Ferris 5900621 manual

5100798 Re vision 01 Re v . Date: 9/2006 TP 100-7306-01-45-F Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 Model Number: Description 5901178 IS4500ZBL35, 35HP Zero-T urn Riding Mower 5901179 IS4500ZBL3561, 35HP , 61” Cut Zero-T urn Riding Mower 5901180 IS4500ZC28D61, 28HP , 61” Cut Zero-T urn Riding Mower 5901181 I[...]

W ARNING Engine exhaust fr om this product contains chemicals known, in certain quantities, to cause cancer , birth defects, or other reproductive harm. Thank y ou f or purchasing this quality-b uilt F erris product. W e’ re pleased that y ou’v e placed y our confidence in the F erris brand. When operated and maintained according to the instruc[...]

T able of Contents Safety Rules & Inf ormation ................................2 Identification Numbers .....................................11 Safety Decals .....................................................12 Safety Icons .......................................................13 Safety Interloc k System ....................................[...]

2 www .ferrisindustries.com Safety Safety Rules & Information Operating Safety Congratulations on purchasing a superior-quality piece of lawn and garden equipment. Our products are designed and manuf actured to meet or e xceed all industry standards for saf ety . Do not operate this machine unless y ou hav e been trained. Reading and understand[...]

3 Safety Safety Rules & Information Slope Operation Operation on slopes can be dangerous. Using the unit on a slope that is too steep where you do not ha v e adequate wheel traction (and control) can cause sliding, loss of steering, control, and possible rollo v er . Y ou should not operate on a slope greater than a 3.5 f oot rise over a 20 f o[...]

4 www .ferrisindustries.com Safety Roll Bar Use K eep the roll bar in the raised position and f asten the seat belt. There is no roll ov er protection when the roll bar is down! Do not jump off if the mo wer tips (it is saf er to be secured by the seat belt with the roll bar raised.) Lower the roll bar only when necessary (such as to temporarily cl[...]

5 Safety Safety Rules & Information Enclosed Areas Only operate this unit outdoors and aw a y from unv entilated areas such as inside garages or enclosed trailers . The engine emits poisonous carbon mono xide gas and prolonged e xposure in an enclosed area can result in serious injur y or death. Fuel and Maintenance Alwa ys disengage all drives[...]

6 www .ferrisindustries.com Safety 2. Mow only in the da ylight or with good artificial light, keeping a wa y 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 provided. 4. Be sure of your f ooting while us[...]

7 Safety Safety Rules & Information 23. Use care when approaching blind corners, shrubs, trees or other objects that ma y obscure vision. 24. T o reduce fire hazard, keep unit free of gr ass, leav es & e xcess oil. Do not stop or park ov er dry leav es , grass or comb ustib le materials. 25. The engine in this unit is not factory equipped w[...]

8 www .ferrisindustries.com Safety 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 flammab le and the v apor s are e xplosive . Safe Handling of Gasoline 1. Extinguish all cigarettes, cigars , pipes, and other sources of igni[...]

9 Safety Safety Rules & Information 27. Models equipped with an engine radiator : W ARNING: Stored energy device. T o prev ent serious bodily injur y from hot coolant or steam blo w-out, ne v er attempt to remov e the radiator cap while the engine is running. Stop the engine and wait until it is cool. Ev en then, use e xtreme care when removing[...]

10 www .ferrisindustries.com Safety INSPECT BUCKLE & LA TCH INSPECT WEBBING Safety Rules & Information W ARNING Failure to pr operly inspect and maintain the seat belt can cause serious injury or death. INSPECTION AND MAINTENANCE OF THE ROLL B AR SEA T BEL T • The seat belt like the R OLL BAR, needs to be periodically inspected to verify [...]

11 Safety All Models CE Models S S A A M M P P L L E E When contacting your authorized dealer f or replacement parts, service, or information you MUST have these number s. Record your model/serial number and engine serial numbers on the space provided f or easy access . These numbers can be f ound in the locations shown. NO TE: F or location of eng[...]

12 SAFETY DECALS This unit has been designed and manuf actured to provide y ou with the saf ety and reliability you w ould e xpect from an industr y leader in outdoor pow er equipment manuf acturing. Although reading this manual and the saf ety instructions it contains will provide you with the necessar y basic knowledge to oper ate this equipment [...]

13 Safety Safety Icons W arning: Read Operator’ s Manual. Read and understand the Operator’ s Manual before using this machine. Danger: Thro wn Objects. This machine is capable of throwing objects and debris. K eep bystanders a wa y . W arning: Remove Ke y Bef ore Servicing. Remov e the k ey and consult technical literature bef ore perf or ming[...]

14 www .ferrisindustries.com Safety 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 s witches , and ne v er tamper with saf ety de vices. Check their operation regularly . Operational SAFETY Checks T est 1 — Engine should NOT cra[...]

15 Ground Speed Le ver 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 controls the r ight rear drive wheel. Moving a le v er f orward increases the FOR W ARD speed of the associated wheel, and pulling back on a le ver increases the REVERSE speed. Note: The fur ther a le v e[...]

16 www .ferrisindustries.com Controls PT O (P ower T ake Off) Switch The PT O s witch 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 orw ard is FULL throttle position. Alwa ys operate the unit at FULL throttle when mowing.[...]

17 Operation GENERAL OPERA TING SAFETY Bef ore first time operation: • Be sure to read all inf ormation in the Safety 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 mo wing to become accustomed to the unit. CHE[...]

18 www .ferrisindustries.com Operation Operation PRIMING THE FUEL SYSTEM Diesel Model Only Priming the fuel system fills the fuel filters and remov es any air b ubb les from the fuel system. This must be perf ormed before the first use , after any fuel filter maintenance or if the fuel system is run dr y . T o prime the fuel system: On the water se[...]

19 Operation ST AR TING THE ENGINE (Diesel Model) 1. While sitting in the operators seat, engage the parking brake and mak e sure the PT O s witch is disengaged and the ground speed control le v ers 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 urn the ke y to [...]

20 www .ferrisindustries.com Operation Figure 3. Hydraulic Release V alve Location A. Hydraulic Release V alve (Right-hand side shown) 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 swi[...]

21 Operation Operation ZER O TURN DRIVING PRA CTICE The le ver controls of the Zero T urn r ider are responsive , and learning to gain a smooth and efficient control of the rider’ s f orward, re v erse , and turning movements will tak e some practice . Spending some time going through the maneuvers shown and becoming f amiliar with ho w the unit [...]

22 www .ferrisindustries.com Operation Operation AD V ANCED DRIVING Executing an End-Of-Ro w Zero T urn Y our Zero T urn Rider’ s unique ability to turn in place allows y ou to turn around at the end of a cutting row rather than ha ving to stop and Y -turn before starting a new row . F or e xample, to e x ecute a left end-of ro w zero turn: 1. Sl[...]

23 Operation Operation Figure 10. T railer W eight Recommendations A. Clevis Pin B. Clip W ARNING A V OID SERIOUS INJUR Y OR DEA TH FROM ROLL O VER: Keep r oll bar in the raised position and use seat belt. THERE IS NO ROLL O VER PRO TECTION WHEN THE ROLL B AR IS DO WN Lower the r oll bar only when necessary and NEVER remove it. Do NO T use seat bel[...]

24 www .ferrisindustries.com Operation T all Grass Requires Incremental Cutting F or e xtremely tall grass , set the cutting height at maximum f or the first pass, and then reset it to the desired height and mow a second or third time . Don’t cov er the gr ass surf ace with a heavy la y er of clippings. Consider using a grass collection system an[...]

25 Operation When and How Often to Mo w The time of da y and condition of the grass g reatly aff ect the results you’ll get when mo wing. F or the best results, f ollo w these guidelines: 1. Mow when the g rass is between three and fiv e inches high. 2. Mow with sharp blades. Shor t clippings of grass one inch or shor ter decompose more quickly t[...]

26 www .ferrisindustries.com Operation Proper Mulc hing Mulching consists of a mower dec k which cuts and recuts clippings into tiny par ticles and which then blo ws them down INT O the lawn. These tiny par ticles decompose rapidly into b y-products your la wn can use. UNDER PROPER CONDITIONS, y our mulching mower will virtually eliminate noticeabl[...]

27 NO TE: Diesel fuel, if permitted to stand unused for e xtended periods (30 days or more), ma y de v elop gummy deposits which can adv ersely aff ect the fuel pump and injector tubes and cause engine malfunction. T o a void this condition, add a diesel fuel stabiliz er to the fuel tank and run the engine a fe w minutes , or drain all fuel from th[...]

28 www .ferrisindustries.com Operation Operation 11. Drain fuel system completely or add a gasoline stabilizer to the fuel system. If you ha v e chosen to use a fuel stabilizer and ha v e not drained the fuel system, f ollow all saf ety instructions and storage precautions in this manual to pre v ent the possibility of fire from the ignition of gas[...]

29 Operation Operation Notes[...]

30 www .ferrisindustries.com Maintenance MAINTENANCE SCHEDULE & PR OCEDURES The f ollowing schedule should be f ollo wed f or normal care of your rider and mower . Y ou will need to keep a record of your oper ating time. Determining operating time is easily accomplished by observing the hour meter . * See the engine manuf acturer's owner&a[...]

31 Operation CHECKING / ADDING FUEL (Diesel) T o add fuel: 1. Remov e the fuel cap (A, Figure 13). 2. Fill the tank to the bottom of the fill tube. This will leav e room in the tank f or fuel e xpansion. Ref er to your engine man ual f or specific fuel recommendations. 3. Install and hand tighten the fuel cap . 4. Repeat same process f or opposite [...]

32 www .ferrisindustries.com Maintenance Regular Maintenance CHECKING / ADDING FUEL (Gas) T o add fuel: 1. Remov e the fuel cap (see A, Figure 13). 2. Fill the tank to the bottom of the filler neck. This will allow f or fuel e xpansion. NO TE: Do not overfill. Ref er to y our engine manual f or specific fuel recommendations. 3. Install and hand tig[...]

33 Maintenance Regular Maintenance CHECK / ADD ENGINE OIL Ref er to Figure 15 f or dipstick and oil fill locations . Ref er to the engine owners manual f or specific engine oil check and fill procedures . Also ref er to the engine owners manual f or specific engine oil and filter change procedures. CHECK / CHANGE AIR FIL TER Ref er to the engine ow[...]

34 www .ferrisindustries.com Maintenance Regular Maintenance Figure 18. 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 check ed bef ore each use, when the engine is cool and off . 1. Remov e the radiator pre[...]

35 Maintenance Regular Maintenance LUBRICA TION Lubricate the unit at the locations shown in Figure 20 through 25. 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. F erris Red Grease (P/N 5022285) is recommended, automotive-type high[...]

36 www .ferrisindustries.com Maintenance 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 26). 2. Remov e the battery retainer strap (C). 3. Remov e the battery and clean the tray[...]

37 Maintenance 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 blades as described in f ollowing steps . 2. T o remo ve b lade f or sharpening, use a 1” wrench on the flats of the spindle shaft while removing the blade mounting bolt with a 15/16” wrench (Figure 28). 3. U[...]

38 www .ferrisindustries.com T roubleshooting 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 perf or med to allo w it to continue operating properly . The troubleshooting guide belo w lists the most common problems , their caus[...]

39 T roubleshooting Rider Troubleshooting Continued. PROBLEM CA USE REMED Y Engine runs, but rider will 1. Hydraulic dump v alve(s) 1. T urn dump valve(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. Drive belt slips. 3. See problem and cause be[...]

T roubleshooting, Adjustment & Service 40 www .ferrisindustries.com T roubleshooting TR OUBLESHOO TING COMMON CUTTING PR OBLEMS PROBLEM CA USE REMED Y Streaking. 1. Blades are not shar p . 1. Shar pen your b lades. 2. Blades are worn down to f ar . 2. Replace your b lades. 3. Engine speed is too slow . 3. Always mo w at full throttle. 4. Ground[...]

41 SEA T ADJUSTMENT See Figure 31. The seat can be adjusted f ore and aft. Mov e the le v er f orward, position the seat as desired, and release the le ver to loc k the seat into position. GR OUND SPEED CONTR OL 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 vers [...]

42 www .ferrisindustries.com T roubleshooting T roubleshooting, Adjustment & Service NEUTRAL POSITION AND RETURN SPRING ADJUSTMENT T o determine if it is necessar y to adjust the neutral position, perf or m the f ollo wing steps. 1. Disengage the PT O , engage the parking brak e and tur n off the engine . 2. Mov e the ground speed control le v [...]

43 T roubleshooting T roubleshooting, Adjustment & Service P ARKING BRAKE ADJUSTMENT 1. Disengage the PT O , stop the engine , b lock the front wheels, remo ve the ignition k e y , 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[...]

44 www .ferrisindustries.com T roubleshooting T roubleshooting, Adjustment & Service DECK LIFT R OD TIMING ADJUSTMENT 1. P ark 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 [...]

45 T roubleshooting DECK LEVELING ADJUSTMENT NO TE: Bef ore adjusting the deck le v el, the dec k lift rod timing must be chec ked and/or adjusted. 1. P ark 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. I[...]

46 www .ferrisindustries.com T roubleshooting T roubleshooting, Adjustment & Service SUSPENSION ADJUSTMENT This unit is equipped with adjustable shoc k assemblies . The shocks can be adjusted to vary 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 c[...]

47 T roubleshooting T roubleshooting, Adjustment & Service W ARNING T o av oid serious injury , perf orm adjustments only with engine stopped, key removed and tractor on level gr ound. B A C A B B B Figure 47. PTO Clutch Adjustment A. Adjustment Window (Qty . 3, one shown) B. Adjustment Nut Figure 48. Adjust PTO Clutch A. Window B. Adjustment N[...]

48 www .ferrisindustries.com T roubleshooting T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Pump Drive Belt Remov al 1. P ark the tractor on a smooth, le v el 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. Remov e the PT O d[...]

49 T roubleshooting T roubleshooting, Adjustment & Service PT O Drive Belt Remo v al 1. P ark the tractor on a smooth, le v el 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. Release the hood cam latches and raise the hood until it locks in place . 3. R[...]

50 www .ferrisindustries.com T roubleshooting T roubleshooting, Adjustment & Service Figure 51. PTO Belt Routing NO TE: Gray areas indicate the flat side of the belt. Figure 52. Spindle Drive Belt Removal A. Idler Arm B. T rim Side Spindle Pulley Figure 53. Spindle Drive Belt Removal A. Spindle Pulley B. Idler Pulley C. Drive Belt B A C B A A A[...]

51 T roubleshooting T roubleshooting, Adjustment & Service B A TTER Y SER VICE Checking Battery V oltage A voltmeter can be used to determine condition of batter y . When engine is off , the v oltmeter shows batter y v oltage, which should be 12 v olts . When engine is running, the voltmeter shows v oltage of charging circuit which normally is [...]

52 www .ferrisindustries.com T roubleshooting W ARNING Any pr ocedure other than the preceding could result in: (1) personal injury caused by electr ol yte squirting out the batter y 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 [...]

53 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, Battery: 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 cc) [...]

Thank you f or purchasing F erris commercial mowing equipment. Please take a fe w minutes to read this limited w arranty inf ormation. It contains all the information you will need to ha v e your F erris mower repaired in the unlik ely ev ent that a breakdo wn cov ered by this limited w arranty should occur . Owner's Responsibilities - As a co[...]

Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 www .ferrisindustries.com IS4500Z Series Zero-T urn Riding Mower OPERA TOR’S MANUAL BEL TS AND BLADES: TRA CT OR Pump Drive Belt 5023388 61” SIDE DISCHARGE MO WER DECK - DIESEL MODELS Deck Drive Belt 5023297 PT O Drive Belt 5023304 Mower Blade 5020842 61” SIDE DISCHAR[...]