Ferris Industries 5000/72RCE manual

23458 Revision 00 Rev. Date: 11/2004 TP 100-7166-00-5Z-F IS5000Z Series Zero-T urn Riding Mower T ractor Serial No. 1226 & above Mower Serial No. 1210 & above Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 OPERA TOR’S MANUAL T ractor: Model IS5000Z/C31D IS5000Z/C31DCE IS5000ZC31D61CE Mower Deck: Model 5000/72 [...]

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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 .......25 T roub leshooting the Rider .....................................25 T roub leshooting the Mower .........................[...]

2 TP 600-7124-02-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 PRODUCT 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) XXX[...]

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 Glow Plug Indicator Indicates that the glow plugs are heating. Holding the ignition ke y in the “HEA T” position until indicator star ts to glow , then turn the ke y to star t. 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 .[...]

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[...]

11 Operation PRIMING THE FUEL SYSTEM 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, loosen the vent[...]

ST ARTING THE ENGINE 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 position an hold[...]

13 Figure 4. Hydraulic Release V alve Location A. Hydraulic Release V alve (Right-hand side sho wn) A MO WING 1. Engage the parking brake . Make sure the PT O s witch is disengaged, the motion control handles are lock ed in the NEUTRAL position and the operator is on the seat. 2. Star t the engine (see ST ARTING THE ENGINE). 3. Set the mower cuttin[...]

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 [...]

17 Regular Maintenance MAINTENANCE SCHEDULE & PR OCEDURES[...]

18 CHECKING / ADDING FUEL T o ad d fuel: 1. Remov e 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. 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: The fuel tanks are t[...]

Regular Maintenance 19 OIL & FIL TER CHANGE Ref er to Figure 14 f or oil filter , dipstick and filler neck locations. T o drain the oil: 1. Place a drain pan below the engine oil pan. 2. Remov e the oil drain plug and allow the engine oil to completely drain. 3. Remov e and replace the oil filter 4. Reinstall the oil drain plug. 5. Refill the e[...]

20 Figure 17. Radiator & Oil Cooler A. Radiator Pressure Cap B. Radiator Screen C . Screen K eeper Handle (LH side hidden) D . Hydraulic Oil Cooler E. Wing Bolt 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 1[...]

21 CHECK INDICA T OR LIGHTS AND ALARM 1. T ur n the ignition ke y to the ON position, but DO NO T star t the engine. 2. View the indicator light gauge . The red lights con- taining each symbol f or water temperature and oil pressure should be illuminated and the alar m should be audible . Once the engine is running, the alar m and the indicator lig[...]

22 LUBRICA TION Lubricate the unit at the locations shown in Figure 19 through 24. 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, lithium g rease ma y[...]

23 Regular Maintenance B A TTER Y MAINTENANCE (Note: The tractor equipped with a maintenance-free BCI58 batter y) Checking the Battery Fluid (Standard batter y only . NOT maintenance-free battery .) 1. Raise the seat plate to access batter y . 2. Remov e the batter y filler cap (A, Figure 25). Fluid must be e ven with the split ring full mar k. If [...]

24 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[...]

25 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[...]

26 Rider Troubleshooting Continued. PROBLEM CA USE REMED Y Engine runs, b ut rider will 1. Hydraulic dump v alve(s) 1. T urn dump valv e(s) clockwise 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 below . 4. Brak e i[...]

27 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 LEVER ADJUSTMENT The control le vers can be adjusted in three w ays. The alignment of the control le vers[...]

28 NEUTRAL ADJUSTMENT If the tractor “creeps” while the g round speed control le vers are loc ked in NEUTRAL, then it ma y 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. Disengage the PT O, engage the parking brak e and turn off the engine . 2. Loosen the ja[...]

29 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. Locate the upper brak e spring (A, Figure 34). 3. With the parking brake engaged, measure the com- pressed spring length. The spr ing should be 2” to[...]

FR ONT SUSPENSION ADJUSTMENT The shock assemb ly can be adjusted to var y the amount of pre-load applied to the springs. This allows the oper- ator to customize the ride according to operator’ s weight and/or operating conditions. Less Pre-Load: • Light operator weight • Softer , more cushioned ride • Best f or relatively flat terr ain More[...]

31 T roubleshooting, Adjustment & Service MO WING HEIGHT ADJUSTMENT See Deck Lift Rod Timing Adjustment and Dec k Lev eling Adjustment sections to ensure that the actual cutting height is consistent with the cutting height adjustment pin placement. The cutting height adjustment pin (A, Figure 38) controls the mower cutting height. The cutting h[...]

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 (124 kP a); front tires to 25 psi (172 kP a). 2. T o check the inner lift rod timing, measure and record the distance betwe[...]

33 T roubleshooting, Adjustment & Service 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 (124 kP a); front tires to[...]

34 T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Mower Drive Belt Remov al & Replacement - 72” Mower Dec ks 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. See Figure 45. Remov e[...]

35 T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Mower Drive Belt Remov al & Replacement - 61” Mower Dec k 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 . T o av oid damaging belts,[...]

36 T roubleshooting, Adjustment & Service Clutch Belt Remo val 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 rear skid plate by removing the bolts that f asten the skid plate to the bumper and slide[...]

37 T roubleshooting, Adjustment & Service 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 clutch belts (see CLUTCH BEL T REMO V AL f or instructions). 3. Using a 1/2” breake[...]

38 T roubleshooting, Adjustment & Service To p Front Figure 54. Gearbo x Oil Level A. Fill Plug B. Drain Plug A B GEARBO X MAINTENANCE Check Gearbo x Oil Level 1. Remov e fill plug (A, Figure 54) on gearbox. 2. Once plug is remov ed, oil should seep out of fill plug hole. If no oil drains out, fill with SAE 80-90 w eight gear oil until oil star[...]

39 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 nor mally is 13 to 14 v olts[...]

40 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 GR OUND VEHICLES MAKE CERT AIN VEHICLES DO NO T TOUCH 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 [...]

41 Common Replacement Parts COMMON REPLA CEMENT P ARTS Listed below are par ts numbers f or the more common replacement par ts. Use only genuine F err is replace- ment par ts to assure optimum perf or mance and safety . 61” Deck Belt (Gearbo x to Spindle) .....................23123 61” Deck Blades (Set of 3) ................................2084[...]

42 Specifications NO TE: Specifications are correct at time of printing and are subject to change without notice. * Actual sustained equipment horsepow er will likely be lo wer due to operating limitations and en vironmental f actors. ENGINE: 31.5 HP* Caterpillar Make Caterpillar Model 3013 Horsepower 31.5 @ 3600 rpm Displacement 91.54 Cu. in (1500[...]

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 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 [...]

LC-9 Notes[...]

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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 2004 Ferris Industries All Rights Reser v ed. Printed in USA. IS5000Z Series Zero-T urn Riding Mower OPERA TOR’S MANUAL[...]