Ferris Industries 5900646, 5900638, 5900644, 5900972, 5900645 User Manual

OPERATOR’S

MANUAL

Comfort Control DD Series

Walk-Behind Mowers

Tractor:

Model Number: Description

5900633 CCWKAV19,
5900635 CCWKAV25,
5900637 CCWKAV19CE,
5900638 CCWKAV25CE,
5900972 CCWKAV26,

Mower Deck:

Model Number: Description

5900636 CCW/48, 48” Cut
5900644 CCW/52, 52” Cut
5900645 CCW/61, 61” Cut
5900646 CCW/48CE, 48” Cut
5900647 CCW/52CE, 52” Cut

Combo Models:

Model Number: Description

5900677 CCWKAV1948
5900678 CCWKAV1952
5900679 CCWKAV2552
5900680 CCWKAV2561
5900688 CCWKAV1948CE
5900689 CCWKAV2552CE
5900727 CCWKAV1948SDCE
5900973 CCWKAV2652
5900974 CCWKAV2661
5900975 CCWKAV2048
5900976 CCWKAV2052
5900552 CCWKAV2148
5900553 CCWKAV2152
5900555 CCWKAV2452
5900554 CCWKAV2461

5100647

Revision T

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. Save these original instructions for future reference.

PRODUCT REFERENCE DATA

Unit Model Number Unit SERIAL Number

Mower Deck Model Number Mower Deck SERIAL Number

Dealer Name Date Purchased

ENGINE REFERENCE DATA

Engine Make Engine Model

Engine Type/Spec Engine Code/Serial Number

See Features & Controls Section for the location of
Identification Numbers

Briggs & Stratton Power Products Group, LLC
Copyright © 2012 Briggs & Stratton Corporation
Milwaukee, WI, USA. All rights reserved.

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

Contact Information:
Briggs & Stratton Power Products Group, LLC

5375 N. Main St.
Munnsville, NY 13409-4003
[phone]
www.ferrisindustries.com

WARNING

Engine exhaust from this product contains
chemicals known by the state of California
to cause cancer, birth defects, or other
reproductive harm.

WARNING

Battery posts, terminals, and related
accessories contain lead and lead
compounds—chemicals known to the
state of California to cause cancer or other
reproductive harm. Wash hands after
handling.

Table of Contents

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

Identification Tags ............................................. 8

Safety Decals ...................................................... 9

Safety Interlock System .................................. 10

Safety Icons ...................................................... 11

Features & Controls ......................................... 12

Control Functions (S/N: 2013964104 & Below) ....12

Control Functions (S/N: 2013964105 & Above) ....14

Operation

General Operating Safety......................................16

Checks Before Starting .........................................16

Starting the Engine ................................................17

Stopping the Mower ..............................................17

Driving the Mower .................................................18

Mowing ..................................................................20

Mowing Recommendations ...................................20

Mowing Methods ...................................................21

Pushing the Mower by Hand .................................22

Storage..................................................................23

Starting After Long Term Storage .........................23

Regular Maintenance

Maintenance Schedule .........................................24

Checking Tire Pressures .......................................25

Checking/Adding Fuel ...........................................25

Fuel Filter ..............................................................25

Oil & Filter Change ................................................25

Check Hydraulic Oil Level .....................................26

Check / Change Air FIlter ......................................26

Lubrication ............................................................27

Cleaning the Battery and Cables...........................28

Servicing the Mower Blades ..................................29

Troubleshooting, Adjustments & Repair

Troubleshooting the Mower ...................................30

Troubleshooting the Mower Deck .........................31

Troubleshooting Common Cutting Problems ........32

Mowing Height Adjustment ...................................33

Deck Lift Rod Timing Adjustment ..........................33

Deck Leveling Adjustment .....................................34

Mower Belt Replacement ......................................35

Transmission Drive Belt Replacement ..................37

Transmission Neutral & Tracking Adjustments .....38

Transmission Maintenance & Service ...................39

Battery Service ......................................................40

Specifications ................................................... 42

Slope Identification Guide ............................... 43

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

1

Safety Rules & Information

Read the Manual

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.

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.

2

Safety Rules & Information

Slope Operation

You could be seriously injured if you use this unit on too steep of
a slope. Using the unit on a slope that is too steep where you do
not have adequate footing and unit traction (and control) can cause
you to lose control and possibly slip and fall or roll the unit over.

Always mow across slopes, not up and down (you could slip and
fall.)

Also, note that the surface you are on can greatly impact your
ability to safely operate this machine. Wet grass or soft soil can
seriously affect your footing and traction of the unit. Do not
operate on slopes that are slippery, wet, or have soft soil.

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.

This equipment has many moving parts that can injure
you or someone else. However, if you stay in the
operator zone (area behind the handles and controls),
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.

Moving Parts

3

Safety Rules & Information

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
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.

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.

4

Safety Rules & Information

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 mowing deck is capable of amputating hands and feet and throwing objects.
The triangle in text signifies important cautions or warnings which must be followed.

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.

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.

5

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.

WARNING

It is a violation of California Public Resource
Code, Section 4442, to use or operate the
engine on any forest-covered, brush-covered
or grass-covered land unless the exhaust
system is equipped with a spark arrester,
as defined in Section 4442, maintained in
effective working order. Other states or federal
jurisdictions may have similar laws. Contact
an Authorized Service Dealer to obtain a spark
arrester designed for the exhaust system
installed on this engine.

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

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.

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.

WARNING

Operating on steep slopes can cause sliding
and loss of steering, control and rollover.

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.

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.

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 mow excessively steep slopes.

6. Do not use grass catcher on steep slopes.

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 allow children to operate the unit.

5. 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.

IGNITION SYSTEM (GASOLINE MODELS)

1. This spark ignition system complies with Canadian
ICES-002.

Do

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

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.

7

SAMPLE

Identification Numbers

SAMPLE

Identification Numbers

SAMPLE

North American
Models

PRODUCT IDENTIFICATION

SAMPLE

XXXX

XXXXXXXXXXXXXXX

MODEL XXXXXXX

SERIAL

XXXXXXXX

NO

0

123456 789012

Briggs & Stratton Power Product Group, LLC
XXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXX

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.

min

kW

XXX

kg

XXX

XXX

20xx

Assembled in U.S.A

CE Models

Power Head

Identification Tag

Mower Deck

Identification Tag

Fig. 1 Location of Identification Tags.

CE IDENTIFICATION TAG
MARKINGS

A. Manufacturer’s Identification Number
B. Product Description
C. Serial Number
D. Manufacturer’s Address
E. CE Compliance Logo
F. Year of Manufacture
G. Maximum Engine Speed in Rotations per Minute
H. Power Rating in Kilowatts
I. Mass of Unit in Kilograms
J. Sound Power in Decibels*

This unit complies with European Harmonized Lawn Mower
Standard EN 836, European Machinery Directive 2006/42/
EC, and European EMC Directive 2004/108/EEC

* Tested according to 2000/14/EC

B

A

C

XXXXXXXXXXXXXXX
MODEL XXXXXXX

SERIAL

XXXXXXXX

NO

0

123456 789012

Briggs & Stratton Power Product Group, LLC
XXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXX

D

G

PRODUCT IDENTIFICATION

XXXX

min

kW

XXX

kg

XXX

XXX

20xx

Assembled in U.S.A

F

E

H

I

J

8

www.ferrisindustries.com

Safety Decals

SAFETY DECALS

Before operating your unit, read the safety decals.
The cautions and warnings are for your safety.
To avoid a personal injury or damage to the unit,
understand and follow all the safety decals.

WARNING

If any safety decals become worn or damaged, and
cannot be read, order replacement decals from your
local dealer.

6, 7

1

2

ALL MODELS

1

NORTH AMERICAN MODELS

2

3

4

3

8

5, 9, 10

CE MODELS (EXPORT)

7

4, 9, 10

5

6

9

8

This decal is installed on the battery for CE models only.

10

9

Safety Interlock System / Safety Icons

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.

Safety Icons

The alert symbol is used to identity safety
information about hazards that can result in personal
injury. A signal word (DANGER, WARNING, or
CAUTION) is used with the alert symbol to indicate
the likelihood and the potential severity of the injury.
In addition, a hazard icon may be used to represent
the type of hazard. An explanation of hazard levels
and icons are as follows:

Operational SAFETY Checks

Test 1 — Engine should NOT crank if:

• PTO switch is engaged, OR

• Parking brake is not engaged, OR

• Motion control handle is not in the NEUTRAL
position

Test 2 — Engine SHOULD crank if:

• PTO switch is NOT engaged, AND

• Parking brake is engaged, AND

• Motion control handle is in the NEUTRAL position

Test 3 — Engine should SHUT OFF if:

• Operator releases the operator presence handles
with PTO engaged, OR

• Operator releases the operator presence handles
with parking brake disengaged.

Test 4 — Blade Brake Check

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

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.

NOTE: Once the engine has stopped, PTO switch
must be turned off, parking brake must be engaged,
and the motion control handle must be returned to
the NEUTRAL position 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.

10

www.ferrisindustries.com

CE Safety Icons

NORTH AMERICAN SAFETY ICONS

Hazard

Alert

Toxic
Fumes

Read the
Manual

Open flame
hazard

Fire
Hazard

Amputation
Rotating
Parts

Amputation
Hand in
Blade

Safety
Icon

Hazard

Amputation
Foot in
Blade

Thrown
Objects

Maintain
a safe
distance

Keep
children
away

Hot
surface

Wear
Protective
Gear

Pinch
Point

Safety
Icon

CE 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.

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 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: Dismemberment.

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

Danger: Dismemberment.

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

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.

Warning : Fire hazard

Keep children, open flames and
sparks away from the battery,
which could ignite explosive gases.

Warning: Sulfuric acid can cause
blindness or severe burns

Always wear safety goggles or a
face shield when working on or
near a battery.

Warning: Batteries produce
explosive gases

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

Important: Do not discard a
battery in the trash

Contact local authorities for
disposal and/or recycling of
batteries.

11

Features & Controls

S/N: 2013964104 & Below

Please take a moment and familiarize
yourself with the name, location, and
function of these controls so that you will
better understand the safety and operating
instructions provided in this manual.

CONTROL FUNCTIONS

The information below briefly describes the function of 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.

Forward Speed Control Lever

Reverse Speed Control Levers

These levers control the ground speed of the mower.

The forward lever control the forward ground speed of
both drive wheels.

The left reverse lever controls the steering and
reverse ground speed of the left drive wheel and the
right reverse lever controls the steering and reverse
ground speed of the right drive wheel.

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

See the Operation section for steering instructions.

Left Hand Forward Speed Override
Lever

Right Hand Forward Speed Override
Lever

The forward speed override levers were designed
to provide increased traction and controllability for
operation on slopes and sidehills.

To increase the speed of the left drive tire press the
Left Hand Forward Speed Override Lever down.

To increase the speed of the right drive tire press the
Right Hand Forward Speed Override Lever down.

12

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Features & Controls

Ignition Switch

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

OFF Stops the engine and shuts off the

electrical system.

RUN Allows the engine to run and powers

the electrical system.

START Cranks the engine for starting.

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

Parking Brake Handle

The parking brake is released by pushing DOWN on
the parking brake handle until it stops. To engage
the parking brake, pull UP on the handle until it locks
over center.

PTO (Power Take Off) Switch

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

Engine Kill/Operator Presence
Handles

These handles are a major factor in the safety
interlock system of the mower. The handles are
sensitive to touch, and if you release the handles
while operating the machine, the machine will stall.
The operator must be touching the handles in order to
deactivate the engine kill system. The operator must
be in the operator’s area touching the handles to
engage the Engine Kill / Operator Presence Handles
before disengaging the parking brake and engaging
the PTO switch. Also, see Auxillary Engine Kill/
Operator Presence Lever.

Neutral Return Pedal

The neutral return pedal provides a hands-free
return to neutral. This is used in conjunction with the
Reverse Speed Control Levers (B) to properly stop
the machine.

See the Operation section for steering instructions.

Fuel Tank Cap

To remove the cap, turn counterclockwise.

Cutting Height Adjust Handle

The Cutting height adjust handle controls the mower
cutting height. To adjust the mower cutting height,
turn the crank handle clockwise to raise the cutting
height. Turn the crank handle counterclockwise to
lower the cutting height.

x

Auxillary Engine Kill/Operator
Presence Lever

This lever is a major factor in the safety interlock
system of the mower. The engine kill/operator
presence handles are sensitive to touch, and if
you wear gloves while operating this machine, the
handles may not detect your presence. The operator
must be touching the handles or have the auxillary
lever depressed in order to deactivate the engine kill
system. The operator must be in the operator’s area
touching the handles or depress the auxillary lever to
engage the Engine Kill / Operator Presence Safety
System before disengaging the parking brake and
engaging the PTO switch.

Throttle Control

The throttle controls engine speed. Move the throttle
forward to increase engine speed and back to
decrease engine speed. Always operate at FULL
throttle.

Choke

Close the choke for cold starting. Open the choke
once the engine starts. A warm engine may not
require choking. Pull the knob UP to close the choke.
Push to knob DOWN to open the choke.

13

Features & Controls

S/N: 2013964105 - 2014550197

Please take a moment and familiarize
yourself with the name, location, and
function of these controls so that you will
better understand the safety and operating
instructions provided in this manual.

CONTROL FUNCTIONS

The information below briefly describes the function of 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.

Forward Speed Control Lever

Reverse Speed Control Levers

These levers control the ground speed of the mower.

The forward lever control the forward ground speed of
both drive wheels.

The left reverse lever controls the steering and
reverse ground speed of the left drive wheel and the
right reverse lever controls the steering and reverse
ground speed of the right drive wheel.

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

See the Operation section for steering instructions.

Left Hand Forward Speed Override
Lever

Right Hand Forward Speed Override
Lever

The forward speed override levers were designed
to provide increased traction and controllability for
operation on slopes and sidehills.

To increase the speed of the left drive tire press the
Left Hand Forward Speed Override Lever down.

To increase the speed of the right drive tire press the
Right Hand Forward Speed Override Lever down.

14

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Features & Controls

Parking Brake Handle

The parking brake is released by pushing DOWN on
the parking brake handle until it stops. To engage
the parking brake, pull UP on the handle until it locks
over center.

Engine Kill/Operator Presence
Handles

These handles are a major factor in the safety
interlock system of the mower. The handles are
not tied together, but the safety switches are, so
depressing one handle will operate the safety interlock
system. The operator must depress the handles in
order to deactivate the engine kill system. Handles
must be depressed to disengage the parking brake
and engage the PTO switch.

Throttle Control

The throttle controls engine speed. Move the throttle
forward to increase engine speed and back to
decrease engine speed. Always operate at FULL
throttle.

Choke

Close the choke for cold starting. Open the choke
once the engine starts. A warm engine may not
require choking. Pull the knob UP to close the choke.
Push to knob DOWN to open the choke.

S/N: 2014550198 & Above

Ignition Switch

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

OFF Stops the engine and shuts off the

electrical system.

RUN Allows the engine to run and powers

the electrical system.

START Cranks the engine for starting.

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

Neutral Return Pedal

The neutral return pedal provides a hands-free
return to neutral. This is used in conjunction with the
Reverse Speed Control Levers (B) to properly stop
the machine.

See the Operation section for steering instructions.

Fuel Tank Cap

To remove the cap, turn counterclockwise.

Cutting Height Adjust Handle

The Cutting height adjust handle controls the mower
cutting height. To adjust the mower cutting height, turn
the crank handle clockwise to raise the cutting height.
Turn the crank handle counterclockwise to lower the
cutting height.

PTO (Power Take Off) Switch

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

15

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.

WARNING

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.

CHECKS BEFORE STARTING

• Check that crankcase is filled to full mark on
dipstick (B, Figure 2). See the engine Operator’s
Manual for instructions and oil recommendations.

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

• Fill the fuel tank (A) with fresh fuel. Refer to
engine manual for fuel recommendations.

• Check the hydraulic oil tank (C) and make sure
that the oil level is up to the FULL COLD mark.

A

B

C

Figure 2. Pre-start Checks
A. Fuel Tank Filler Neck
B. Crankcase Oil Fill
C. Hydraulic Oil Fill

16

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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

STARTING THE ENGINE

1. Engage the parking brake and make sure the PTO
switch is disengaged and the motion control lever
is in the NEUTRAL position.

2. Set the engine throttle control to FULL throttle
position. Then fully close the choke by pulling the
knob OUT fully.

NOTE: A warm engine may not require choking.

3. Insert the key into the ignition switch and turn it to
the START position.

4. After the engine starts, gradually open the choke
(push knob down fully). Reduce to half throttle
speed and allow to warm up.

Warm up the engine by running it for at least a minute
before engaging the PTO switch or driving the mower.

5. After warming the engine, ALWAYS operate
the unit at FULL THROTTLE when mowing.

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 MOWER

STOPPING THE MOWER

1. Gently squeeze both steering control levers evenly
to stop the machine.

3. Once the machine is stopped, firmly depress the
neutral return pedal to place the transmissions in
neutral.

2. Disengage the PTO by pushing down on the PTO
switch.

3. Engage the parking brake by pulling the handle up
and back until it stops.

4. Move the throttle control to mid-throttle position
and turn the ignition key to OFF. Remove the key.

17

Operation

DRIVING THE MOWER

NOTE: Before attempting to drive the mower make
sure you have read the Features and Controls section
and understand the location and function of the
controls.

The hydrostatic transmission has an infinite number
of speeds between full speed forward and reverse,
with the faster speeds being achieved by moving
the forward speed control lever and reverse steering
control levers farthest in the direction of travel.

For normal use, the throttle should be kept fully open
and the ground speed of the machine determined
by the speed control lever. When transporting the
machine or when loading or unloading from a truck
or trailer, partial throttle should be used to slow the
reaction time of the controls and reduce noise.

Practice maneuvering the machine at a slow engine
speed on level ground with the blade engagement
switch in the “OFF” position until you are familiar with
the controls.

TO MOVE FORWARD AND SET FORWARD SPEED
(See Figure 3.)

1. Disengage the parking brake.

2. Gently move the forward speed control lever (A,
Figure 3) forward until desired speed is achieved.

A

Figure 3. Forward Travel.
A. Forward Speed Control Lever

TO MOVE BACKWARD (See Figure 4.)

1. Disengage the parking brake.

2. Gently squeeze both reverse steering control
levers (A, Figure 4) evenly, until desired speed is
achieved.

TO SLOW OR STOP MACHINE

1. Gently squeeze both steering control levers evenly
to slow the machine.

2. Continuing to squeeze the steering control levers
will stop the machine.

3. Once the machine is stopped, firmly depress the
neutral return pedal to place the transmissions in
neutral.

4. Engage the parking brake.

NOTE: Continuing to squeeze the steering control

levers after the machine is stopped, will cause the
machine to move in reverse.

TO TURN MACHINE

NOTE: ALWAYS REDUCE SPEED IN A TURN.

To make a left-hand turn (See Figure 5):

Gently squeeze the left hand steering control lever (A,
Figure 5). A sharp or gentle turn is determined by the
amount of force applied to the steering control lever.

A

Figure 4. Reverse Travel.
A. Reverse Steering Control Levers

A

Figure 5. Left Turn Travel.
A. Left Hand Steering Control Lever

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To make a right-hand turn (See Figure 6):

Gently squeeze the right hand steering control lever
(A, Figure 6). A sharp or gentle turn is determined
by the amount of force applied to the steering control
lever.

TEMPORARILY INCREASE FORWARD SPEED

The forward override levers were designed to provide
increased traction and controllability for operation on
slopes and side hills.

Operation

A

Figure 6. Right Turn Travel.
A. Right Hand Steering Control Lever

To increase the forward speed to the left hand
wheel (See Figure 7):

Gently depress the left hand forward speed override
lever (A, Figure 7) to temporarily increase the speed
to the left hand wheel.

To increase the forward speed to the right hand
wheel (See Figure 8):

Gently depress the right hand forward speed override
lever (A, Figure 8) to temporarily increase the speed
to the right hand wheel.

Increase forward movement speed:

Gently depress both forward speed override levers
evenly to temporarily increase the forward speed of
the machine.

A

Figure 7. Increase Speed To The Left Wheel.
A. Left Hand Forward Speed Override Lever

A

Figure 8. Increase Speed To The Right Wheel.
A. Right Hand Forward Speed Override Lever

19

Operation

MOWING

Before mowing, set the cutting height as described in
the Troubleshooting, Adjustments & Repair section.

1. Engage the parking brake. Make sure the PTO
switch is disengaged and the motion control lever
is in the NEUTRAL position.

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

3. Set the throttle to FULL.

4. Engage the PTO by pulling up on the PTO switch.

5. Begin mowing.

6. When finished, shut off the PTO.

7. 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.

Cut Here On
First Pass

Cut
Here On
Second
Pass

20

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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.

Operation

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.

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

21

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.

PUSHING THE MOWER BY HAND

DO NOT TOW MACHINE

Towing the machine will cause hydraulic
transaxle damage. Do not use another
vehicle to push or pull this unit.

1. Disengage the PTO, engage the parking brake,
turn the ignition OFF, and remove the key.

2. To disengage the transmissions (free-wheel
position), lift the hydraulic release levers (A,
Figure 9) located in front of the gas tank. Lock
into position shown in Figure 9.

3. Disengage the parking brake.

The mower can now be pushed by hand.

4. After moving the mower, re-engage the
transmissions (drive position) by unlocking
the levers and returning them to the down
position. If the levers are not completely down,
a partial by-pass may potentially damage the
transmissions.

A

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.

22

Figure 9. Hydraulic System By-Pass
A. Hydraulic Release Levers

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Operation

STORAGE

Temporary Storage (30 Days Or Less)

Remember, the fuel tank will still contain some
gasoline, 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 spark
plug (s) and put in a safe place. Be sure the spark
plug opening is protected from foreign objects with
a suitable cover.

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

• Clean all grass and dirt from the mower.

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. 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.

3. Clean external surfaces and engine.

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

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

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

7. Completely grease and oil unit as outlined in the
Normal Care section.

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

9. 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.

WARNING

Never store the unit, with gasoline in engine
or fuel tank, in a heated shelter or in enclosed,
poorly ventilated enclosures. Gasoline fumes
may reach an open flame, spark or pilot light
(such as a furnace, water heater, clothes dryer,
etc.) and cause an explosion.
Handle gasoline carefully. It is highly
flammable and careless use could result in
serious fire damage to your person or property.
Drain fuel into an approved container outdoors
away from open flame or sparks.

10. Drain fuel system completely or add a gasoline
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 gasoline
fumes. Remember, gasoline fumes can travel to
distant sources of ignition and ignite, causing risk
of explosion and fire.

NOTE: Gasoline, if permitted to stand unused for
extended periods (30 days or more), may develop
gummy deposits which can adversely affect the
engine carburetor and cause engine malfunction. To
avoid this condition, add a gasoline 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 gasoline. 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.

23

Regular Maintenance

MAINTENANCE SCHEDULE & PROCEDURES

The following schedule should be followed for normal care of your mower. You will need to keep a record of
your operating time.

SAFETY ITEMS Before

Each
Use

Check Safety Interlock System

Check Rider Brakes

Check Mower Blade Stopping Time

••

••

RIDER MAINTENANCE Before

Each
Use

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 and Filter ***

••

••

ENGINE MAINTENANCE Before

Each
Use

Every
5
Hours

Every
5
Hours

Every
5
Hours

Every
25
Hours

Every
25
Hours

•

•

•

Every
25
Hours

Every
100
Hours

Every
250
Hours

Spring &
Fall

••

Every
100
Hours

Every
250
Hours

Spring &
Fall

•

Every 500 Hours

Every
100
Hours

Every
250
Hours

Spring &
Fall

Check Engine Oil Level

Check / Clean Cooling Fins & Intake *,***

Service Air Filter *,***
(See Check / Change Air Filter)
Change Oil & Filter *,**,***

Check / Replace Spark Plugs *

Check / Replace Fuel Filter *

Inspect Muffler and Spark Arrester****

* 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.

**** If equipped. Replace if damaged.

•

•

Every 50 Hours

Every 50 Hours

•

•

•

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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

Front N/A (Flat free tire)

Rear 15 psi (103 kPa)

Tire Pressure

CHECKING / ADDING FUEL

To add fuel:

1. Remove the fuel cap (see A, Figure 11).

2. Fill the tank to the bottom of the filler neck. This
will allow for fuel expansion.

NOTE: Do not overfill. Refer to your engine manual
for specific fuel recommendations.

3. Install and hand tighten the fuel cap.

FUEL FILTER

The fuel filter is located in the fuel line between fuel
tank and carburetor, near the fuel pump. If filter is
dirty or clogged, replace as follows:

1. Disconnect the negative battery cable.

2. Place a container below the filter to catch spilled
fuel.

3. Using a pliers, open and slide hose clamps from
fuel filter.

4. Remove hoses from filter.

5. Install new filter in proper flow direction in fuel line.

6. Secure with hose clamps.

7. Reconnect the negative battery cable when
finished.

INSPECT MUFFLER AND SPARK
ARRESTER

Inspect the muffler for cracks, corrosion, or other
damage. Remove the spark arrester, if equipped,
and inspect for damage or carbon blockage. If
replacement parts are required, make sure to use
only original equipment replacement parts.

Figure 10. Checking Tire Pressure

WARNING

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 remove fuel filter when engine is hot,
as spilled gasoline may ignite. DO NOT spread
hose clamps further than necessary. Ensure
clamps grip hoses firmly over filter after
installation.

Do not use gasoline containing
METHANOL, gasohol containing more than
10% ethanol, gasoline additives, premium
gasoline, or white gas because engine/fuel
system damage could result.

A

B

C

Figure 11. Fuel Tank, Oil Reservoir & Fuel Filter
A. Fuel Cap
B. Oil Reservoirs
C. “FULL” Line

WARNING

Replacement parts must be the same and
installed in the same position as the original
parts or fire could result.

25

Regular Maintenance

CHECK HYDRAULIC OIL LEVEL

1. Observe the oil reservoir (B, Figure 11). The oil
level should be at the “FULL” line (C).

2. Before removing the reservoir cap, make sure the
area around the reservoir cap is free of dust, dirt,
or other debris.

3. If necessary, unscrew the reservoir cap and add
SAE straight 20 or 30 weight motor oil. DO NOT
use multi-grade oils. Fill until oil level reaches
“FULL” line.

4. Reinstall oil reservoir cap.

CHANGE OIL & FILTER

1. Warm engine by running for a few minutes.
(Refer to the engine operator’s manual for oil &
filter replacement instructions.)

2. Remove the oil drain hose (A, Figure 12) from the
cable clamp (C) on the back left-hand side of the
engine deck and route over the back of the engine
deck as shown in Figure 12.

3. Place a small pan under the oil drain hose to
catch the oil. Using the appropriate tools, remove
the cap from the oil drain hose (A) and drain the
engine oil.

4. After draining, replace the cap and wipe up any
spilled oil. Reinstall the oil drain hose into the
cable clamp to retain the hose during normal
operation.

5. Place an absorbent shop cloth under the engine
oil filter. Remove the engine oil filter and replace
with a new one.

6. Add engine oil (Refer to the engine operator’s
manual for oil filling instructions.)

7. Remove the shop cloth and wipe up any spilled
oil.

CHANGE AIR FILTER

Refer to engine owners manual.

Primary Element: Replace the primary element
every 250 hrs.

Secondary Element: Replace the secondary element
with a new one, if the secondary element is dirty
when the primary element is checked OR

3. Install the new air cleaner elements into the air
cleaner body.

4. Reinstall the case and the cap then securely
fasten the two retaining clamps.

C

Figure 12. Engine Oil Drain
A. Oil Drain Hose (Storage Position)
B. Oil Drain Hose (Draining Position)
C. Cable Clamp

C

D

Figure 13. Changing the Air Filter
A. Retaining Clamps
B. Cap
C. Air Cleaner Case
D. Dust Cap

A

A

A

B

B

B

Replace the secondary element with a new one every
500 hrs.

1. Unfasten the two retaining clamps (A, Figure 13)
and remove the cap (B) from the air cleaner body
(C.)

2. Remove the primary element (B, Figure 14) and
the secondary element (A) from the air cleaner
body by pulling them out.

26

Figure 14. Air Cleaner Elements
A. Secondary Element
B. Primary Element

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Regular Maintenance

LUBRICATION

Lubricate the unit at the locations shown in Figure 15
as well as the following lubrication points.

Grease:

• front caster wheel axles & yokes

• deck lift pivot blocks

• mower deck spindles

• mower deck idler arm

Use grease fittings when present. 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.

Oil:

• control handle pivots

• deck lift pivots

• discharge chute hinge

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.

Mower Deck Lubrication Points*

*Shown with guards removed for
illustration purposes only.

RE-PACK

BEARING

ANNUALLY

Figure 15. Lubrication Points

27

Regular Maintenance

CLEANING THE BATTERY AND
CABLES

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.

1. Disconnect the cables from the battery, negative
cable first (B, Figure 16).

2. Clean the battery terminals and cable ends with a
wire brush until shiny.

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

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

B

A

Figure 16. Battery Compartment
A. Positive (+) Cable & Terminal
B. Negative (-) Cable & Terminal

28

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SERVICING THE MOWER BLADES

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 70-90 ft.lbs. (94-120 N.m.)

Regular Maintenance

1. Blades should be sharp and free of nicks and
dents. If not, sharpen blades as described in
following steps.

2. Remove the deck guard.

3. Raise the mower deck and secure with jack
stands.

4. To remove blade for sharpening, use two (2)
15/16” wrenches to remove the nut from the top of
the blade bolt. (Figure 17).

5. Use a file or hand-held grinder, sharpen blade to
fine edge. Remove all nicks and dents in blade
edge. If blade is severely damaged, it should be
replaced.

6. Balance the blade as shown in Figure 18. Center
the blade’s hole on a nail lubricated with a drop of
oil. A balanced blade will remain level.

7. Reinstall each blade with the tabs pointing
up toward deck as shown in Figure 19. The
blade spacers, blade, washer and bolt must be
reinstalled in the exact same order in which they
were removed. Torque bolts to 70-90 ft.lbs.
(94-120 N.m.).

LOOSEN

Figure 17. Removing the Blade

Nail

Figure 18. Balancing the Blade

B

TIGHTEN

Figure 19. Installing the Blade
A. Bolt
B. Flat Washer

A

29

Troubleshooting, Adjustment & Repair

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

WARNING

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

Always remove the ignition key, disconnect
the spark plug wire and fasten it away from
the plug before beginning the maintenance, to
prevent accidental starting of the engine.

adjustments and service repairs yourself. If you
prefer, all of these procedures can be performed for
you by your local authorized dealer.

TROUBLESHOOTING THE MOWER

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 tank.

4. Engine flooded. 4. Move throttle control out of CHOKE
position.

5. Fuse blown. 5. Replace fuse.

6. Battery terminals require 6. Clean the battery terminals
cleaning.

7. Battery discharged or dead. 7. Recharge or replace.

8. Wiring loose or broken. 8. Visually check wiring & replace broken or
frayed wires. Tighten loose connections.

9. Solenoid or starter motor faulty. 9. Repair or replace. See authorized service
dealer

10. Safety interlock switch 10. Replace as needed. See authorized
faulty. service dealer.

11. Spark plug(s) faulty, fouled 11. Clean and gap or replace.
or incorrectly gapped. See engine manual.

12. Water in fuel. 12. Drain fuel & refill with fresh fuel.

13. Gas is old or stale. 13. Drain fuel & replace with fresh fuel.

Engine starts hard or runs poorly. 1. Fuel mixture too rich. 1. Clean air filter. Check choke adjustment
(throttle control).

2. Spark plug faulty, fouled, or 2. Clean and gap or replace.
incorrectly gapped. (See engine manual.)

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 engine fins, blower screen 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. Engine choke control 2. Open choke control.
is in closed position.

30

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Troubleshooting, Adjustment & Repair

Rider Troubleshooting Continued.

PROBLEM CAUSE REMEDY

Engine runs, but mower will 1. Transmission release lever(s) 1. Move into drive position.
not drive. in “neutral” position.

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

Transmission 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. Internal brake disc on 1. See authorized service dealer
transaxle worn.

Mower steers hard or 1. Steering linkage is loose. 1. Check and tighten any loose connections.
handles poorly. 2. Improper tire inflation. 2. See Regular Maintenance Section.

TROUBLESHOOTING THE MOWER DECK

PROBLEM CAUSE REMEDY

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 screws 1. Tighten to 70-90 ft.lbs. (94-120 N.m.).
are loose.

2. Mower blades, arbors, 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 1. Belt tension improperly adjusted. 1. Adjust belt tension. See Belt
or fails to drive. Replacement

2. Idler pulley spring broken or not 2. Repair or adjust as needed.

properly adjusted.

3. Mower drive belt broken. 3. Replace drive belt.

31

Troubleshooting, Adjustment & Repair

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.

32

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MOWING HEIGHT ADJUSTMENT

See Figure 20. The mowing height adjustment can
be changed by turning the cutting height adjustment
handle.

To Raise the Mower Deck:

Turn the cutting height adjustment handle (A, Figure

20) clockwise.

To Lower the Mower Deck:

Turn the cutting height adjustment handle counter
clockwise.

Troubleshooting, Adjustment & Repair

A

Figure 20. Mowing Height Adjustment
A. Cutting Height Adjustment Handle

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 15 psi (103
kPa).

2. Crank the deck height adjustment handle so
that the rear deck lift rod lever (A, Figure 21) is
straight up and down. This is the middle height
adjustment.

S/N: 2015444202 & Below:

3a. Position the cutting height indicator (B) so that

it is centered between the fourth and fifth height
indication line and tighten.

S/N: 2015444203 & Above:

3b. Position the deck height plate (C) so that the

cutout is centered on the notched area (D) on the
deck lift rod (E).

4. To check the deck lift rod timing, measure and
record the distance between the lift pivots and
the rod pivots. Repeat for other side of unit. See
Figure 22.

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

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

A

A

Figure 21. Deck Height Position
A. Rear Deck Lift Rod Lever
B. Cutting Height Indicator
C. Deck Lift Height Plate
D. Notched Area
E. Deck Lift Rod

E

B

S/N: 2015444203 & Above:

E

C

D

S/N: 2015444202

& Below:

33

Troubleshooting, Adjustment & Repair

7. Refer to Figure 23. To adjust the lift rods the
1/2-20 steel clevises (A, Figure 23) will need to
be adjusted. Loosen the 1/2-20 jam nut (B) that
tightens against the clevis. Remove the cotter pin
(C), and the clevis pin (D) that are connected to
the rear deck lift rod (E). Turn the clevis to adjust
the length of the rod. Reinstall the clevis pin and
the hair pin. Tighten the 1/2-20 jam nut. Measure
and record the distance between the lift pivots
and the rod pivots. Repeat this process until the
measurements are equal.

C

D

Measure

Second

Measure

First

Figure 22. Measure and Adjust Deck Lift Rod
Timing

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, engage the parking
brake, and remove the key from the ignition. Rear
tires must be inflated to 15 psi (103 kPa);

2. Crank the deck height adjustment handle so
that the rear deck lift rod lever (A, Figure 21) is
straight up and down. This is the middle height
adjustment.

3. Place 2 x 4 blocks under each corner of the
mower deck with the 3-1/2” sides being vertical.
See Figure 24.

4. Adjust the front 3-link hanger chain bolt to the top
of the slot on the deck and tighten. Adjust the rear
5-link hanger chain bolt to the bottom of the slot
on the rear of the deck and tighten.

5. Remove the blocks from under the deck.

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 or death.

A

B

Figure 23. Lift Rod Clevis Adjustment
A. Clevis, 1/2-20
B. 1/2-20 Jam Nut
C. Cotter Pin
D. Clevis Pin
E. Rear Deck Lift Rod

Figure 24. 2x4 Position

A

A

Figure 25. Measuring the Blade Height

E

A

34

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6. Manually position the left hand mower blade so
that the tip of the blade is pointing towards the
front and back of the mower. Measure from the
front tip of the blade on the cutting edge to the
ground. Record this distance. Measure from the
back tip of the blade on the cutting edge to the
ground. Record this distance.

Repeat this process for the right hand mower

blade.

The front measurement should be 3” and the

rear measurement should be 3-1/4”. If the
measurements are correct, no further adjustment
is necesary. If they are not correct continue with
Step 7.

7. Loosen the jam nut (A, Figure 26) on the adjuster
bolt (B) in the chain hanger clevis (C). Turn the
adjuster bolt until the correct measurements are
achieved. Ensure that all four hanger chains are
taut, then retighten the jam nut against the chain
hanger clevis.

Troubleshooting, Adjustment & Repair

B

A

Figure 26. Deck Level Adjustment
A. Jam nut
B. Adjustment Bolt
C. Chain Hanger Clevis

C

MOWER BELT REPLACEMENT

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

PTO Clutch to Deck Belt

1. Park the machine 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 mower deck guard.

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.

3. Using a 1/2” breaker bar, place the square end
in the square hole located on the end of the idler
arm (A, Figure 27). Carefully rotate the breaker
bar COUNTER-CLOCKWISE, which will relieve
the tension on the belt exerted from the idler arm.

A

B

C

C

Figure 27. Mower PTO Belt
A. Idler Arm
B. Stationary Idler Pulley
C. Idler Tension Spring
D. Anchor Bolt

35

Troubleshooting, Adjustment & Repair

4. Slide the drive belt over the edge of the stationary

idler pulley (B). Carefully release the tension on
the breaker bar until the idler arm comes to a
stop.

6. Unhook the idler tension spring (C) from the

anchor bolt (D). Remove the old belt and replace
with a new one. Make sure the V-side of the belt
runs in the pulley grooves.

7. Install the drive belt on the PTO pulley, the spindle

pulleys, and all idler pulleys except the stationary
pulley. Rehook the idler tension spring from the
anchor bolt. Carefully rotate the breaker bar
COUNTER-CLOCKWISE and install the belt on
the stationary idler pulley. Carefully release the
tension on the breaker bar. The belt should be
routed exactly as shown in Figure 28.

8. Reinstall the mower deck guard.

9. Run the mower under no-load condition for about

5 minutes to break-in the new belt.

Check / Adjust the Mower Belt Idler
Tensioner Spring Length

52” & 61” Models - S/N: 2015782584 & Below:

feature a stationary mower belt idler tensioner and
cannot be adjusted.

48” Models - All; 52” & 61” Models - 2015782585
& Above: feature an adjustable mower belt idler

tensioner which must be to checked to make sure the
mower deck belt is set to the correct tension.

1. Position the mower deck at its middle cutting

position.

2. Use the Mower Belt Idler Tensioner Spring Length

chart to determine the correct spring length

Mower Belt Idler Tensioner Spring Length

48” Mower Decks 5-3/4” (14.6 cm)

52” & 61” Mower Decks 6-1/2” (16.5 cm)

2. Measure the coil length of the mower

belt tensioner spring (A, Figure 29). The
measurement should equal the measurement as
indicated in the chart. If it does not, adjustment is
necessary, continue with step # 3.

3. Loosen the jam nut (C).

4. Turn the adjustment nut (D) until the measurement

as indicated in the chart is achieved.

5. Retighten the jam nut.

B

C

A

A

Figure 28. Mower PTO Belt Routing
A. Spindle Pulley
B. PTO Drive Belt
C. Stationary Idler Pulley
D. Spring-loaded Idler Pulley

B

Figure 29. Check / Adjust the Mower Belt Idler
Tensioner Spring Length
A. Mower Belt Tensioner Spring
B. Measurement
C. Jam Nut
D. Adjustment Bolt

D

A

C

A

C

D

36

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Troubleshooting, Adjustment & Repair

TRANSMISSION DRIVE BELT
REPLACEMENT

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

1. Remove the deck drive belt. See MOWER BELT
REPLACEMENT sections.

2. Remove the clutch anchor bolts (A, Figure 30) that
fasten the clutch anchor pad to the anchor.

3. Unplug the PTO clutch from the wire harness.

4. Remove the spring anchor nut (E) and remove the
belt tension spring (D).

WARNING

STORED ENERGY DEVICE: Improper release
of the belt tension spring can result in personal
injury.
Use extreme caution when removing this
spring.

5. Drop the belt (H) from the crankshaft pulley and
around the PTO clutch.

6. From the front of the machine, pull the belt
towards the front while sliding it up and over the
transmission cooling fans.

7. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves.

8. Install belt over the transmission cooling fans and
on the transmission input pulleys (G), around the
idler pulleys (F & I) and on the crankshaft pulley.

9. Reinstall the belt tension spring (D) onto the
anchor bolt and reinstall the nylon nut (E).

10. Plug the PTO clutch into the wire harness.

11. Reinstall the clutch anchor pad and hardware (B &
A). Tighten securely.

12. Reinstall the deck drive belt. See MOWER BELT
REPLACEMENT section.

B

A

D

E

F

G

H

Figure 30. Transmission Drive Belt
A. Anchor Hardware
B. Clutch Anchor Pad
C. PTO Clutch & Drive Pulley
D. Belt Tension Spring
E. Spring Anchor Nut
F. Spring-loaded Idler Pulley
G. Transmission Input Pulley
H. Belt
I. Stationary Idler Pulley

C

FRONT

I

G

37

Troubleshooting, Adjustment & Repair

TRANSMISSION NEUTRAL &
TRACKING ADJUSTMENTS

Neutral Adjustment

1. Park the machine on a smooth, level surface such
as a concrete floor, away from bystanders and
preferably facing a wall. Disengage the PTO,
engage the parking brake, turn off the engine, and
remove the ignition key.

2. Chock the front caster wheels. Raise the drive
wheels off the ground and secure the machine
with jack stands.

3. Start the engine and adjust throttle control to
SLOW (lowest setting). See the STARTING THE
ENGINE section for proper starting instructions.

4. Disengage the parking brake.

5. Using a 1/2” deep socket, SLOWLY turn the
adjustment nut COUNTER-CLOCKWISE until the
drive tire begins to rotate forward.

6. SLOWLY turn the adjustment nut CLOCKWISE
until the drive tire begins to rotate backwards.

7. Set the adjustment half way in between where the
forward and backwards rotations began.

8. Adjust the throttle control to FULL (highest
setting). Cycle the speed control lever and neutral
return pedal several times to insure and accurate
adjustment has been made.

B

A

Figure 31. Neutral & Tracking Adjustment Points
A. Left-Hand Adjustment
B. Right-Hand Adjustment

Tracking Adjustment

Before making a tracking adjustment, be sure to
check the following:

• Drive tires are inflated to 15 psi (103 kPa).

• All controls are free from damage and operate
freely.

• Machine is at full operating temperature.

• Make sure the machine is in neutral when the
foot pedal is depressed. If not, adjust neutral as
described above.

If Machine Veers to the LEFT:

1. Turn the LEFT adjustment nut 1/8 - 1/4 turn
COUNTER-CLOCKWISE.

2. Turn the RIGHT adjustment nut 1/8 - 1/4 turn
CLOCKWISE.

3. Drive machine on a flat, level surface to test and
repeat steps 1 & 2 as necessary.

If Machine Veers to the RIGHT:

1. Turn the RIGHT adjustment nut 1/8 - 1/4 turn
COUNTER-CLOCKWISE.

2. Turn the LEFT adjustment nut 1/8 - 1/4 turn
CLOCKWISE.

3. Drive machine on a flat, level surface to test and
repeat steps 1 & 2 as necessary.

38

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TRANSMISSION MAINTENANCE

The hydrostatic transmissions are sealed units that
require no maintenance other than the following.

• Keep the machine and the transmission cooling
fins clear or grass, leaves and debris.

• Keep oil level in the reservoir (A, Figure 32) at the
“FULL” line (B). Extra oil in the reservoir will not
benefit the machine.

• If it is necessary to add oil to the reservoir, use
SAE straight 20 or 30 weight motor oil. DO NOT
use a multi-grade oils. Make sure the area
around the oil reservoir is free from dust, dirt and
debris before opening the reservoir.

• Make sure the oil reservoir cap are tight.

• Keep water, dirt and debris from entering the oil
reservoir. A small amount of a contaminant could
damage the transmissions.

Make sure transmissions and
immediate surrounding areas are
free from dirt and debris before
changing the oil and filters.
Cleanliness while performing this
operation is extremely important.

Troubleshooting, Adjustment & Repair

A

B

Figure 32. Oil Reservoirs
A. Oil Reservoirs
B. “FULL” Line

Changing Oil & Filters

1. Park the machine 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. Place a drain pan under each transmission and
remove the filters to drain the oil. See Figure 33.

NOTE: Before removing the right hand transmission
filter the filter guard must be removed.

3. Once oil has drained from transmissions, replace
with new filters (P/N 5021068X1), placing a light
film on the seal of the filter before installing.
Hand-tighten filter only.

4. Fill oil reservoirs 3/4 full with SAE straight 20 or 30
weight motor oil.

To Bleed Air From Transmissions

1. Locate the machine in a secure area, away from
bystanders and preferably facing a wall. Raise
the drive tires off the ground and secure with jack
stands.

2. Continue to fill reservoirs to the FULL LINE until
the oil level stops going down.

A

Figure 33. Transmission Oil Filter Location
(left-hand side shown with deck guard cut away.)
A. Transmission Oil Filter

3. Start the engine and adjust throttle control to just
above idle. See the STARTING THE ENGINE
section for proper starting instructions.

4. Run engine for 5 minutes. Watch the oil level
in the reservoirs. Add oil to the “FULL” line (B,
Figure 32) as necessary.

5. With engine running, cycle controls forward and
reverse until positive response to the drive is
achieved. Do not attempt to move the unit until
bleeding is complete or serious damage may
occur.

6. Watch oil levels for the next few days and add oil
to the reservoirs as necessary.

39

Troubleshooting, Adjustment & Repair

BATTERY SERVICE

WARNING

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

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
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.

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 34.

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.

40

www.ferrisindustries.com

Troubleshooting, Adjustment & Repair

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.

THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES

To
Starter
Switch

Jumper Cable

Starting
Vehicle
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.

To
Starter
Switch

Discharged
Vehicle
Battery

Jumper Cable

To Ground

MAKE CERTAIN VEHICLES DO NOT TOUCH

Figure 34. Jump Starting

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.

Engine
Block

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.

41

Specifications

SPECIFICATIONS

NOTE: Specifications are correct at time of printing
and are subject to change without notice.

ENGINE:

19 Gross HP† Kawasaki

Make Kawasaki
Model FH580V
Displacement 35.7 Cu. in (585 cc)
Electrical System 12 Volt, 13 amp, Alternator,

Battery: 340 CCA

Oil Capacity 1.9 US qt. (1.8 L) w/ Filter

20 Gross HP† Kawasaki

Make Kawasaki
Model FX600V
Displacement 36.8 Cu. in (603 cc)
Electrical System 12 Volt, 15 amp, Alternator,

Battery 340 CCA

Oil Capacity 1.8 US qt. (1.7 L) w/ filter

20.5 Gross HP† Kawasaki

Make Kawasaki
Model FX651V-DS00-S
Displacement 44.3 Cu. In (726 cc)
Electrical System 12 volt, 15 amp charging coil;

Battery: 340 cca

Oil Capacity 2.2 US qt (2.1 L) w/ filter

CHASSIS:

Fuel Tanks Capacity: 5 Gallons (18.9 L)
Rear Wheels Tire Size: 17 x 7.50 -12

Inflation Pressure: 15 psi (1,03 bar)

Front Wheels Tire Size: 9 x 3.5 - 6

TRANSMISSION:

Eaton 771-101 & 771-102

Type Unitized Drive Transaxles
Hydraulic Fluid Mobil DTE26 Hydraulic Oil OR SAE

20W-20 Motor Oil OR SAE 30 Motor Oil

Speeds Forward: 0-6 MPH (0-9.65 km/h)
@ 3400 rpm Reverse: 0-2 MPH (0-3.22 km/h)

DIMENSIONS:

48” Model 52” Model 61” Model

Overall Length

Overall Width
(Deflector down)

Overall Width
(Deflector up)

Height

Weight (apx.)

74.5”

(189 cm)

54” (137 cm) 57.5” (146 cm) 66” (168 cm)

49” (124 cm) 53.5” (136 cm) 62” (cm)

739 lbs.

(335 kg)

76.5”

(194 cm)

42” (107 cm)

780 lbs.

(353.8 kg)

87”

(221 cm)

815 lbs.
(370 kg)

23.5 Gross HP† Kawasaki

Make Kawasaki
Model FX730V-DS00-S
Displacement 44.3 Cu. In (726 cc)
Electrical System 12 volt, 15 amp charging coil;

Battery: 340 cca

Oil Capacity 2.2 US qt. (2.1 L) w/ filter

25 Gross HP† Kawasaki

Make Kawasaki
Model FH721V
Displacement 41.2 Cu. in (675 cc)
Electrical System 12 Volt, 13 amp, Alternator,

Battery: 340 CCA

Oil Capacity 2.0 US qt. (1.9 L) w/ Filter

26 Gross HP† Kawasaki

Make Kawasaki
Model FX730V
Displacement 44.3 Cu. in (726 cc)
Electrical System 12 Volt, 15 amp, Alternator,

Battery: 340 CCA
Oil Capacity 2.2 US qt. (2.1 L) w/ filter

†Power Ratings: All power levels are stated gross horsepower per
SAE J2723 as rated by Kawasaki and tested per the SAE J1995
test standard. The gross power curves and more information can be
viewed at www.kawasaki-criticalpower.com.

42

www.ferrisindustries.com

2

ALIGN THIS EDGE WITH A VERTICAL SURFACE

(TREE, POLE, FENCE POST, BUILDING, ETC)

SLOPE INDENTIFICATION GUIDE

THIS IS A 10 DEGREE SLOPE

THIS IS A 15 DEGREE SLOPE

INSTRUCTIONS

1. Fold this page along the

dotted line indicated above.

2. Align the left edge of this guide

with a vertical tree, a power line

pole, a fence post, or any vertical

structure.

3. Compare the angle of the fold

with the angle of the hill.

COMPARE THE ANGLE

OF THE FOLD TO THE

ANGLE OF THE SLOPE

3

1

FOLD ALONG APPROPRIATE DOTTED LINE

43

Notes

Ferris Industries - a division of Briggs & Stratton Power Products Group, LLC.

Owner’s Limited Warranty Information

(Effective 04/28/2004)

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.

OPERATOR’S

MANUAL

Comfort Control DD Series

Walk-Behind Mowers