipped with a s[...]

Safety Rules & Information SER VICE AND MAINTENANCE T o a v oid per sonal injury or pr oper ty dama ge, use e xtreme care in handling gasoline . Gasoline is e xtremel y flammable and the v apor s are e xplosive . Safe Handling of Gasoline 1. Extinguish all cigarettes, cigars , pipes, and other sources of ignition. 2. Use only approv ed gasoline[...]

5 ENGINE REFERENCE D A T A Unit Model Number PR ODUCT REFERENCE D A T A Unit SERIAL Number Dealer Name Date Purchased Engine Make Engine Model Mower Deck Model Number Mower Deck SERIAL Number Model No.: kW: Engine RPM: LpA: Vibration @ Wheels: Vibration @ Seat: Ferris Industries, Inc. Munnsville, NY USA 13409 XXX XXX XXXXXXXXXX XXX XXXX XX dB(A) XX[...]

6 Decal - W arning P art 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 pow er equipment manuf actur ing. Although reading this manual and the saf ety instr uctions it contains will provide y ou with the necessar y basic kn[...]

7 Safety Icons / Identification Numbers SAFETY INTERLOCK SYSTEM This unit is equipped with saf ety interlock s witches. These saf ety systems are present f or your saf ety , do not attempt to bypass saf ety switches , and ne ver tamper with saf ety de vices. Chec k their operation regularly . Operational SAFETY Checks T est 1 — Engine should NO T[...]

Features & Controls Ground Speed Le vers 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 controls the right rear dr iv e wheel. Moving a le ver f orward increases the FORW ARD speed of the associated wheel, and pulling back on a le ver increases the REVERSE speed. Note: Th[...]

9 PT O (P ower T ake Off) Switch The PT O switch engages and disengages the mow er . Pull UP on the s witch to engage the mower , and push DO WN to disengage the mower . Throttle Contr ol Moving the throttle control fully f orward is FULL throttle position. Alwa ys operate the unit at FULL throttle when mowing. Choke (gas model only) Close the chok[...]

Operation GENERAL OPERA TING SAFETY Bef ore first time operation: • Be sure to read all inf or mation in the Saf ety and Operation sections bef ore attempting to operate this tractor and mow er . • Become f amiliar with all of the controls and how to stop the unit. • Drive in an open area without mowing to become accustomed to the unit. CHECK[...]

Operation PRIMING THE FUEL SYSTEM Diesel Model Only Priming the fuel system fills the fuel filters and removes any air b ubb les from the fuel system. This must be per- f or med bef ore the first use, after any fuel filter mainte- nance or if the fuel system is run dr y . T o prime the fuel system: On the water separator: 1. Using a 1/2” wrench, [...]

ST ARTING THE ENGINE (Diesel Model) 1. While sitting in the operators seat, engage the park- ing brak e and make sure the PT O switch is disen- gaged and the ground speed control le vers are lock ed in the neutral position. 2. Set the throttle to middle position (set throttle to FULL when star ting in cold weather) 3. T ur n the ke y to the HEA T p[...]

13 Figure 3. Hydraulic Release V alve Location A. Hydraulic Release V alve (Right-hand side sho wn) A DRIVING THE TRA CT OR 1. Sit in the seat and adjust the seat so that you can comf or tably reach all of the controls and see the instrument and gauge panels. 2. Engage the parking brake . 3. Make sure the PT O s witch is disengaged and the ground s[...]

14 ZER O TURN DRIVING PRA CTICE The le ver controls of the Zero T ur n rider are responsive , and learning to gain a smooth and efficient control of the rider’ s forward, re verse , and tur ning mov ements will take some practice. Spending some time going through the maneuvers shown and becoming f amiliar with how the unit acceler- ates, tra vels[...]

15 AD V ANCED DRIVING Executing an End-Of-Ro w Zero T urn Y our Zero T urn Rider’ s unique ability to tur n in place allows y ou to turn around at the end of a cutting row rather than ha ving to stop and Y -tur n bef ore star ting a new ro w . F or e xample, to e xecute a right end-of-row Zero T ur n: 1. Slow do wn at the end of the row . 2. Mov [...]

NO TE: Diesel fuel, if per mitted to stand unused f or e xtend- ed periods (30 days or more), ma y dev elop gummy deposits which can adversely aff ect the fuel pump and injector tubes and cause engine malfunction. T o av oid this condition, add a diesel fuel stabilizer to the fuel tank and run the engine a fe w minutes, or dr ain all fuel from the [...]

NO TE: Gasoline, if per mitted to stand unused f or extended periods (30 days or more), ma y dev elop gummy deposits which can adversely aff ect the engine carburetor and cause engine malfunction. T o av oid this condition, add a gasoline stabilizer to the fuel tank and run the engine a f ew minutes , or drain all fuel from the unit bef ore placing[...]

18 Regular Maintenance MAINTENANCE SCHEDULE & PR OCEDURES The f ollowing schedule should be f ollowed f or normal care of your rider and mower . Y ou will need to keep a record of your oper ating time. Deter mining operating time is easily accomplished b y obser ving the hour meter . * See the engine manuf acturer's owner's manual. **[...]

CHECKING / ADDING FUEL (Diesel) T o ad d fuel: 1. Remov e the fuel cap (A, Figure 11). 2. Fill the tank to the bottom of the fill tube. This will leav e room in the tank for fuel e xpansion. Ref er to your engine man ual for specific fuel recommenda- tions. 3. Install and hand tighten the fuel cap . 4. Repeat same process f or opposite tank. NO TE:[...]

Regular Maintenance 20 CHECKING / ADDING FUEL (Gas) T o add fuel: 1. Remov e the fuel cap (see A, Figure 11). 2. Fill the tank to the bottom of the filler neck. This will allow f or fuel expansion. NO TE: Do not ov erfill. Refer to y our engine manual f or specific fuel recommendations. 3. Install and hand tighten the fuel cap . 4. Repeat same proc[...]

Regular Maintenance CHECK / ADD ENGINE OIL Ref er to Figure 13 f or dipstick and oil fill locations . Ref er to the engine owners manual f or specific engine oil check and fill procedures . Also refer to the engine owners manual f or specific engine oil and filter change procedures. CHECK / CHANGE AIR FIL TER Ref er to the engine owners manual f or[...]

22 Regular Maintenance Figure 16. Radiator & Oil Cooler (Diesel model shown) A. Radiator Pressure Cap B. Radiator Screen C . Hydraulic Oil Cooler CHECK ENGINE COOLANT LEVEL The engine coolant le vel and quality should be chec ked bef ore each use, when the engine is cool and off . 1. Remov e the radiator pressure cap (A, Figure 16) to check the[...]

Regular Maintenance 23 LUBRICA TION Lubricate the unit at the locations shown in Figure 18 through 23. Grease: Use grease fittings when present. Disassemble par ts to apply grease to moving parts when grease fittings are not installed. Not all greases are compatib le. Ferris Red Grease (P/N 22285) is recommended, automotive-type high- temperature, [...]

24 Regular Maintenance B A TTER Y MAINTENANCE NO TE: This unit is equipped with a maintenance-free BCI58 batter y) Cleaning the Battery and Cables 1. Disconnect the cables from the battery , negative cable first (A, Figure 24). 2. Remov e the batter y retainer strap (C). 3. Remov e the batter y and clean the tra y and surround- ing areas with a sol[...]

25 Regular Maintenance SER VICING THE MO WER BLADES 1. Blades should be shar p and free of nic ks and dents. If not, shar pen b lades as described in following steps. 2. T o remove b lade for sharpening, use a 1” wrench on the flats of the spindle shaft while removing the b lade mounting bolt with a 15/16” wrench (Figure 26). 3. Use a file to s[...]

26 T roubleshooting Adjustments & Service TR OUBLESHOO TING While nor mal care and regular maintenance will e xtend the lif e of your equipment, prolonged or constant use ma y e ventually require that service be performed to allow it to continue oper ating properly . The troubleshooting guide belo w lists the most common problems , their causes[...]

27 Rider Troubleshooting Continued. PROBLEM CA USE REMED Y Engine runs, b ut rider will 1. Hydraulic dump valv e(s) 1. T ur n dump v alve(s) cloc kwise to close. not drive. in “open” position. T orque to 80-120 in.lbs. (9-13.5 N.m.) 2. Belt is broken. 2. See Drive Belt Replacement. 3. Dr iv e belt slips. 3. See problem and cause below . 4. Brak[...]

28 T roubleshooting, Adjustment & Service SEA T ADJUSTMENT See Figure 29. The seat can be adjusted f ore and aft. Mov e the lev er f orward, position the seat as desired, and release the le ver to loc k the seat into position. GR OUND SPEED CONTROL LEVER ADJUSTMENT The control le vers can be adjusted in three w ays. The alignment of the control[...]

29 T roubleshooting, Adjustment & Service NEUTRAL POSITION AND RETURN SPRING ADJUSTMENT T o deter mine if it is necessar y to adjust the neutral posi- tion, perf or m the f ollowing steps. 1. Disengage the PT O, engage the parking brak e and turn off the engine. 2. Mov e the ground speed control lev ers in the operat- ing position, pull le vers[...]

30 T roubleshooting, Adjustment & Service P ARKING BRAKE ADJUSTMENT 1. Disengage the PT O, stop the engine , block the front wheels, remo ve the ignition k ey , and engage the parking brake . 2. Jac k up the rear of the machine and secure with jackstands . Remov e both drive tires. 3. With the parking brake engaged, measure the com- pressed spr[...]

T roubleshooting, Adjustment & Service DECK LIFT R OD TIMING ADJUSTMENT 1. P ar k machine on a flat, le vel surf ace. Disengage the PT O, stop the engine and engage the parking brak e. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72 bar). 2. Install the cutting height adjustment pin in the 3-3/4” (9,5 cm) positio[...]

DECK LEVELING ADJUSTMENT NO TE: Bef ore adjusting the deck le vel, the dec k lift rod timing must be chec ked and/or adjusted. 1. P ar k machine on a flat, le vel surf ace. Disengage the PT O, stop the engine and engage the parking brak e. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72 bar). 2. Install the cutting hei[...]

33 T roubleshooting, Adjustment & Service SUSPENSION ADJUSTMENT This unit is equipped with adjustable shoc k assemblies. The shocks can be adjusted to v ar y the amount of pre- load applied to the springs. This allows the operator to customize the ride according to operator’ s weight and/or operating conditions. Less Pre-Load: • Light opera[...]

T roubleshooting, Adjustment & Service 34 W ARNING T o a void serious injury , perform adjustments only with engine stopped, key removed and tractor on level gr ound. B A C[...]

T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Pump Drive Belt Remov al 1. P ar k the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PTO , engage the parking brake , tur n off the engine, and remo ve the ignition ke y . 2. Remov e the PTO driv e belt from the clutch (see PT O DRIVE BEL T[...]

T roubleshooting, Adjustment & Service PT O Drive Belt Remov al 1. P ar k the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PTO , engage the parking brake , tur n off the engine, and remo ve the ignition ke y . 2. Release the hood cam latches and raise the hood until it locks in place . 3. Release the rear guard [...]

37 T roubleshooting, Adjustment & Service PTO Clutch Pulley Flat Stationary Pulley V-Groove Spring- Loaded Pulle y V-Groove Guide Pulley V-Groove Guide Pulley Flat Guide Pulley Flat Guide Pulley Center Spindle Pulley FRONT IMPORT ANT : V-side of belt must contact v-groove pulleys Flat side of belt must contact flat pulleys Figure 49. PT O Belt [...]

38 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 voltmeter shows battery voltage , which should be 12 volts. When engine is r un- ning, the voltmeter sho ws voltage of charging circuit which normally is 13 to 14 volts. [...]

39 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 [...]

40 Specifications ENGINE: 28 HP* Caterpillar Make Caterpillar Model 3011C Horsepower 28 @ 3600 rpm Displacement 69 Cu. in (1131 cc) Electrical System 12 V olt, 40 amp . Alternator , Batter y: 500 CCA Oil Capacity 5.2 US qt. (4.9 L) w/ Filter 35 HP* Briggs Make Briggs & Stratton Model 613177 Horsepower 35 @ 3600 rpm Displacement 61 Cu. in (993 c[...]

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[...]

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 v ailable 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 [...]

Thank you f or purchasing Ferris commercial mowing equipment. Please take a fe w minutes to read this limited warranty inf or mation. It contains all the information you will need to ha ve your F err is mower repaired in the unlik ely event that a breakdo wn cov ered by this limited w arranty should occur . Owner's Responsibilities - As a cond[...]

Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 www .f errisindustr ies.com © Cop yright 2005 Ferris Industries All Rights Reser v ed. Printed in USA. IS4500Z Series Zero-T urn Riding Mower OPERA TOR’S MANUAL[...]