Briggs & Stratton Ferris 5900619 User Manual

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5100804

Revision 02

Rev. Date: 10/2006

TP 100-7301-02-5Z-F

IS5100Z Series

Zero-Turn Riding Mower

Briggs & Stratton Yard Power Products

5375 North Main Street Munnsville, NY 13409 800-933-6175

OPERATOR’S MANUAL

Models: Description:

5900602 33HP Caterpillar Diesel w/ ROPS (IS5100Z/C33D) 5900617 33HP Caterpillar Diesel w/ ROPS (IS5100Z/C33DCE) 5900618 33HP Caterpillar Diesel w/ 61" Mower Deck & ROPS (IS5100Z/C33D61CE) 5900622 61" Rear Discharge Deck (5100/61R)590062361" Rear Discharge Deck Export (5100/61RCE) 5901167 72" Side Discharge Deck (5100/72) 5901168 72" Rear Discharge Deck (5100/72R) 5901169 72" Rear Discharge Deck Export (5100/72RCE) 5901171 72" Side Discharge Deck Export (5100/72CE)

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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 and risks associated with this machine and how to avoid them. This machine is designed and intended to be used and maintained according to the manual and operated by trained professionals for finish cutting of established lawns and is not intended for any other purpose. It is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment.

The Ferris logo is a trademark of Briggs & Stratton Corporation Milwaukee, WI, USA.

Contact Information: Briggs & Stratton Yard Power Products

5375 N. Main St. Munnsville, NY 13409-4003 (800) 933-6175 www.ferrisindustries.com

ENGINE REFERENCE DATA

Unit Model Number

PRODUCT REFERENCE DATA

Unit SERIAL Number

Dealer Name

Date Purchased

Engine Make

Engine Model

Mower Deck Model Number

Mower Deck SERIAL Number

Engine Type/Spec.

Engine Code/Serial Number

DATE PURCHASED

See Page 11 for the location of Identification Numbers

WARNING

Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

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Table of Contents

Safety Rules & Information ................................2

Identification Numbers ..........................................11

Safety Decals & Icons...........................................12

Safety Interlock System ........................................14

Features & Controls..........................................15

Control Functions..................................................15

Operation ...........................................................17

General .................................................................17

Checks Before Starting.........................................17

Priming the Fuel System.......................................18

Starting the Engine ...............................................19

Stopping the Tractor and Engine...........................19

Driving the Tractor .................................................19

Pushing the Rider by Hand...................................20

Zero Turn Driving Practice ....................................21

Mowing..................................................................23

Mowing Recommendations...................................23

Mowing Methods...................................................24

Attaching a Trailer .................................................25

Raising & Lowering the Roll Bar...........................26

Storage..................................................................27

Starting After Long Term Storage.........................27

Diesel Fuel Recommendations.............................27

Regular Maintenance ........................................28

Maintenance Schedule .........................................28

Checking Tire Pressures.......................................28

Checking/Adding Fuel...........................................29

Fuel Filter ..............................................................29

Check / Add Engine Oil.........................................30

Check / Change Air Filter......................................30

Check Hydraulic Oil Level .....................................30

Hydraulic Oil Filter Change...................................30

Check Engine Coolant Level.................................31

Change Engine Coolant........................................31

Clean Radiator, Screen & Oil Cooler....................31

Lubrication ............................................................32

Battery Maintenance .............................................33

Anti-Scalp Deck Casters.......................................33

Servicing the Mower Blades .................................34

Troubleshooting, Adjustments & Service .......35

Troubleshooting the Rider .....................................35

Troubleshooting the Mower ...................................36

Troubleshooting Common Cutting Problems ........37

Seat Adjustment....................................................38

Ground Speed Control Lever Adjustment.............38

Speed Balancing Adjustment................................38

Neutral Adjustment ...............................................39

Neutral Position & Return Spring Adjustment.......39

Parking Brake Adjustment ....................................40

Rear Tire Camber Adjustment ..............................41

Suspension Adjustment ........................................42

Mowing Height Adjustment ...................................43

Deck Lift Rod Timing Adjustment..........................44

Deck Leveling Adjustment.....................................45

Deck Lift Spring.....................................................45

Belt Removal & Replacement...............................46

Gearbox Maintenance...........................................49

Battery Service .....................................................50

Specifications ....................................................52

NOTE: In this manual, “left” and “right” are referred to as seen from the operating position.

Safety

Controls

Operation Maintenance Troubleshooting Specifications

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Safety

Safety Rules & Information

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 yourself.

Power equipment is only as safe as the operator. If it is misused, or not properly maintained, it can be dangerous! Remember, you are responsible for your safety and that of those around you.

Use common sense, and think through what you are doing. If you are not sure that the task you are about to perform can be safely done with the equipment you have chosen, ask a professional: contact your local authorized dealer.

Read the Manual

The operator’s manual contains important safety information you need to be aware of BEFORE you operate your unit as well as DURING operation.

Safe operating techniques, an explanation of the product’s features and controls, and maintenance information is included to help you get the most out of your equipment investment.

Be sure to completely read the Safety Rules and Information found on the following pages. Also completely read the Operation section.

Children

Tragic accidents can occur with children. Do not allow them anywhere near the area of operation. Children are often attracted to the unit and mowing activity. Never assume that children will remain where you last saw them. If there is a risk that children may enter the area where you are mowing, have another responsible adult watch them.

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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 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

3.5 foot rise over a 20 foot length (10 degrees).

Always mow across slopes, not up and down (to maintain traction on the wheels) and avoid sudden turns or rapid speed changes. Reduce speed and use extreme caution on ALL slopes.

Also, note that the surface condition you are on can greatly impact your ability to safely operate this machine. Operating on wet or slippery slopes can cause sliding and loss of steering and control. Do not operate on slopes that are slippery, wet, or have soft soil conditions.

If you feel unsure about operating the unit on a slope, don’t do it. It’s not worth the risk.

Thrown Objects

This unit has spinning mower blades. These blades can pick up and throw debris that could seriously injure a bystander. Be sure to clean up the area to be mowed and remove objects that could be thrown by the blade BEFORE you start mowing.

Do not operate this unit without the entire grass catcher or discharge guard (deflector) in place.

Also, do not allow anyone in the area while the unit is running! If someone does enter the area, shut the unit off immediately until they leave.

Moving Parts

This equipment has many moving parts that can injure you or someone else. However, if you stay in the operator zone (stay seated in the seat), and follow the safety rules in this operator’s manual, the unit is safe to operate.

The mower deck has spinning mower blades that can amputate hands and feet. Do not allow anyone near the unit while it is running! Keep safety devices (guards, shields, and switches) in place and working.

To help you, the operator, use this equipment safely, it is equipped with an operator-present safety system. Do NOT attempt to alter or bypass the system. See your dealer immediately if the system does not pass all the safety interlock system tests found in this manual.

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Safety

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 NEVER remove it. Do NOT use the seat belt when the roll bar is down. Raise the roll bar as soon as clearance permits.

Retaining Walls, Drop-

offs, and Water

Retaining walls and drop-offs around steps and water are a common hazard. Give yourself a minimum of two mower widths of clearance around these hazards and hand-trim with a walk behind mower or string trimmer. Wheels dropping over retaining walls, edges, ditches, embankments, or into water can cause rollovers, which may result in serious injury, death, or drowning.

Overhead Obstacles

Check for overhead clearances before driving under any objects. Do not allow the roll bar to contact low overhanging obstacles such as tree branches and guide wires.

Safety Rules & Information

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Safety

Safety Rules & Information

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 remove the key before doing any cleaning, refueling, or servicing.

Gasoline and its vapors are extremely flammable. Do not smoke while operating or refueling. Do not add fuel while engine is hot or running. Allow engine to cool for at least 3 minutes prior to adding fuel.

Do not add fuel indoors, in an enclosed trailer, garage, or any other enclosed area that is not well ventilated. Gasoline spills should be cleaned up promptly and before operation begins.

Gasoline should be stored only in sealed containers approved for fuel.

Proper maintenance is critical to the safety and performance of your unit. Keep the unit free of grass, leaves, and excess oil. Be sure to perform the maintenance procedures listed in this manual, especially periodically testing the safety system.

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Safety

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, especially when backing up. Walk, don’t run. Reduced footing could cause slipping.

5. Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides. Turf conditions can affect the machines stability. Use caution when operating near dropoffs.

6. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while traveling in reverse.

7. Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the deflector in place.

8. Slow down and use caution when making turns and when changing directions on slopes.

9. Never raise deck with the blades running.

10. Never leave a running unit unattended. Always disengage the PTO, set parking brake, stop engine, and remove keys before dismounting. Keep hands and feet away from the cutting units.

11. Turn off the PTO switch to disengage the blades when not mowing.

12. Never operate with guards not securely in place. Be sure all interlocks are attached, adjusted properly and functioning properly.

13. Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

14. Do not change the engine governor setting or overspeed the engine.

15. Stop on level ground, lower implements, disengage drives, engage parking brake, shut off engine before leaving the operator’s position for any reason including emptying the grass catchers or unclogging the chute.

16. Stop equipment and inspect blades after striking objects or abnormal vibration occurs. Make necessary repairs before resuming operations.

17. Keep hands and feet away from the cutting units.

18. Look behind and down before backing up to be sure of a clear path.

19. Never carry passengers and keep pets and bystanders away.

20. Do not operate the unit while under the influence of alcohol or drugs.

21. Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing.

22. Use care when loading or unloading the machine into a trailer or truck.

TRAINING

1. Read, understand, and follow all instructions in the manual and on the unit before starting. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

2. Become familiar with the safe operation of the equipment, operator controls, and safety signs.

3. All operators and mechanics should be trained. The owner is responsible for training the users.

4. Only allow responsible adults, who are familiar with the instructions, to operate the unit.

5. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

6. The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property.

7. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

PREPARATION

1. Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Use only accessories and attachments approved by the manufacturer.

2. Wear appropriate clothing including safety shoes, safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

3. Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire, which can be thrown by the machine.

4. Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive.

a) Use only an approved container.

b) Never remove fuel cap or add fuel with the

engine running. Allow engine to cool before refueling. Do not smoke.

c) Never refuel or drain the machine indoors.

5. Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

OPERATION

1. Never run an engine in an enclosed area.

Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of unit, severe personal injury or death to you, or bystanders, or damage to property or equipment. This mo

wing deck is capab

le of amputating hands and feet and throwing objects.

The triangle in text signifies important cautions or warnings which must be followed.

Safety Rules & Information

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Safety

Safety Rules & Information

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. The engine in this unit is not factory equipped with a spark arrester. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on or near any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester meeting any applicable local or state laws. Other states or federal area may have similar laws.

26. OSHA regulations may require the use of hearing protection when exposed to sound levels greater than 85 dBA for an 8 hour time period.

SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not drive on it.

1. Mow across slopes, not up and down.

2. Remove obstacles such as rocks, tree limbs, etc.

3. Watch for holes, ruts, or bumps. Uneven terrain could overturn the unit. Tall grass can hide obstacles.

4. Use slow speed. Choose a slow speed so that you will not have to stop or change speed while on the slope.

5. Use extra care with grass catchers or other attachments. These can change the stability of the unit.

6. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.

7. See your authorized dealer for recommendations of available weights to improve stability.

Do Not

1. Avoid starting, stopping, or turning on a slope. If tires lose traction (i.e. machine stops forward motion on a slope), disengage the blade(s) (PTO) and drive slow off the slope.

2. Do not turn on slopes unless necessary, and then, turn slowly and gradually uphill, if possible. Never mow down slopes.

3. Do not mow near drop-offs, ditches, or embankments. The operator could lose footing or balance or mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

4. Do not mow on wet grass. Reduced footing or traction could cause sliding.

5. Do not try to stabilize the unit by putting your foot on the ground. (ride-on units)

6. Do not mow excessively steep slopes.

7. Do not use grass catcher on steep slopes.

8. Do not mow slopes if you cannot back up them.

TOWED EQUIPMENT (RIDE-ON UNITS)

1. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

2. Follow the manufacturer’s recommendations for weight limit for towed equipment and towing on slopes. See attaching a trailer under OPERATION.

3. Never allow children or others in or on towed equipment.

4. On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

5. Travel slowly and allow extra distance to stop.

6. Do not shift to neutral and coast down hill.

CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them.

1. Keep children out of the mowing area and under the watchful care of another responsible adult.

2. Be alert and turn unit off if children enter the area.

3. Before and during reverse operation, look behind and down for small children.

4. Never carry children, even with the blade(s) off. They may fall off and be seriously injured or interfere with safe unit operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

5. Never allow children to operate the unit.

6. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

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.

CAUTION

This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss though extended periods of exposure.

Wear hearing protection when operating this machine.

WARNING

Never operate on slopes greater than 17.6 percent (10°) which is a rise of 3-1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally.

Select slow ground speed before driving onto slope. Use extra caution when operating on slopes with rear-mounted grass catchers.

Mow across the face of slopes, not up and down, use caution when changing directions and DO NOT START OR STOP ON SLOPE.

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Safety

Safety Rules & Information

SERVICE AND MAINTENANCE

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

Safe Handling of Gasoline

1. Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

2. Use only approved gasoline containers.

3. Never remove the gas cap or add fuel with the engine running. Allow the engine to cool before refueling.

4. Never fuel the machine indoors.

5. Never store the machine or fuel container where there is an open flame, spark, or pilot light such as near a water heater or other appliance.

6. Never fill containers inside a vehicle or on a truck bed with a plastic bed liner. Always place containers on the ground away from your vehicle before filling.

7. Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

8. Keep nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

9. If fuel is spilled on clothing, change clothing immediately.

10. Never over-fill the fuel tank. Replace gas cap and tighten securely.

11. Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.

12. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

13. Replace all fuel tank caps and fuel container caps securely.

Maintenance and Storage

1. Always observe safe refueling and fuel handling practices when refueling the unit after transportation or storage.

2. Always follow the engine manual instructions for storage preparations before storing the unit for both short and long term periods.

3. Always follow the engine manual instructions for proper start-up procedures when returning the unit to service.

4. Never store the machine or fuel container inside where there is an open flame, such as in a water heater. Allow unit to cool before storing.

5. Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

6. Keep all hardware, especially blade attachment bolts, tight and keep all parts in good working condition. Replace all worn or damaged decals.

7. Never tamper with safety devices. Check their proper operation regularly.

8. Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

9. Clean grass and debris from cutting units, drives,

mufflers, and engine to prevent fires. Clean up oil or fuel spillage.

10. Let engine cool before storing and do not store near flame.

11. Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

12. Park machine on level ground. Never allow untrained personnel to service machine.

13. Use jack stands to support components when required.

14. Carefully release pressure from components with stored energy.

15. Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

16. Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

17. Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

18. Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothes and use insulated tools.

19. Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

20. Check brake operation frequently. Adjust and service as required.

21. Use only factory authorized replacement parts when making repairs.

22. Always comply with factory specifications on all settings and adjustments.

23. Only authorized service locations should be utilized for major service and repair requirements.

24. Never attempt to make major repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturer’s warranty.

25. Units with hydraulic pumps, hoses, or motors: WARNING: Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Keep body and hands away from pin holes or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, and not hands, to search for leaks. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. If leaks occur, have the unit serviced immediately by your authorized dealer.

26. WARNING: Stored energy device. Improper release of springs can result in serious personal injury. Springs should be removed by an authorized technician.

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Safety

Safety Rules & Information

27. Models equipped with an engine radiator: WARNING: Stored energy device. To prevent serious bodily injury from hot coolant or steam blow-out, never attempt to remove the radiator cap while the engine is running. Stop the engine and wait until it is cool. Even then, use extreme care when removing the cap.

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 is in the down position so it is very important to always keep the roll bar in the raised position whenever possible.

• Lower the roll bar to the down position only when it is absolutely necessary.

• Check for overhead clearances before driving under any objects. Do not allow roll bar to contact low overhanging obstacles such as tree branches and guide wires.

• Never remove the roll bar from the vehicle.

• Do not exceed the machine weight rating of the roll bar.

• Read and follow all of the instructions shown below regarding the inspection and maintenance of the roll bar structure and the seat belt.

INSPECTION OF THE ROLL BAR PROTECTIVE STRUCTURE

A ROLL BAR, like any other safety device, needs to be periodically inspected to verify that the integrity of the device has not been compromised through normal machine use, misuse, age degradation, modifications, or a roll over.

To maintain operator roll over protection and roll bar effectiveness:

• If a ROLL BAR becomes damaged for any reason, such as a collision, roll over or impact, the ROLL BAR must be replaced. Small undetectable cracks can reduce the effectiveness of the ROLL BAR. Never weld, straighten, or repair the ROLL BAR.

WARNING

In order to avoid serious injury or death from roll over, it is important to follow the warnings listed below.

WARNING

Failure to properly inspect and maintain the ROLL BAR protective structure can cause serious injury or death.

• Never alter the ROLL BAR by welding anything to it or by drilling additional holes.

• BEFORE FIRST TIME USE - Inspect the ROLL BAR structure and mounting hardware for:

1) Check to make sure the machine GVW (Gross Vehicle Weight), including attachments, restrained payload, fuel and operator, is not in excess of the maximum weight specified on the ROLL BAR label.

2) Make sure there isn’t any missing, damaged, or loose mounting hardware.

3) Make sure the ROLL BAR has been correctly and completely installed.

• EVERY 100 HOURS - Inspect the ROLL BAR structure and mounting hardware for:

1) Any cracks in the structure (structural members and/or welds).

2) Significant corrosion on any part of the ROLL BAR structure or hardware.

3) Missing, damaged, or loose mounting hardware

4) Mounting hardware that is of a grade lesser than specified.

5) Machine GVW (Gross Vehicle Weight), including attachments, restrained payload, fuel and operator, in excess of the maximum weight specified on the ROLL BAR label.

6) Any modifications that have been made, such as unauthorized welds and holes.

7) Any permanent deformation or twisting of the ROLL BAR structure.

8) That the ROLL BAR label is still in place and is readable.

9) That the ROLL BAR on-product warning labels are still on the ROLL BAR and are readable.

• If there is any doubt as to the condition of the ROLL BAR, remove the machine from service and contact your dealer for assistance.

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Safety

INSPECT BUCKLE & LATCH

INSPECT WEBBING

Safety Rules & Information

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 normal machine use, misuse, age degradation, modifications, or a roll over. If the seat belt does not pass all of the following tests, it should be replaced.

• BEFORE EACH USE – Conduct the following inspections/maintenance of the seat belt and retraction mechanism:

1) Check for dirt or debris in the retraction mechanism. If dirt or debris is found, it should be removed.

2) Check to make sure the retraction mechanism retracts easily and completely.

3) Check for damage to any part of the seat belt such as nicks, cuts, loose stitching, or fraying.

4) Check that the buckle and latch operate properly and that the latch plate is not excessively worn, deformed, or the buckle is damaged or cracked. The seat belt should latch and release easily.

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Safety

North American Models

CE Models

SSAAMMPPLLEE

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 numbers, refer to the engine owner’s manual.

SSAAMMPPLLEE

Mower Deck

Identification Tag

Tractor

Identification Tag

Identification Numbers

CE IDENTIFICATION TAG MARKINGS

A.Manufacturer’s Identification Number B.Power Rating in Kilowatts C.Maximum Engine Speed in Rotations per Minute D.Sound Pressure at Operator’s Position in Decibels

** E.Vibration at the Wheels * F.Vibration at the Seat * G. Manufacturer’s Address H.Year of Manufacture I.CE Compliance Logo J.Sound Power in Decibels *** K.Mass of Unit in Kilograms

This unit complies with European Harmonized Lawn Mower Standard EN 836, European Machinery Directive 98/37/EC, and European EMC Directive 89/336/EC

* Tested according to EN 836:1997/A2:2001, EN 1032:

1996, EN 1033:1995

** Tested according to EN836:1997/A2:2001

*** Tested according to 2000/14/EC

CE Models: Place copy of Identification Tag here.

Model No.: kW: Engine RPM: LpA: Vibration @ Wheels: Vibration @ Seat:

Ferris Industries Munnsville, NY 13409 USA

590XXXX XX.X XXXX XX dB(A)

X.X X.X

200X

XXX

54XXXXX

Model No.: kW: Engine RPM: LpA: Vibration @ Wheels: Vibration @ Seat:

590XXXX XX.X XXXX XX dB(A)

X.X X.X

Ferris Industries Munnsville, NY 13409 USA

200X

XXX

54XXXXX

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Safety

Safety Decals

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 knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit.

All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important! The safety decals below are on your rider and mower.

If any of these decals are lost or damaged, replace them at once. See your local dealer for replacements.

These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation.

NORTH AMERICAN MODELS

CE MODELS (EXPORT)

2, 3

10, 11

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Safety

Safety Icons

Warning: Read Operator’s Manual.

Read and understand the Operator’s Manual before using this machine.

Danger: Thrown Objects.

This machine is capable of throwing objects and debris. Keep bystanders away.

Warning: Remove Key Before Servicing.

Remove the key and consult technical literature before performing repairs or maintenance.

Danger: Machine Rollover.

Operating on steep slopes can cause sliding and loss of steering, control and rollover. Do not use this machine on slopes greater than 10°.

Danger: Dismemberment.

This machine can amputate limbs. Keep bystanders and children away when engine is running.

Danger: Dismemberment.

This mower deck can amputate limbs. Keep hands and feet away from blades.

Danger: Carbon Monoxide Poisoning.

Do not operate the engine in an unventilated area.

Danger: Fire Hazard.

Keep unit free of grass, leaves and excess oil. Do not add fuel while engine is hot or running. Stop engine and allow to cool for at least 3 minutes prior to adding fuel. Do not add fuel indoors, in an enclosed trailer, garage or other enclosed areas. Clean up spilled fuel. Do not smoke while operating this machine.

Danger: Dismemberment.

This machine can crush and cut. Keep hands away from belts and pulleys.

Danger: Machine Rollover.

Do not operate on any slopes when wet or slippery. Do not operate near drop-offs or near water.

Danger: Dismemberment.

This machine can crush and cut. Keep hands away from deck lift rod.

Warning: Avoid Serious Injury or Death from Roll Over

Do NOT jump off if the mower tips. Read and follow all operating instructions and warnings in the operator’s manual.

Warning: Avoid Serious Injury or Death from Roll Over

Keep roll bar in the raised position and use seat belt. Do NOT use seat belt when the roll bar is down

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 roll bar is down. Lower roll bar only when necessary and NEVER remove it. Raise the roll bar as soon as clearance permits.

Warning: Low Overhanging Obstacles Hazard

Check for overhead clearances before driving under any objects. Stay clear. Do NOT allow roll bar to contact low overhanging obstacles, such as tree branches and guide wires. Read and follow all operating instructions and warnings in the operator’s manual.

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 injury.

CAUTION or NOTICE

These messages presented without the alert symbol indicate a situation where the unit or property could be damaged.

Hazard

Safety Icon

Alert

Toxic Fumes

Read the Manual

Open flame hazard

Fire Hazard

Amputation Rotating Parts

Amputation Hand in Blade

Hazard

Safety Icon

Amputation Foot in Blade

Thrown Objects

Maintain a safe distance

Keep children away

Hot surface

Wear Protective Gear

Pinch Point

NORTH AMERICAN SAFETY ICONS

Rollover Hazard

Overhead Obstacles

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Safety

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 brake is not engaged, OR

• Motion control handles are not in the NEUTRAL position, OR

• Operator is not on the seat.

Test 2 — Engine SHOULD crank if:

• PTO switch is NOT engaged, AND

• Parking brake is engaged, AND

• Motion control handles are locked in the NEUTRAL position, AND

• Operator is on the seat.

Test 3 — Engine should SHUT OFF if:

• Operator rises off seat with PTO engaged, OR

• Operator rises off seat with parking brake disengaged.

• Operator moves motion control handles inward before disengaging parking brake.

Test 4 — Blade Brake Check

Mower blades and mower drive belt should come to a complete stop within seven (7) seconds after electric PTO switch is turned off (or operator rises off seat). If mower drive belt does not stop within seven (7) seconds, see your dealer.

NOTE: Once the engine has stopped, PTO switch must be turned off, parking brake must be engaged, and the motion control handles must be locked in the NEUTRAL position after the operator returns to the seat in order to start the engine.

WARNING

If the unit does not pass a safety test, do not operate it. See your authorized dealer. Under no circumstance should you attempt to defeat the purpose of the safety interlock system.

Safety Interlock System

Page 17

Controls

Ground Speed Levers

These levers control the ground speed of the rider. The left lever controls the left rear drive wheel and the right controls the right rear drive wheel.

Moving a lever forward increases the FORWARD speed of the associated wheel, and pulling back on a lever increases the REVERSE speed.

Note: The further a lever is moved away from the neutral position the faster the drive wheel will turn.

See the Operating the Zero Turn Rider section for steering instructions.

Seat Adjustment Lever

The seat can be adjusted forward and back. Move the lever forward, position the seat as desired, and release the lever to lock the seat in position.

Figure 1. CONTROL FUNCTIONS

The information below briefly describes the function of the individual controls. Starting, stopping, driving, and mowing require the combined use of several controls applied in specific sequences. To learn what combination and sequence of controls to use for various tasks see the OPERATION section.

Ignition Switch

The ignition switch starts and stops the engine, it has four positions:

Heats the glow plugs.

Stops the engine and shuts off the

electrical system.

Allows the engine to run and powers

the electrical system.

Cranks the engine for starting.

NOTE: Never leave the ignition switch in the ON position with the engine stopped–this drains the battery.

Features & Controls

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Controls

Features & Controls

PTO (Power Take Off) Switch

The PTO switch engages and disengages the mower. Pull UP on the switch to engage the mower, and push DOWN to disengage the mower.

Throttle Control

Moving the throttle control fully forward is FULL throttle position. Always operate the unit at FULL throttle when mowing.

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 the parking brake.

NOTE: To start the unit

the parking brake must be engaged.

Deck Lift Pedal, Cutting Height Adjustment Pin & Deck Lift Lock Lever

These control the cutting height of the mower deck. Depress the pedal until it locks into the 6” (15,2 cm) position. Place the adjustment pin in the desired cutting height and release the lift lock lever.

Hour Meter / Maintenance Reminder

Measures the time of the PTO being engaged. The hour meter measures the number of hours the PTO has been engaged. The hour meter will flash an initial oil change indicator at 5 hours, and a lubrication reminder every 50 hours. These reminders display for approximately two hours and will automatically reset themselves.

Note: The hour meter will register the passage of time only when the PTO is engaged. The hour meter has a self contained power source so the total hours are always visible.

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 indicator lamp is ON, it will turn the PTO OFF.

Water Temperature Gauge & Indicator

Gauge measures the engine coolant temperature. Lamp that indicates a high coolant temperature. If the indicator lamp is ON, it will turn the PTO OFF.

Fuel Tank Cap

To remove the cap, turn counterclockwise.

Fuel Level Gauge

Displays the fuel level in the tank.

Power Outlet

Unit is equipped with a +12VDC, 20A power outlet.

Page 19

Operation

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 unit.

CHECKS BEFORE STARTING

• Check that crankcase is filled to full mark on dipstick. See the engine Operators Manual for instructions and oil recommendations.

• Check the radiator fluid level. See engine operator’s manual for instructions.

• Check the hydraulic oil level. Refer to REGULAR MAINTENANCE section.

• Make sure all nuts, bolts, screws and pins are in place and tight.

• Adjust the seat position, and make certain you can reach all controls from the operators position.

• Fill the fuel tanks with fresh fuel. Refer to engine manual for fuel recommendations.

WARNING

Never allow passengers to ride on the unit.

Before leaving the operator’s position for any reason, engage the parking brake, disengage the PTO, stop the engine and remove the key.

To reduce fire hazard, keep the engine, tractor and mower free of grass, leaves and excess grease. Do not stop or park tractor over dry leaves, grass or combustible materials.

Gasoline is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills.

Do not load this zero-turn rider on a trailer or truck using two separate ramps. Only use a single ramp that is at least one foot wider than the width of the rear wheels of this rider. This rider has a zero turning radius and the rear wheels could fall off the ramps, or the rider could tip over injuring the operator or bystanders.

WARNING

Never operate on slopes greater than 17.6 percent (10°) which is a rise of 3-1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally.

Select slow ground speed before driving onto a slope. Use extra caution when operating on slopes with a rear-mounted grass catcher.

Mow across the face of slopes, not up and down,use caution when changing directions and DO NOT START OR STOP ON SLOPE.

WARNING

Operation

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Operation

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) on the water separator 2-3 revolutions.

2. Unscrew the priming hand pump (B) located on top of the water separator. Operate the hand pump up and down until fuel that is free of air flows from the vent.

3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). DO NOT OVER TIGHTEN!

On the engine fuel filter:

1. Using the appropriate size wrench, loosen the vent screw (C) on the engine fuel filter 2-3 revolutions.

2. Operate the hand pump up and down until fuel that is free of air flows from the vent.

3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). DO NOT OVER TIGHTEN!

On the engine injector pump:

1. Using a 13mm wrench, loosen the vent screw (D) on the fuel inlet 2-3 revolutions.

2. Operate the hand pump up and down until fuel that is free of air flows from the vent.

3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). DO NOT OVER TIGHTEN!

4. Tighten the priming fuel pump finger tight.

5. Start the engine. (See STARTING THE ENGINE). If the engine will not start, further priming is necessary. If the engine starts but misfires or continues to emit smoke, further priming is necessary.

6. If the engine starts but runs rough, continue to run the engine at low idle until the engine runs smoothly.

WARNING

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the ignition switch off when changing fuel filter or water separator element. Clean up fuel spills immediately.

Figure 2. Fuel System Priming A. Water Separator Vent Screw B. Priming Hand Pump C. Engine Fuel Filter Vent Screw D. Injector Pump Vent Screw

Operation

Page 21

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 the HEAT position. Hold the key to turn the glow plug indicator light on and activate the glow plugs.

4. Wait until the glow plug indicator light turns off, then turn the key to START. If the engine does not start immediately, move the throttle control to FULL.

NOTE: Do not crank the engine continuously for more than 30 seconds. Allow the starter motor to cool for two minutes before cranking the engine again.

5. After the engine starts, move the engine throttle control to SLOW. Warm up the engine by running it for at least a minute.

6. Move the throttle to FULL before engaging the PTO switch or driving the machine.

In the event of an emergency the engine can be

stopped by simply turning the ignition switch to STOP. Use this method only in emergency situations.

For normal engine shut down follow the procedure given in STOPPING THE TRACTOR.

STOPPING THE TRACTOR & ENGINE

1. Returning the ground speed control levers to the middle position will stop tractor movement. Pivot the levers outward and lock them in neutral.

2. Disengage the PTO.

3. Engage the parking brake.

4. Move the throttle control to SLOW and allow the engine to cool down for a short time.

5.Turn the ignition key to OFF. Remove the key.

DRIVING THE TRACTOR

1. Sit in the seat and adjust the seat so that you can comfortably reach all of the controls and see the instrument and gauge panels.

2. Engage the parking brake.

3. Make sure the PTO switch is disengaged and the ground speed control levers are locked in the neutral position.

4. Start the engine (see STARTING THE ENGINE).

5. Disengage the parking brake and pivot the ground speed control levers inward.

6. Move the levers evenly forward to travel forward. Return them to the neutral position to stop. Note that the further the levers are moved forward the faster the tractor will travel.

7. Stop the tractor by returning the control levers to the neutral position, pivoting the levers outward to lock into the neutral position, engaging the parking brake, and stopping the engine (see STOPPING THE TRACTOR AND ENGINE).

NOTE: See the ZERO-TURN DRIVING PRACTICE section on pages 16 & 17 for detailed instructions on

driving the tractor.

WARNING

If you do not understand how a specific control functions, or have not yet thoroughly read the FEATURES & CONTROLS section, do so now.

Do NOT attempt to operate the tractor without first becoming familiar with the location and function of ALL controls.

Operation

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Operation

Figure 3. Hydraulic Release Valve Location A. Hydraulic Release Valve (Right-hand side shown)

Operation

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 righthand pump, counter-clockwise 2 full turns MAX

. Then turn the left-hand release valve, which is located on the bottom of the left-hand pump, counter-clockwise 2 full turns MAX

3. Disengage the parking brake. The tractor can now be pushed by hand.

4. After moving the tractor, engage the parking brake. Re-engage the pumps (drive position) by turning the release valves clockwise and tighten to 80-120 in/lbs (9-13.5 N.m.)

DO NOT TOW RIDER

Towing the unit will cause hydraulic pump and wheel motor damage. Do not use another vehicle to push or pull this unit.

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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 accelerates, travels, and steers — before you begin mowing —is absolutely essential to getting the most out of the Zero Turn rider.

Locate a smooth, flat area of your lawn — one with plenty of room to maneuver. (Clear the area of objects, people and animals before you begin.) Operate the unit at mid-throttle during this practice session (ALWAYS operate at full throttle when mowing), and turn slowly to prevent tire slippage and damage to your lawn.

We suggest you begin with the Smooth Travel procedure to the right, and then advance through the forward, reverse, and turning maneuvers.

You must release the parking brake prior to moving the control levers inward.

BASIC DRIVING

Forward Travel Practice

Gradually move both ground speed control levers — evenly FORWARD from neutral. Slow down and repeat.

NOTE: Straight forward travel takes practice. If necessary, top speed can be balance-adjusted — see the Speed Balancing Adjustment in the Adjustments section.

Reverse Travel Practice

LOOK DOWN & BEHIND, then gradually move both ground speed control levers evenly BACK from neutral. Slow down and repeat.

NOTE: Practice backing up for several minutes before attempting to do so near objects. The rider turns sharply in reverse as well as forward, and backing up straight takes practice.

Figure 5. Forward Travel Figure 6. Reverse Travel

Smooth Travel

The lever controls of the Zero Turn rider are

RESPONSIVE

The BEST method of handling the ground speed control levers is in three steps — as shown in Figure 4.

FIRST place your hands onto the levers as shown.

SECOND, to go forward gradually push the levers forward with your palms.

THIRD, to speed up move the levers farther forward. To slow down smoothly, slowly move the levers toward neutral.

Figure 4. Move Control

Levers Gradually

Operation

Forward Travel

Reverse Travel

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Operation

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 control lever forward slightly while moving the RIGHT ground speed control lever back to center and then slightly back from center.

3. Begin mowing forward again.

This technique turns the rider RIGHT and slightly overlaps the row just cut —eliminating the need to back up and re-cut missed grass.

As you become more familiar and experienced with operating the Zero Turn rider, you will learn more maneuvers that will make your mowing time easier and more enjoyable.

Remember, the more you practice, the better your control of the Zero Turn will be!

Practice Turning In Place

To turn in place, “Zero Turn,” gradually move one ground speed control lever forward from neutral and one lever back from neutral simultaneously. Repeat several times.

NOTE: Changing the amount each lever is pulled— forward or back, changes the “pivot point” you turn on.

Practice Turning Around a Corner

While traveling forward allow one handle to gradually return back toward neutral. Repeat several times.

NOTE: To prevent pivoting directly on the tire tread, it is best to keep both wheels going at least slightly forward.

Figure 7. Turning Around a Corner

Figure 8. Turning in Place

Figure 9. Executing an End-Of-Row Turn

Operation

Executing Turns

Turning In-Place

Page 25

Operation

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 switch.

6. Begin mowing. See Section LC for tips on mowing patterns, lawn care, and trouble shooting information.

7. When finished, shut off the PTO.

8. Stop the engine (see STOPPING THE TRACTOR AND ENGINE).

MOWING RECOMMENDATIONS

Several factors can affect how well your machine cuts grass, Following proper mowing recommendations can improve the performance and life of your machine.

Height of Grass

Often cutting height is a matter of personal preference. 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 rainfall, the prevailing temperature, and the lawn’s overall condition.

Cutting the grass too short causes weak, thin grass plants, which are easily damaged by dry periods and pests. Cutting too short is often more damaging than allowing the grass to be slightly higher.

Letting grass grow a bit longer—especially when it is hot and dry—reduces heat build-up, preserves needed moisture and protects the grass from heat damage and other problems. However, allowing grass to grow too high can cause thin turf and additional problems.

Cutting off too much at one time shocks the plant’s growth system and weakens the grass plants. A good

rule of thumb is the 1/3 rule: to cut no more than one third of the grass height, and never more than 1 inch at a time.

The amount of grass you are able to cut in one pass is also effected by the type of mowing system you are using (for example, broadcasting with side discharge decks can process a much larger volume of grass than mulching does).

Tall Grass Requires Incremental Cutting

For extremely tall grass, set the cutting height at maximum for the first pass, and then reset it to the desired height and mow a second or third time.

Don’t cover the grass surface with a heavy layer of clippings. Consider using a grass collection system and starting a compost pile.

Proper Cutting Height

Incremental Cutting

Cut Here On Second Pass

Cut Here On First Pass

Operation

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Operation

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. Sharp mower blades cut grass cleanly and efficiently, preventing frayed edges which harm the grass.

3. Mow at time of day when the grass is cool and dry. Late afternoon or early evening often provide these ideal mowing conditions.

4. Avoid mowing after rain or even heavy dew, and never mulch when the grass is wet (moist grass does not mulch well, and clumps beneath the mower deck).

Mowing Patterns

Always start mowing on a smooth, level area.

The size and type of area to be mowed will determine the best mowing pattern to use. Obstructions such as trees, fences and buildings, and conditions such as slopes and grades must also be considered.

1. Cut long straight strips overlapping slightly.

2. Where possible, change patterns occasionally to eliminate matting, graining or a corrugated appearance.

3. For a truly professional cut, mow across the lawn in one direction, then recut the lawn by mowing perpendicular to the previous cut.

Note: Always operate the engine at full throttle when mowing.

If you hear the engine slowing down, you are mowing too fast—using a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems. Use an appropriate ground speed for the thickness and height of the grass you are cutting (3rd gear or slower for manual gear models). If you hear the engine slowing down you are mowing too fast, use a slower ground speed.

MOWING METHODS

Proper Broadcast Mowing

Broadcasting, or side-discharging, disperses fine clippings 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 SPEED FOR BROADCASTING

Always operate the engine at full throttle when mowing. If you hear the engine slowing down, you are mowing too fast—using a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems.

ALWAYS use an appropriate ground speed for the thickness and height of the grass you are cutting (3rd gear or slower for manual gear models). If you hear the engine slowing down you are mowing too fast, use a slower ground speed.

HOW MUCH GRASS TO CUT OFF WHEN BROADCASTING

Mow when the grass is 3-5 inches long. Do not cut the grass shorter than 2 to 2-1/2 inches. Do not cut off more that 1 inch of grass in a single pass.

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.

The remainder of the mowing should be done in the opposite direction so that the clippings are dispersed OUT onto the area of lawn previously cut.

Operation

Page 27

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 clippings on the lawn surface.

NOTE: When mulching under heavy cutting conditions, a rumbling sound may be present and is normal.

MULCHING REQUIRES EXCELLENT MOWING CONDITIONS

Mulching mowers cannot function properly if the grass is wet, or if the grass is simply to high to cut. Even more than normal mowing, mulching requires that the grass be dry and the the appropriate amount is cut.

Do not use the mower as a mulching mower during the first two or three mowings in the spring. The long grass blades, quick growth, and often wetter conditions are more suitable for broadcasting (sidedischarging) or grass bagging operation.

ENGINE SPEED & GROUND SPEED FOR BROADCASTING

Use full engine throttle matched with a slow ground speed so that clippings will be finely cut. Ground speed while mulching should be HALF of the speed that would be used when broadcasting (side discharging) under similar conditions. Since mulching requires more horsepower than broadcasting, using a slower ground speed is vitally important for proper mulching operation.

HOW MUCH GRASS TO MULCH

The best mulching action typically results from cutting only the top 1/2 inch to 3/4 inch of grass blade. This provides short clippings which decompose properly (much more quickly than longer clippings). The ideal cutting height will vary with climate, time of year, and quality of your lawn. We recommend that you experiment with both the cutting height and ground speed until you achieve the best cut. Start with a high cutting height and using progressively lower settings until you find a cutting height that is matched to your mowing conditions and preferences.

ATTACHING A TRAILER

The maximum weight of a towed trailer should be less than 300 lbs (138kg). Secure the trailer with a appropriately sized clevis pin (A, Figure 10) and clip (B).

Excessive towed loads can cause loss of traction and loss of control on slopes. Reduce towed weight when operating on slopes. The surface being driven on greatly impacts traction and stability. Wet or slippery surfaces can greatly reduce traction and the ability to stop or turn. Carefully evaluate the surface conditions before operating the unit and trailer, and never operate on slopes greater than 10°. See SLOPE OPERATION and TOWED EQUIPMENT in the safety section of this manual for additional safety information.

Figure 10. Trailer Weight Recommendations A. Clevis Pin B. Clip

Operation

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Operation

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 mower tips.

Figure 11. Raise & Lower the Roll Bar A. Hair Pin Clip B. Retainer Pin C. Roll Bar D. Rubber Stop

RAISE & LOWER THE ROLL BAR

To lower the roll bar:

1. Pull the hair pin clips (A, Figure 11) out of the retainer pins (B).

2. Push or pull the top of the roll bar (C) forward against the rubber stops (D) and remove the retainer pins (B).

3. Lower the roll bar and reinstall the retainer pins and hair pin clips to secure the roll bar in the down position (see insert, Figure 11).

To raise the roll bar:

1. Pull the hair pin clips (A) out of the retainer pins (B) and remove the retainer pins.

2. Raise the roll bar (C) until the rubber stops (D) contact the upright tubes.

3. Push or pull the top of the roll bar forward against the rubber stops and reinstall the retainer pins and hair pin clips to secure the roll bar in the raised position.

Page 29

Operation

NOTE: Diesel fuel, if permitted to stand unused for extended periods (30 days or more), may develop gummy deposits which can adversely affect the fuel pump and injector tubes and cause engine malfunction. To avoid this condition, add a diesel fuel stabilizer to the fuel tank and run the engine a few minutes, or drain all fuel from the unit before placing it in storage.

STARTING AFTER LONG TERM STORAGE

Before starting the unit after it has been stored for a long period of time, perform the following steps.

1. Remove any blocks from under the unit.

2. Install the battery if it was removed.

3. Unplug the exhaust outlet and air cleaner.

4. Fill the fuel tank with fresh fuel. See engine manual for recommendations.

5. See engine owner’s manual and follow all instructions for preparing engine after storage.

6. Check crankcase oil level and add proper oil if necessary. If any condensation has developed during storage, drain crankcase oil and refill.

7. Inflate tires to proper pressure. Check fluid levels.

8. Start the engine and let it run slowly. DO NOT run at high speed immediately after starting. Be sure to run engine only outdoors or in well ventilated area.

DIESEL FUEL RECOMMENDATIONS

Fuel companies provide fuel tailored to meet the existing weather conditions. These fuels change at the start of the predominant season according to regional weather trends.

Winter fuels are tailored to give ease of starting for cold weather. Summer fuel may be somewhat heavier than winter fuel resulting in slightly better fuel economy and power. Spring and fall fuel is an average blend between winter and summer blend.

For these reasons an effort should be made to purchase fuels in such quantities that they are not carried over into the next season. Using the wrong blend of fuel can cause problems with the engine.

Refer to the engine manufacturer’s manual for specific fuel recommendations.

STORAGE

Temporary Storage (30 Days Or Less)

Remember, the fuel tank will still contain some fuel, so never store the unit indoors or in any other area where fuel vapor could travel to any ignition source. Fuel vapor is also toxic if inhaled, so never store the unit in any structure used for human or animal habitation.

Here is a checklist of things to do when storing your unit temporarily or in between uses:

• Keep the unit in an area away from where children may come into contact with it. If there’s any chance of unauthorized use remove the ignition key.

• If the unit can’t be stored on a reasonable level surface, chock the wheels.

• Clean all grass and dirt from the mower.

• If temperature is expected to drop below 35 degrees, refer to Long Term Storage, Item 2.

Long Term Storage (Longer Than 30 Days)

Before you store your unit for the off-season, read the Maintenance and Storage instructions in the Safety Rules section, then perform the following steps:

1. Drain crankcase oil while engine is hot and refill with a grade of oil that will be required when unit is used again.

2. Use an Antifreeze tester to check the cooling system’s level of protection. Read the instructions on the Antifreeze container for the appropriate ratio of water to Antifreeze for your geographical area.

3. Prepare the mower deck for storage as follows:

a. Remove mower deck from the unit.

b. Clean underside of mower deck.

c. Coat all bare metal surfaces with paint or light coat

of oil to prevent rusting.

4. Clean external surfaces and engine.

5. Prepare engine for storage. See engine owner’s manual.

6. Clean any dirt or grass from cylinder head, engine housing and air cleaner element.

7. Cover air cleaner and exhaust outlet tightly with plastic or other waterproof material to keep out moisture, dirt and insects.

8. Completely grease and oil unit as outlined in the Regular Maintenance section.

9. Clean up unit and apply paint or rust preventative to any areas where paint is chipped or damaged.

10. Be sure the battery is filled to the proper level with water and is fully charged. Battery life will be increased if it is removed, put in a cool, dry place and fully charged about once a month. If battery is left in unit, disconnect the negative cable.

11. Drain fuel system completely or add a diesel fuel stabilizer to the fuel system. If you have chosen to use a fuel stabilizer and have not drained the fuel system, follow all safety instructions and storage precautions in this manual to prevent the possibility of fire from the ignition of diesel fumes. Remember, diesel fumes can travel to distant sources of ignition and ignite, causing risk of explosion and fire.

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 flammable and careless use could result in serious fire damage to your person or property.

Drain fuel outdoors into an approved container and away from open flame or sparks.

Operation

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Maintenance

MAINTENANCE SCHEDULE & PROCEDURES

The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by observing the hour meter.

* See the engine manufacturer's owner's manual.

** Change original engine oil after first 5 hours of operation.

*** More often in hot (over 85° F: 30° C) weather or dusty operating conditions.

**** Change gearbox oil after first 100 hrs. and every 500 hrs. thereafter

(see Gearbox Maintenance)

Tire Pressure

Front 25 psi (1,72 bar)

Rear 18 psi (1,24 bar)

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 life.

Regular Maintenance

SAFETY ITEMS

Before Each Use

Every 5 Hours

Every 25 Hours

Every 100 Hours

Every 250 Hours

Spring & Fall

Check Safety Interlock System

• •

Check Rider Brakes

• •

RIDER MAINTENANCE

Before Each Use

Every 5 Hours

Every 25 Hours

Every 100 Hours

Every 250 Hours

Spring & Fall

Check Gearbox Oil Level ****

• •

Check Rider / Mower for loose hardware

•

Clean Deck & Check / Replace Mower Blades**

•

Lubricate Rider & Mower **

•

Clean Battery & Cables

•

Check Tire Pressure

•

Check Hydraulic Oil

•

Change Hydraulic Oil Filter **

•

ENGINE MAINTENANCE

Before Each Use

Every 5 Hours

Every 25 Hours

Every 100 Hours

Every 250 Hours

Spring & Fall

Check Engine Oil Level / Engine Coolant Level

•

Check / Clean Cooling Fins & Intake **

•

Service Air Filter *

Change Oil & Filter *

Check / Replace Spark Plugs *

Check Fuel Filter / Drain Water Separator*

•

Check & Clean Radiator Screens

• •

Check Coolant Level

•

Change Coolant

•

Page 31

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 process for opposite tank.

NOTE: The fuel tanks are tied together through a “tee” in the supply lines. By filling only one tank, the level will balance between the two tanks, effectively having 1/2 tank of fuel for each side.

FUEL FILTER

This unit is equipped with two fuel filters. One is a water separator/filter mounted to the frame, under the seat and the other is located on the engine. The water separator should be drained every 25 hours or whenever water is visible in the bowl. Replace both fuel filters every 500 hours of operation or as required.

To drain the fuel filter:

1. Turn the engine off, set the parking brake, remove the ignition key, and wait for all moving parts to stop.

2. Allow the engine and surrounding areas to cool to room temperature.

3. Place a container under the fuel filter tube and turn the drain valve (B, Figure 14) approximately 1 turn.

4. Allow the filter to drain until all water and debris have drained out.

5. Turn the drain valve to close it when finished draining..

WARNING

Diesel fuel is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills.

Do not drain or replace fuel filter when engine is hot, as spilled fuel may ignite. Make sure the filter drain valve is fully closed before returning the unit to service.

Do not use Kerosene in place of diesel fuel. Kerosene will damage the engine. Consult the engine manufacturer’s manual for specific fuel recommendations.

Figure 14. Drain Fuel Filter A. Fuel Filter Bowl B. Drain Valve

WARNING

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the ignition switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

The water separator is under suction during normal engine operation. Ensure the drain valve is tightened securely to help prevent air from entering the fuel system.

Figure 13. Fill Fuel Tank A. Fuel Cap

Regular Maintenance

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Maintenance

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 service procedures.

CHECK HYDRAULIC OIL LEVEL

NOTE: Do not open the hydraulic oil reservoir unless oil is being added.

1. Visually check that the hydraulic oil level is filled to the recess area (A, Figure 16) of the hydraulic oil reservoir.

2. If necessary, remove the reservoir cap (B) and add either Mobil 1™, 15W-50 synthetic oil or Castrol Syntec™ 5W-50 oil. DO

NOT use conventional oils. Make sure area around the filler neck is free of dust, dirt, or other debris.

HYDRAULIC OIL FILTER CHANGE

Change Interval: Every 500 Hours

Filter Part Number: 5021357

NOTE: Removing the oil filter from the filter base will drain the oil reservoir. Have a suitable container ready to catch any spilled oil. Ferris recommends this be a dealer-only service item.

1. Locate the hydraulic oil filter (A, Figure 17) behind the battery.

2. Fill the new filter with oil. Lubricate the new filter seal with a few drops of oil.

3. Remove the oil filter and quickly thread the new filter onto the filter base until the gasket makes contact, then tighten 3/4 of a turn more.

4. Refill reservoir with fresh oil to replace any oil lost during filter change.

5. Raise the rear of the unit and secure with jackstands. Chock the front wheels to prevent the unit from rolling. Run the unit for several minutes to purge any air from the hydraulic system and check the hydraulic oil level.

IMPORTANT NOTE: Use caution after changing the filter; air in the hydraulic system may affect the responsiveness of the control levers. Repeat step 5 until the air is out of the system.

Figure 15. Change Oil & Filter A. Oil Fill Cap B. Crankcase Dip Stick

Figure 17. Hydraulic Oil Filter Location A. Oil Filter B. Battery

Figure 16. Hydraulic Oil Reservoir A. Tank Recess (“FULL” level) B. Cap

Regular Maintenance

Page 33

Maintenance

Figure 18. Radiator & Oil Cooler A. Radiator Pressure Cap B. Radiator Screen C. Hydraulic Oil Cooler

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 level is low, add coolant until level is 1/2” (13mm) below the bottom of the filler tube. Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water. See engine owners manual for engine coolant specifications.

3. Check the coolant level in the radiator expansion tank (Figure 19). If coolant level is low, remove the cap add coolant until level is at the “FULL” line. Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water. See engine owners manual for engine coolant specifications.

CHANGE ENGINE COOLANT

See engine owners manual for specific engine coolant procedures. The drain valve is located at the base of the right-hand side of the radiator.

CLEAN RADIATOR, SCREEN & OIL COOLER

Clean the radiator, screen and oil cooler fins before each use, or as required (depending on conditions) to allow proper air-flow through radiator and hydraulic oil cooler.

1. Raise the seat plate.

2. Lift the radiator screen straight up to remove the screen. Flush the screen with water or blow clean with air. Flush the radiator core with water or blow clean with air. See engine owners manual for proper radiator cleaning procedures.

3. Clean all dirt, grass, and debris from the oil cooler fins.

4. Reinstall the radiator screen. Make sure the screen is fully seated in the carrier.

5. Lower the seat plate.

WARNING

PRESSURIZED SYSTEM

Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order the relieve the pressure.

Figure 19. Radiator Expansion Tank

Regular Maintenance

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Maintenance

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. Ferris Red Grease (P/N 5022285) is recommended, automotive-type high-temperature, lithium grease may be used when this is not available.

Regular Maintenance

Figure 20. Deck Lift Linkage Pivots

Figure 21. Deck Lubrication

RE-PACK

BEARINGS

ANUALLY

Figure 22. Front Caster & Wheel

Figure 23. Control Handle Pivots & Seat Pivots

Oil:

Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Remember to wipe fittings and surfaces clean both before and after lubrication.

Figure 24. Gearbox Drive Idler Pivot

RE-PACK

BEARINGS

ANUALLY

Page 35

Maintenance

Regular Maintenance

BATTERY MAINTENANCE

(Note: The tractor equipped with a maintenance-free BCI58 battery)

Cleaning the Battery and Cables

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 and cable ends with a wire brush until shiny.

4. Reinstall the battery and reattach the battery cables, positive cable first (A).

5. Coat the cable ends and battery terminals with petroleum jelly or non-conducting grease.

WARNING

Be careful when handling the battery. Avoid spilling electrolyte. Keep flames and sparks away from the battery.

When removing or installing battery cables, disconnect the negative cable FIRST and reconnect it LAST. If not done in this order, the positive terminal can be shorted to the frame by a tool.

ANTI-SCALP DECK CASTERS

The anti-scalp deck casters (A, Figure 26) will aid in preventing the mower deck from scalping or gouging the turf while mowing or turning.

The casters can be adjusted in 1/2” (1,3 cm) increments with the spacers (B). The desired position is just below the leading edge of the deck.

IMPORTANT NOTE: These casters are not intended to be in contact with the ground at all times. If you are mowing at a low cut height, adjust the casters up to prevent the casters from carrying the weight of the deck.

Figure 26. Anti-Scalp Deck Casters A. Deck Caster B. Spacer C. Lynch Pin

Figure 25. Battery Compartment A. Positive (+) Cable & Terminal B. Negative (-) Cable & Terminal

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Maintenance

Regular Maintenance

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

27).

3. Use a file to sharpen blade to fine edge. Remove all nicks and dents in blade edge. If blade is severely damaged, it should be replaced.

4. Balance the blade as shown in Figure 28. Center the blade’s hole on a nail lubricated with a drop of oil. A balanced blade will remain level.

5. Reinstall each blade with the tabs pointing up toward deck as shown in Figure 29. Secure with a bolt and flat washer and torque bolts to 70 ft.lbs. (94 N.m.).

WARNING

Mower blades are sharp. For your personal safety, do not handle mower blades with bare hands. Careless or improper handling of blades may result in serious injury.For your personal safety, blade mounting bolts must each be installed with a flat washer then securely tightened. Torque blade mounting bolts to 70 ft.lbs. (94 N.m.)

Figure 28. Balancing The Blade

Figure 29. Installing The Blade A. Blade Bolt B. Flat Washer

Nail

Figure 27. Removing the Blade

Page 37

Troubleshooting

Troubleshooting, Adjustments & Service

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, their causes and remedies.

See the information on the following pages for instructions on how to perform most of these minor adjustments and service repairs yourself. If you prefer, all of these procedures can be performed for you by your local authorized dealer.

WARNING

To avoid serious injury, perform maintenance on the tractor or mower only when the engine is stopped and the parking brake engaged.

Always remove the ignition key to prevent accidental starting of the engine.

TROUBLESHOOTING THE RIDER

PROBLEM CAUSE REMEDY

Engine will not turnover or start. 1. Parking brake not engaged. 1. Engage parking brake.

2. PTO (electric clutch) switch 2. Place in OFF position. in ON position.

3. Out of fuel. 3. If engine is hot, allow it to cool, then refill

the fuel tanks. Prime the fuel system.

4. Motion Control Handles not 4. Lock handles in neutral position. locked in neutral position.

5. Operator not in seat. 5. Assume operator’s position in seat.

6. Glow plugs not pre-heated. 6. Pre-heat glow plugs.

7. Fuse blown. 7. Replace fuse.

8. Battery terminals require 8. Clean the battery terminals cleaning.

9. Battery discharged or dead. 9. Recharge or replace.

10. Wiring loose or broken. 10. Visually check wiring & replace broken or

frayed wires. Tighten loose connections.

11. Solenoid or starter motor faulty. 11. Repair or replace. See authorized

service dealer

12. Safety interlock switch 12. Replace as needed. See authorized faulty. service dealer.

13. Water in fuel. 13. Drain fuel & refill with fresh fuel.

14. Fuel is old or stale. 14. Drain fuel & replace with fresh fuel.

Engine starts hard or runs poorly. 1. Fuel mixture too rich. 1. Clean air filter.

2. Air in fuel system. 2. Prime the fuel system.

Engine knocks. 1. Low oil level. 1. Check/add oil as required.

2. Using wrong grade oil. 2. See engine manual.

Excessive oil consumption. 1. Engine running too hot. 1. Clean radiator screens and air cleaner.

2. Using wrong weight oil. 2. See engine manual.

3. Too much oil in crankcase. 3. Drain excess oil.

Engine exhaust is black. 1. Dirty air filter. 1. Replace air filter. See engine manual.

2. Air in fuel system 2. Prime the fuel system.

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Troubleshooting

RIDER TROUBLESHOOTING CONTINUED.

PROBLEM CAUSE REMEDY

Engine runs, but rider will 1. Hydraulic dump valve(s) 1. Turn dump valve(s) clockwise to close. not drive. in “open” position. Torque 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. Brake is not fully released. 4. See authorized service dealer

Hydraulic pump drive belt slips. 1. Pulleys or belt greasy or oily. 1. Clean as required.

2. Belt stretched or worn. 2. Replace belt.

Brake will not hold. 1. Brake is incorrectly adjusted. 1. See Brake Adjustment.

2. Brake caliper pads worn. 2. Replace with new brake pads.

Rider steers or handles poorly. 1. Steering linkage is loose. 1. Check and tighten any loose connections.

2. Improper tire inflation. 2. See Regular Maintenance Section.

TROUBLESHOOTING THE MOWER

PROBLEM CAUSE REMEDY

Mower will not raise. 1. Lift linkage not properly attached 1. See authorized service dealer for repair.

or damaged.

Mower cut is uneven. 1. Mower not leveled properly. 1. See Mower Adjustment.

2. Rider tires not inflated 2. See Regular Maintenance Section. equally or properly.

Mower cut is rough looking. 1. Engine speed too slow. 1. Set throttle to full.

2. Ground speed too fast. 2. Decrease Ground Speed.

3. Blades are dull. 3. Sharpen or replace blades.

See Mower Blade Service.

4. Mower drive belt slipping 4. Clean or replace belt as necessary. because it is oily or worn.

5. Blades not properly fastened 5. See Servicing the Mower Blades. to spindles.

Engine stalls easily with 1. Engine speed too slow. 1. Set to full throttle. mower engaged. 2. Ground speed too fast. 2. Decrease Ground Speed.

3. Cutting height set too low. 3. Cut tall grass at maximum cutting

height during first pass.

4. Discharge chute jamming 4. Cut grass with discharge pointing toward with cut grass. previously cut area.

Excessive mower vibration. 1. Blade mounting bolts 1. Tighten to 70 ft.lbs. (94 N.m.).

are loose.

2. Mower blades, spindles, 2. Check and replace as necessary. or pulleys are bent.

3. Mower blades are out 3. Remove, sharpen, and balance blades. of balance. See Maintenance Section.

4. Belt installed incorrectly. 4. Reinstall Correctly.

Excessive belt wear or breakage. 1. Bent or rough pulleys. 1. Repair or replace.

2. Using incorrect belt. 2. Replace with correct belt.

Mower drive belt slips or fails to 1. Idler pulley spring broken or not 1. Repair or replace as needed. drive. properly attached.

2. Mower drive belt broken. 2. Replace drive belt.

Troubleshooting, Adjustment & Service

Page 39

Troubleshooting

Troubleshooting, Adjustment & Service

TROUBLESHOOTING COMMON CUTTING PROBLEMS

PROBLEM CAUSE REMEDY

Streaking. 1. Blades are not sharp. 1. Sharpen your blades.

2. Blades are worn down to far. 2. Replace your blades.

3. Engine speed is too slow. 3. Always mow at full throttle.

4. Ground speed is too fast. 4. Slow down.

5. Deck is plugged with grass 5. Clean out the mower.

6. Not overlapping cutting rows 6. Overlap your cutting rows. enough.

7. Not overlapping enough when 7. When turning your effective cutting width turning. decreases–overlap more when turning.

Scalping. 1. Lawn is uneven or bumpy. 1. Roll or level the lawn.

2. Mower deck cutting height is 2. Raise the cutting height. set too low.

3. Ground speed is too fast. 3. Slow down.

4. Deck is not leveled correctly. 4. Correctly level the deck.

5. Tire pressure is low or uneven 5. Check and inflate the tires.

Stepped Cutting. 1. Deck is not leveled correctly. 1. Level the deck correctly.

2. Tires are not properly inflated. 2. Check and inflate the tires.

3. Blades are damaged. 3. Replace the blades.

4. Deck shell is damaged. 4. Repair or replace the deck.

5. Mower spindle is bent or loose. 5. Repair or replace the spindle.

6. Blades are installed incorrectly. 6. Reinstall the blades correctly.

Uneven Cutting. 1. Deck is not leveled correctly. 1. Level the deck correctly.

2. Blades are dull or worn. 2. Sharpen or replace the blades.

3. Blades are damaged. 3. Replace the blades.

4. Deck is clogged with grass 4. Clean out the deck. clippings.

5. Deck shell is damaged. 5. Repair or replace the deck.

6. Mower spindle is bent or loose. 6. Repair or replace the spindle.

7. Blades are installed incorrectly. 7. Reinstall the blades correctly.

8. Tires are not properly inflated. 8. Check and inflate the tires.

Stingers. 1. Blades are not sharp or nicked. 1. Sharpen your blades.

2. Blades are worn down too far. 2. Replace your blades.

3. Engine speed is too slow. 3. Always mow at full throttle.

4. Ground speed is too fast. 4. Slow down.

5. Deck is plugged with grass. 5. Clean out the mower.

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Troubleshooting

Troubleshooting, Adjustment & Service

SEAT ADJUSTMENT

See Figure 30. 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 to one another) and the height of the levers can be adjusted.

Handle Alignment

Loosen the mount hardware (A, Figure 31) and pivot the lever(s) (C) fore or aft to align with each other.

Handle Placement

Loosen the jam nuts and adjust the placement bolt (B) in or out to properly adjust the lever end spacing.

Handle Height

Remove the mounting hardware (A, Figure 30) and reposition the handle either up or down from its original position. You will need to readjust the handle alignment as described above.

SPEED BALANCING ADJUSTMENT

If the rider veers to the right or left when the ground speed control levers are in the maximum forward position, the top speed of each of these levers can be balanced by turning the adjustment bolt(s) (A, Figure

32). Only adjust the speed of the wheel that is traveling faster.

To Reduce the Speed of the Faster Wheel

1. Loosen the securing nut.

2. turn the top speed adjustment bolt CLOCKWISE to reduce the speed.

3. Retighten the securing nut when adjustment is complete.

WARNING

DO NOT adjust the tractor for a faster overall speed forward or reverse than it was designed for.

Figure 32. Top Speed Adjustment A. Top Speed Adjustment Bolt B. Jam Nut

Seat

Adjustment

Lever

Figure 30. Seat Adjustment

Figure 31. Control Lever Adjustment A. Alignment Hardware B. Placement Hardware C. Ground Speed Control Lever

Page 41

Troubleshooting

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 parking brake and turn off the engine.

2. Loosen the jam nuts (B, Figure 33) and turn the adjustment linkage (A) to adjust. If the machine creeps forward, turn the linkage CLOCKWISE (while standing at the rear of the machine, facing forward), if the machine creeps backward, turn the linkage COUNTER-CLOCKWISE.

3. Lock the jam nuts (B) when neutral is achieved.

NOTE: This adjustment should not be performed while the machine is running. It may take several attempts to achieve neutral, depending upon how much the machine creeps.

NEUTRAL POSITION AND RETURN SPRING ADJUSTMENT

To determine if it is necessary to adjust the neutral position, perform the following steps.

1. Disengage the PTO, engage the parking brake and turn off the engine.

2. Move the ground speed control levers in the operating position, pull levers rearward and release.

3. Move the ground speed control levers towards the neutral position. If the levers do not align with the notches in the neutral lock plate, it is necessary to adjust the reverse return bolts (A, Figure 34).

Neutral Position Adjustment

1. Loosen the jam nut (D, Figure 34) locked against the clevis.

2. Turn the reverse return bolt (A) clockwise to adjust handle rearward, counter-clockwise to adjust handle forward.

4. Pull lever rearward and release to check position again. Adjust as necessary to align levers with notches.

5. Once the lever alignment has been adjusted, lock jam nut against the clevis.

Figure 33. Neutral Adjustment (Left-hand side shown) A. Control Linkage B. Jam Nuts

Return Spring Adjustment

After adjusting the neutral position, lock the levers in the neutral position and measure the reverse return spring (B, Figure 34) length. This should be 2-3/8” (6,03 cm) long. If not, hold the reverse return bolt (A) with a wrench while turning the spring position nut (C)

until the measurement is achieved.

Figure 34. Neutral Spring Return Adjustment A. Reverse Return Bolt B. Reverse Return Spring C. Spring Position Nut D. Jam Nut

Troubleshooting, Adjustment & Service

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Troubleshooting

Troubleshooting, Adjustment & Service

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 35) through the opening under the fuel tanks.

3. With the parking brake engaged, measure the compressed spring length. The spring should be 2” - 2-1/8” (5,0 - 5,4cm) when compressed.

4. If adjustment is required, disengage the parking brake and turn the adjustment nut (B).

5. Engage the parking brake and re-measure the spring.

FRONT

Figure 35. Parking Brake Adjustment A. Upper Brake Spring B. Adjustment Nut

CAUTION

Do not adjust the spring to be shorter than 2” (5,0cm) when compressed. This may damage the brake caliper.

2" - 2-1/8"

(5,0 - 5,4cm)

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Troubleshooting

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 view the machine from behind. If you can visually notice that the top of either rear tire is angled towards the machine then the rear tire camber needs to be adjusted.

To adjust the camber you will need to order and install the correct amount of camber shims (P/N 5100332) for each tire that needs to be adjusted from your dealer. Shims should only be installed in even numbered quantities

To discover how many shims are needed:

1. Park the machine on a flat level surface. Disengage the PTO, stop the engine, remove the ignition key, and engage the parking brake.

2. Place a carpenters square against the rear tire. The bulge in the sidewall will not allow the square to contact the bottom outside edge of the tire where it first contacts the ground.

3. See Figure 36. Measure and record the distance from the carpenters square to the top of the tire (A, Figure 36.) Measure and record the distance from the carpenters square to the bottom of the tire (B.) Subtract the bottom measurement from the top measurement and reference the chart below for the number of shims that are needed. If the measurement is greater than .75” (1,91 cm) contact your dealer.

Installing the camber shims:

1. Park the machine on a flat level surface. Disengage the PTO, stop the engine, remove the ignition key, and engage the parking brake.

2. Jack up the rear of the machine and secure with jack stands. Remove the rear tire.

3. Loosen but do not remove the two (2) 1/2-20 X 3” (A, Figure 37) bolts and the (2) 1/2-20 X 1-3/4” bolts (B.)

4. Install the new camber shims (E) between the adjustable A-arm mount (C) and the rigid A-arm mount (D.) The bottom of the slots on the camber shim should rest snugly against the shaft of the 1/2-20 X 3” bolts and the 1/2-20 X 1-3/4” bolts.

Figure 37. Installing the Rear Tire Camber A. 1/2-20 x 3” Bolt B. 1/2-20 x 1-3/4” Bolt C. Adjustable A-arm Mount D. Rigid A-arm Mount E. Camber Shims F. 1/2-20 Hex Nylon Nut

Figure 36. Measuring the Camber Distance A. Top Measurement B. Bottom Measurement

5. Retighten the two (2) 1/2-20 X 3” bolts and the (2) 1/2-20 X 1-3/4” bolts.

6. Reinstall the tire.

Troubleshooting, Adjustment & Service

Distance Measured

Number of Shims

Needed

.2” (,51 cm) 2

.4” (1,04 cm) 4

.6” (1,52 cm) 6

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Troubleshooting

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 more pre-load for heavy weight operators.

To adjust the spring pre-load:

1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake.

2. See Figure 38. Using the supplied spanner wrench (p/n 5022853), insert the tip of the wrench into the notch in the pre-load adjuster. While holding the wrench with both hands, turn CLOCKWISE to decrease the pre-load, turn COUNTER-CLOCKWISE to increase the pre-load. Make sure that for each pair of shocks (A, B or C, Figure 38) that the left-hand and right-hand are set to the same amount of pre-load.

NOTE: Spanner wrench is located under the seat. Rear tires must be removed to adjust the rear suspension.

Figure 38. Adjust Spring Pre-Load

FRONT REAR

A B C

Troubleshooting, Adjustment & Service

Page 45

Troubleshooting

Troubleshooting, Adjustment & Service

MOWING HEIGHT ADJUSTMENT

The cutting height adjustment pin (A, Figure 39) controls the mower cutting height. The cutting height is adjustable between 1-1/2” (3,8 cm) and 6” (15,2 cm) in 1/4” (0,64 cm) increments.

1. Depress the deck lift foot pedal (B) until it locks into the 6” (15,2 cm) position.

2. Place the cutting height adjustment pin in the desired cutting height.

3. Depress the deck lift foot pedal then push the lock lever (C) towards the right to release the lock.

4. Release the deck lift foot pedal until it comes to rest against the cutting height adjustment pin.

Figure 39. Mowing Height Adjustment A. Cutting Height Adjustment Pin B. Deck Lift Foot Pedal C. Deck Lift Lock lever

Page 46

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Troubleshooting

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 pivots and the inner rod pivots. Repeat for other side of unit. See Figure 40.

3. To check the outer lift rod timing, measure and record the distance between the outer lift pivots and the outer rod pivots. Repeat for other side of unit. See Figure 40.

4. If the measurements for the inner rods are equal, and the measurements for the outer rods are equal, no further adjustment is required. If the measurements are NOT equal (greater than 1/8” (3,17mm) difference), adjustment is required, continue with Step 5.

5. Lock the deck lift pedal in the 6” (15,2cm) position. Remove the cutting height adjustment pin (A, Figure 41) and lower the mower deck.

6. To ensure that the deck is in the lowest position, push the pedal by hand towards the rear of the unit and install the height adjustment pin in the 3” (7.6cm) position to hold in place.

7. Block up the mower deck until all hanger chains are slack.

8. Refer to Figure 42. To adjust the inner lift rod, loosen the jam nut on the front ball joint then remove the 1/2” hardware fastening the ball joint the the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2” hardware previously removed. Tighten the jam nut against the lift rod.

9. Refer to Figure 42. To adjust the inner lift rod, loosen the jam nut on the front ball joint then remove the 1/2” hardware fastening the ball joint the the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2” hardware previously removed. Tighten the jam nut against the lift rod.

10. Remove blocks from under the mower deck.

11. Remove the the cutting height adjustment pin from in front of the deck lift pedal arm. Lift mower deck and reinstall adjustment pin in desired mowing height.

Measure 1st

Measure 2nd

Measure 1st

Measure 2nd

Inner Rod

Outer Rod

Inner Rod

Outer Rod

Adjust Here

Figure 40. Measure the Inner & Outer Lift Rods

Figure 42. Adjust the Inner & Outer Lift Rods

Figure 41. Deck Lift Pedal A. Height Adjustment Pin

Troubleshooting, Adjustment & Service

Page 47

Troubleshooting

Troubleshooting, Adjustment & Service

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 bar).

2. Lock the deck lift pedal in the 6” (15,2cm) position. Place the deck height adjustment pin in the 4" position and lower deck the lift pedal until the arm contacts the pin.

3. Place 2 x 4 blocks under each corner of the mower deck with the 3-1/2” sides being vertical. Place a 1/4” (0,64cm) thick spacer on top of the rear 2 x 4 blocks. See Figure 43.

4. Adjust the front eyebolts until the chains are tight and the deck is still resting on the 2 x 4’s. Tighten jam nuts. For 72” RD Mower Deck: Loosen the nuts and allow the front of the deck to rest on the 2 x 4’s. Slide the chains in the slots until the chains are tight and tighten the nuts. See Figure

44.

5. Loosen the jam nuts (A, Figure 44) and turn the adjustment bolts (B) until the chains are tight and the rear of the deck is resting on the 2 x 4’s and 1/4” spacers. Tighten the jam nuts.

6. Remove all 2 x 4 blocks and spacers from under the mower deck.

Figure 43. 2 x 4 Locations

DECK LIFT SPRING

The deck lift springs (A, Figure 45) are factory set to provide optimal lifting performance.

Although it is fastened with an adjustable anchor, this is NOT AN ADJUSTMENT POINT.

DO NOT attempt to adjust the spring length or lifting performance will be compromised.

Figure 45. Deck Lift Spring Location A. Deck Lift Spring

Figure 44. Deck Level Adjustment A. Jam Nut B. Adjustment Bolt

Adjust Here

Adjust Here 72” RD

Page 48

BELT REMOVAL & REPLACEMENT

Mower Drive Belt Removal & Replacement

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 height adjustment pin (A, Figure 46) and lower deck.

3. Loosen the 5/16” bolts securing the mower deck guards and remove the guards.

4. Using a 3/4” combination wrench, rotate the spring-loaded idler pulley (A, Figure 47) CLOCKWISE to release the belt tension.

5. Slide the drive belt over the edge of the stationary idler pulley (C) and carefully release the tension on the wrench until the spring tension is completely released.

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Troubleshooting

Figure 47. Mower PTO Belt A. Spring-loaded Idler Pulley B. Idler Spring C. Stationary Idler Pulley

To avoid damaging belts, DO NOT PRY BELTS OVER PULLEYS.

WARNING

Use extreme caution when rotating the idler pulley with the wrench, due to the increased tension in the spring as the idler pulley is being rotated. Injury may result if the wrench is prematurely released while the spring is under tension.

Figure 46. Lower the Mower Deck A. Height Adjustment Pin

6. Remove the old belt and replace with a new one.

7. Install the drive belt on the gearbox pulley, the spindle pulleys and idler pulleys.

8. Rotate the spring-loaded idler pulley (A, Figure

47) CLOCKWISE and slide the drive belt over the edge of the stationary idler pulley (C). Make sure the V-side of the belt runs in the pulley grooves (Figure 48). Carefully release the tension on the wrench.

9. Reinstall the mower deck guards and tighten the 5/16” hardware to secure in place.

10. Run the mower under no-load condition for approximately 5 minutes to break in the belt.

Figure 48. Mower PTO Belt Routing A. Spindle Pulley B. PTO Drive Belt C. Spring-loaded Idler Pulley D. Stationary Idler Pulley

72” Side Discharge Model

61” Models & 72” Rear Discharge Models

Troubleshooting, Adjustment & Service

Page 49

Troubleshooting

Troubleshooting, Adjustment & Service

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 5/16” bolt, washer and nut (C, Figure

49) that fasten the rubber pad to the clutch and unscrew the wire ends that connect the clutch to the electrical harness.

5. Using a 1/2” breaker bar, place the square end in the square hole located in the middle of the idler arm (A). Carefully rotate the breaker bar CLOCKWISE, which will relieve the tension on the belts exerted from the idler arm.

6. Remove the belts from the gearbox drive pulley (D).

7. Carefully release the tension on the breaker bar until the idler arm stops.

8. Remove the clutch belts from the clutch pulley grooves and pull around the idler pulley.

Clutch Belt Replacement

1. Install the clutch belts over the top of the clutch, into the grooves of the crankshaft pulley and around the idler pulley.

2. Carefully rotate the idler arm with the breaker bar CLOCKWISE (see Figure 49) and install the belts into the grooves of the gearbox drive pulley.

3. Carefully release the tension on the breaker bar.

4. Reinstall the clutch anchor pad to the clutch with the hardware (C) previously removed. Make sure the hardware is in the same order as is was before being removed.

5. Reinstall the rear belt shield and lower the hood. Make sure the hood is firmly latched.

Figure 49. Clutch Belt Removal & Replacement A. Idler Arm B. Clutch Belt Idler Spring C. Clutch Anchor Hardware D. Gearbox Drive Pulley E. Gearbox

WARNING

Use extreme caution when rotating the idler arm with the breaker bar, due to the increased tension in the spring as the idler arm is being rotated. Injury may result if the breaker bar is prematurely released while the spring is under tension.

Page 50

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Troubleshooting

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 square end in the square hole located in the middle of the idler arm (A, Figures 50). Carefully rotate the breaker bar COUNTER-CLOCKWISE, which will relieve the tension on the belts exerted from the idler arm.

4. Remove the belts from the right-hand and lefthand pump drive pulley grooves.

5. Carefully release the tension on the breaker bar.

6. Unhook the spring (B) from the anchor bolt on the idler arm.

7. Remove the belts from the crankshaft pulley grooves and pull out from behind the clutch.

Pump Drive Belt Replacement

1. Place the belts under clutch into the crankshaft pulley grooves.

2. Wrap the belts around the top side of the idler arm pulley and install the belts in the right-hand pump pulley grooves.

3. Reinstall the spring onto the anchor bolt on the idler arm.

4. Carefully rotate the idler arm with the breaker bar COUNTER-CLOCKWISE (see Figure 50). While holding the breaker bar firmly, install the belts in the left-hand pump pulley grooves and the two stationary idler pulleys grooves.

5. Carefully release the tension on the breaker bar.

6. Inspect the belt path making sure that all belts are properly seated in the pulley grooves.

7. Reinstall the clutch belts (see

CLUTCH BELT

REPLACEMENT

for instructions).

Figure 50. Pump Belt Removal & Replacement A. Pump Drive Idler Arm B. Spring

WARNING

Troubleshooting, Adjustment & Service

Page 51

Troubleshooting

Troubleshooting, Adjustment & Service

Figure 51. Gearbox Oil Level A. Fill Plug B. Drain Plug

GEARBOX MAINTENANCE

Check Gearbox Oil Level

1. Remove fill plug (A, Figure 51) 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 seep from hole, then replace fill plug.

Changing Gearbox Oil

NOTE: The gearbox lubricant should be changed after the first 100 hrs. or 30 days of operation, then after 500 hours or 12 months.

1. Remove the mower deck drive belt (see

MOWER

DRIVE BELT REMOVAL & REPLACEMENT

for

instructions).

2. Rotate the the mower deck drive pulley on the gearbox so the drain plug is aligned with the opening between the pulley spokes.

3. Place a container under the gearbox drain hole and remove the drain plug (B).

4. Replace drain plug and fill with SAE 80-90 weight gear oil until oil starts to seep from hole, then replace fill plug.

5. Using a parts solvent, thoroughly clean any excess oil from the pulley faces and groove.

6. Reinstall the mower deck drive belt (see

MOWER

DRIVE BELT REMOVAL & REPLACEMENT

for

instructions).

Top

Front

Page 52

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Troubleshooting

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 start the engine may not mean the battery needs to be replaced. For example, it may mean that the alternator is not charging the battery properly. If there is any doubt about the cause of the problem, see your dealer. If you need to replace the battery, follow the steps under Cleaning the Battery & Cables in the Regular Maintenance Section.

CHARGING A COMPLETELY DISCHARGED BATTERY

1. Be aware of all the safety precautions you should observe during the charging operation. If you are unfamiliar with the use of a battery charger and hydrometer, have the battery serviced by your dealer.

2. Add distilled water sufficient to cover the plate (fill to the proper level near the end of the charge). If the battery is extremely cold, allow it to warm before adding water because the water level will rise as it warms. Also, an extremely cold battery will not accept a normal charge until it becomes warm.

3. Always unplug or turn the charger off before attaching or removing the clamp connections.

4. Carefully attach the clamps to the battery in proper polarity (usually red to [+] positive and black to [-] negative).

5. While charging, periodically measure the temperature of the electrolyte. If the temperature exceeds 125° F (51.6° C), or if violent gassing or spewing of electrolyte occurs, the charging rate must be reduced or temporarily halted to prevent battery damage.

WARNING

Keep open flames and sparks away from the battery; the gasses coming from it are highly explosive. Ventilate the battery well during charging.

6. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60° F). The best method of making certain a battery is fully charged, but not over charged, is to measure the specific gravity of a cell once per hour. The battery is fully charged when the cells are gassing freely at low charging rate and less than 0.003 change in specific gravity occurs over a three hour period.

JUMP STARTING WITH AUXILIARY (BOOSTER) BATTERY

Jump starting is not recommended. However, if it must be done, follow these directions. Both booster and dis-charged batteries should be treated carefully when using jumper cables. Follow the steps below EXACTLY, being careful not to cause sparks. Refer to Figure 52.

1. Both batteries must be of the same voltage.

2. Position the vehicle with the booster battery adjacent to the vehicle with the discharged battery so that booster cables can be connected easily to the batteries in both vehicles. Make certain vehicles do not touch each other.

3. Wear safety glasses and shield eyes and face from batteries at all times. Be sure vent caps are tight. Place damp cloth over vent caps on both batteries.

4. Connect positive (+) cable to positive post of discharged battery (wired to starter or solenoid).

5. Connect the other end of same cable to same post marked positive (+) on booster battery.

6. Connect the second cable negative (-) to other post of booster battery.

7. Make final connection on engine block of stalled vehicle away from battery. Do not lean over batteries.

8. Start the engine of the vehicle with the booster battery. Wait a few minutes, then attempt to start the engine of the vehicle with the discharged battery.

9. If the vehicle does not start after cranking for thirty seconds, STOP PROCEDURE. More than thirty seconds seldom starts the engine unless some mechanical adjustment is made.

10. After starting, allow the engine to return to idle speed. Remove the cable connection at the engine or frame. Then remove the other end of the same cable from the booster battery.

11. Remove the other cable by disconnecting at the discharged battery first and then disconnect the opposite end from the booster battery.

12. Discard the damp cloths that were placed over the battery vent caps.

Troubleshooting, Adjustment & Service

Page 53

Troubleshooting

Troubleshooting, Adjustment & Service

To Starter Switch

Starting Vehicle Battery

To Ground

To Starter Switch

Discharged Vehicle Battery

Engine Block

THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES

MAKE CERTAIN VEHICLES DO NOT TOUCH

Jumper Cable

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 to jump start a vehicle having a frozen battery because the battery may rupture or explode. If a frozen battery is suspected, examine all fill vents on the battery. If ice can be seen or if the electrolyte fluid cannot be seen, do not attempt to start with jumper cables as long as the battery remains frozen.

WARNING

For your personal safety, use extreme care when jump starting. Never expose battery to open flame or electric spark – battery action generates hydrogen gas which is flammable and explosive. Do not allow battery acid to contact skin, eyes, fabrics, or painted surfaces. Batteries contain a sulfuric acid solution which can cause serious personal injury or property damage.

When removing or installing battery cables, disconnect the negative cable FIRST and reconnect it LAST. If not done in this order, the positive terminal can be shorted to the frame by a tool.

To avoid engine damage, do not disconnect battery while engine is running. Be sure terminal connections are tight before starting.

Figure 52. Jump Starting

Page 54

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 Displacement 91.54 Cu. in (1500 cc) Electrical System 12 Volt, 16 amp. Alternator, Battery: 500

CCA

Oil Capacity 11.5 Pt. (5.4 L) w/ Filter

CHASSIS:

Fuel Tanks Capacity: 13 Gallons (49.2 L) Total Rear Wheels Tire Size: 26 x 12.00 -12

Inflation Pressure: 15 psi (1,03 bar)

Front Wheels Tire Size: 13 x 6.50 - 6

Inflation Pressure: 25 psi (1,72 bar)

TRANSMISSIONS:

HydroGear BDP-21 / Parker TF-040

Type Pump and Wheel Motor Hydraulic Fluid Mobil 1™ 15W-50 synthetic oil or

Castrol Syntec™ 5W-50 oil

Speeds Forward: 0-11 MPH (0-17.7 km/h) @ 3400 rpm Reverse: 0-5 MPH (0-9.65 km/h) Continuous Torque 483 ft. lbs. (654 N.m.) Output Maximum Weight 3000 lbs. (1360 Kg) on Axle

DIMENSIONS:

Overall Length 87” (221 cm) Overall Width 72” Side Discharge 85” (216 cm) 72” Rear Discharge 73” (185 cm) 61” Side Discharge 62” (157 cm) Height 55” (140 cm) Weight (apx.) w/ 72” Deck 1908 lbs. (865 kg) w/ 61” Deck 1887 lbs. (856 kg)

Engine Power Rating Information

The gross power rating labels for individual gas engine models meet or exceed SAE (Society of Automotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure) and rating performance has been obtained and corrected in accordance with SAE J1995 (Revision 2002-05). Actual gross engine power may be lower and is affected by, but not limited to, ambient operating conditions and engine to engine variability. Given both the wide array of products on which engines are placed, and the variety of environmental issues applicable to operating the equipment, the gas engine will not develop the rated gross power when used in a given piece of power equipment (actual “on-site” or net horsepower). This difference is due to a variety of factors including, but not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application limitations, ambient operating conditions (temperature, humidity, altitude), and engine to engine variability.

Specifications

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Specifications

Page 55

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 obligations under this limited warranty, you shall have read the operator's manual and you shall have completed and submitted to Ferris, within 20 days from the date of purchase, the Ferris Product Registration. You must properly service and maintain your Ferris product as described in the operator's manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense. The Ferris equipment, including any defective part covered by this limited warranty, must be returned to an authorized Ferris dealer within the warranty period for warranty service. This limited warranty extends only to equipment operated under normal conditions and in accordance with Ferris' instructions.

Warranty Start Date - The limited warranty coverage begins on the day you buy your new Ferris commercial mowing equipment. An authorized Ferris dealer will assist you in filling out a Ferris Product Registration with specific information for the model you purchase and your personal information, which must be returned to Ferris.

Limited Warranty - The limited warranty, set forth below, is a written guarantee by Ferris, during the warranty period, to repair or replace parts which have a substantial defect in materials or workmanship. The warranty is "limited" because it is for a specified period of time, applies to the original purchaser only, and is subject to other restrictions.

FERRIS LIMITED WARRANTY

Ferris Industries (Ferris) warrants, in accordance with the provisions below, to the original purchaser only, for the periods described below that the commercial mower shall be free from substantial defects in material or workmanship under normal use and service. If you wish to file a claim under this limited warranty, you must provide prompt notice of your claim to an authorized Ferris dealer during the warranty period. Ferris' obligation under this limited warranty is, at Ferris' option, to repair or replace any part or parts of the mower, which, in the judgment of Ferris, are found to be defective and covered by this limited warranty. An authorized Ferris dealer will repair or replace the defective part or parts, at the dealer's place of business, at no charge for the labor or parts. This limited warranty applies only to mowers sold in the United States and Canada and is subject to the following limitations.

Covered Parts Warranty Period

All Mowers 2-years (24 months) from date of retail purchase by the original

purchaser for parts & labor (90 days for rental mowers) (Except as noted below*)

*Belts, Tires, Brake Pads 90 days from date of retail purchase by the original purchaser And Hoses, Battery, Blades

*Attachments 1 year from date of retail purchase by the original purchaser

*Engine If the engine manufacturer provides any warranty on the mower's engine, Ferris will assign that warranty to the

original purchaser of the mower if such assignment is reasonably practicable. Please refer to the engine manufacturer's warranty statement, if any, that is included in the owner's packet. We are not authorized to handle warranty adjustments or repairs on engines. Ferris offers NO WARRANTY on mower engines. Ferris does not guarantee or represent that any engine manufacturer will comply with the terms of its warranty.

Items and Conditions Not Covered

This warranty does not cover, and Ferris makes NO WARRANTY regarding, the following:

• Mowers or their parts if a complete and accurate Ferris Product Registration has not been received by Ferris.

• Loss or damage to person or property other than that expressly covered by the terms of this limited warranty.

• Pickup and delivery charges and risk of loss or damage in transit to and from any authorized Ferris dealer.

• Any damage or deterioration due to normal use, wear and tear, or environmental or natural elements, or exposure.

• Cost of regular maintenance service or parts, such as but not limited to, filters, fuel, lubricants, tune-up parts, and adjustments.

• Claims arising due to failure to follow Ferris' written instructions, or improper storage or maintenance.

• Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the mowing equipment, or other than as recommended in the operator's manual or other written operational instructions provided by Ferris.

• Use of non-Ferris approved parts or accessories.

• Any overtime or other extraordinary repair charges or charges relating to repairs or replacements.

• Rental of like or similar replacement equipment during the period of any warranty, repair or replacement work.

• Loss of revenue, time or use of the mowing equipment.

• Travel, telephone or other communication charges.

• Damage from continued use of defective mowing equipment.

• Freight charges on replacement parts.

• Any mowing equipment or part which, in the judgment of Ferris, has been altered or tampered with in any way or has been subjected to misuse, abuse, abnormal usage, unauthorized repair, neglect or accident, damage in transit, or has had the serial numbers altered, effaced or removed.

• Any equipment, part or item not mentioned under "Covered Parts," above.

General Conditions

Ferris is continually striving to improve its products, and therefore reserves the right to make improvements or changes without incurring any obligation to make changes or additions to products sold previously. Any oral or written description of Ferris products is for the sole purpose of identifying the products and shall not be construed as an express warranty. No warranty claim shall give rise to a right for the purchaser to cancel or rescind any sale. No person is authorized to make any warranty or assume for Ferris any liability not strictly in accordance with this limited warranty. Any assistance Ferris provides to or procures for the purchaser outside the terms, limitations or exclusions of this limited warranty will not constitute a waiver of the terms, limitations or exclusions of this limited warranty, nor will such assistance extend or revive the limited warranty. Ferris will not reimburse the purchaser for any expenses incurred by the purchaser in repairing, correcting or replacing any defective products except for those incurred with Ferris' prior written permission and in accordance with this limited warranty.

Ferris' sole and exclusive liability with respect to this limited warranty, and the purchaser's exclusive remedy, shall be repair or replacement as set forth herein. All warranty work must be performed by an authorized Ferris dealer using only Ferris approved replacement parts. FERRIS SHALL HAVE NO

LIABILITY FOR ANY OTHER COST, LOSS OR DAMAGE, INCLUDING BUT NOT LIMITED TO, ANY INCIDENTAL, COMPENSATORY, INDIRECT, PUNITIVE, SPECIAL OR CONSEQUENTIAL LOSS OR DAMAGE. FERRIS' AGGREGATE LIABILITY WITH RESPECT TO A DEFECTIVE PRODUCT OR PART SHALL BE LIMITED TO AN AMOUNT EQUAL TO THE MONIES PAID BY THE PURCHASER FOR THAT DEFECTIVE PRODUCT OR PART. THIS LIMITED WARRANTY, AND FERRIS' OBLIGATIONS HEREUNDER, ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. FERRIS SHALL NOT BE LIABLE TO THE PURCHASER, OR TO ANYONE CLAIMING UNDER THE PURCHASER, FOR ANY OTHER OBLIGATIONS OR LIABILITIES, INCLUDING, BUT NOT LIMITED TO, OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR WARRANTY, NEGLIGENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY, WITH RESPECT TO FERRIS PRODUCTS OR FERRIS' ACTS OR OMISSIONS OR OTHERWISE.

It is the express wish of the parties that this agreement and any related documents be drafted in English. Il est la volonté expresse des parties que cette convention et tous les documents s'y rattachent soient rédigés en anglais.

Ferris Industries - a division of Simplicity Manufacturing Inc.

Owner's Limited Warranty Information

(Effective 04/28/2004)

Page 56

IS5100Z Series

Zero-Turn Riding Mower

OPERATOR’S MANUAL

Briggs & Stratton Yard Power Products

5375 North Main Street Munnsville, NY 13409 800-933-6175 www.ferrisindustries.com

Product Quick Specs:

ENGINE:

33 HP Caterpillar

Make Caterpillar Model 3013E Oil Capacity 11.5 Pt. (5.4 L) w/ Filter

CHASSIS:

Fuel Tanks Capacity: 13 Gallons (49.2 L) Total Rear Wheels Tire Size: 26 x 12.00 -12

Inflation Pressure: 15 psi (1,03 bar)

Front Wheels Tire Size: 13 x 6.50 - 6

Inflation Pressure: 25 psi (1,72 bar)

BELTS AND BLADES:

TRACTOR

Pump Drive Belt 5023388 Gear Box Belt 5022575

61” SIDE DISCHARGE MOWER DECK

Deck Drive Belt 5021724 Mower Blade 5020842

72” SIDE DISCHARGE MOWER DECK

Deck Drive Belt 5022439 Mower Blade 5022476

61” REAR DISCHARGE MOWER DECK

Deck Drive Belt 5021724 Mower Blade 5023272

72” REAR DISCHARGE MOWER DECK

Deck Drive Belt 5022439 Mower Blade 5023273

Briggs & Stratton Ferris 5900619 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual