Ferris Industries IS5000Z, 5000 manual

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1 W ARNING Engine exhaust fr om this product contains chemicals known, in certain quantities, to cause cancer , bir th defects, or other reproductive harm. T able of Contents T roubleshooting, Adjustments & Ser vice .......30 T roub leshooting the Rider .....................................30 T roub leshooting the Mower ........................[...]

2 01 TP 600-7124-01-UV-FD OPERA TION • Nev er run an engine in an enclosed area. • Mow only in the daylight or with good artificial light, keeping a way from holes and hidden hazards . • Be sure all dr iv es are in neutral and parking brake is engaged bef ore star ting engine. Only star t engine from the operator’ s position. Use seat belts[...]

3 01 TP 600-7124-01-UV-FD Safety Rules & Information Operation - Con’t. • T ur n off the PT O switch to disengage the b lades when not mowing. • Nev er operate with guards not securely in place. Be sure all interlocks are attached, adjusted properly and functioning properly . • Nev er operate with the discharge deflector raised, remov e[...]

00 TP 600-7124-01-UV-FD Safety Rules & Information CHILDREN T ragic accidents can occur if the operator is not aler t to the presence of children. Children are often attracted to the unit and the mowing activity . Ne ver assume that chil- dren will remain where you last sa w them. • Keep children out of the mo wing area and under the watchful[...]

5 00 TP 600-7124-01-UV-FD Safety Rules & Information W ARNING ST ORED ENERGY DEVICE: Improper release of springs can result in serious personal injury . Spring should be removed b y an author iz ed dealer only . W ARNING Hydraulic fluid escaping under pressure may have sufficient f orce to penetrate skin and cause serious injury . If f oreign f[...]

6 06 Decal - W arning P art No. 20337 SAFETY DECALS This unit has been designed and manuf actured to pro- vide you with the saf ety and reliability you would e xpect from an industr y leader in outdoor power equipment manuf actur ing. Although reading this manual and the saf ety instr uctions it contains will provide y ou with the necessar y basic [...]

06 7 Safety Icons / Identification Numbers Identification Numbers ENGINE REFERENCE D A T A Unit Model Number PRODUCT REFERENCE D A T A Unit SERIAL Number Dealer Name Date Purchased Engine Make Engine Model Mower Deck Model Number Mower Deck SERIAL Number MODEL NO. MODEL NO. SERIAL NO. SERIAL NO. FERRIS INDUSTRIES, INC. FERRIS INDUSTRIES, INC. MUNNS[...]

05 Features & Controls of the Zero T urn Rider A. Ground Speed Contr ol Levers These le vers control the g round speed of the rider . The left le ver controls the left rear driv e wheel and the right le ver controls the right rear drive wheel. Moving a le ver f orward increases the FORW ARD speed of the associated wheel, and pulling back on a l[...]

9 00 A. Ignition Switch (Diesel) The ignition s witch star ts and stops the engine, it has f our positions: HEA T Heats the glow plugs. OFF Stops the engine and shuts off the electrical system. ON Allows the engine to run and powers the electrical system. ST ART Cranks the engine f or star ting. NO TE: Nev er leav e the ignition switch in the ON po[...]

10 00 Features & Controls SAFETY INTERLOCK SYSTEM This unit is equipped with saf ety interlock s witches and other saf ety de vices. These safety systems are present f or your well being, do not attempt to b ypass safety s witches, and ne ver tamper with saf ety de vices. Check their operation regularly . Operational SAFETY Checks Y our unit is[...]

11 00 Notes[...]

01 Operating the Zero T urn Rider GENERAL OPERA TING SAFETY Bef ore first time operation: • Be sure to read all information in the Safety and Operation sections bef ore attempting to operate this tractor and mow er . • Become familiar with all of the controls and how to stop the unit. • Dr ive in an open area without mo wing to become accusto[...]

13 01 Operating the Zero T urn Rider PRIMING THE FUEL SYSTEM Diesel Model Only Priming the fuel system fills the fuel filters and removes any air b ubb les from the fuel system. This must be per- f or med bef ore the first use, after any fuel filter mainte- nance or if the fuel system is run dr y . T o prime the fuel system: On the water separator:[...]

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

Operating the Zero T urn Rider 15 05 Figure 6. Hydraulic Release V alve Location A. Hydraulic Release V alve (Right-hand side sho wn) A MO WING 1. Engage the par king brake . Make sure the PT O s witch is disengaged, the motion control handles are lock ed in the NEUTRAL position and the operator is on the seat. 2. Star t the engine (see ST ARTING T[...]

16 00 Operating the Zero T urn Rider ZER O TURN DRIVING PRA CTICE The le ver controls of the Zero T ur n rider are responsive, and learning to gain a smooth and efficient control of the rider’ s forward, re verse , and tur ning mov ements will take some practice. Spending some time going through the maneuvers shown and becoming f amiliar with how[...]

17 00 AD V ANCED DRIVING Executing an End-Of-Ro w Zero T urn Y our Zero T urn Rider’ s unique ability to tur n in place allows y ou to turn around at the end of a cutting row rather than ha ving to stop and Y -tur n before star ting a new ro w . F or e xample, to e xecute a right end-of-row Zero T ur n: 1. Slow down at the end of the row . 2. Mov[...]

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

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

20 05 Regular Maintenance[...]

DIESEL MODEL CHECKING / ADDING FUEL T o ad d fuel: 1. Remove the fuel cap . 2. Fill the tank to the bottom of the fill tube. This will leav e room in the tank for fuel e xpansion. Ref er to your engine man ual for specific fuel recommenda- tions. 3. Install and hand tighten the fuel cap. 4. Repeat same process for opposite tank. NO TE: The fuel tan[...]

22 01 Regular Maintenance GAS MODEL CHECKING / ADDING FUEL T o add fuel: 1. Remove the fuel cap (see A, Figure 2). 2. Fill the tank to the bottom of the filler neck. This will allow f or fuel expansion. NO TE: Do not o verfill. Ref er to your engine man ual f or specific fuel recommendations. 3. Install and hand tighten the fuel cap. 4. Repeat same[...]

23 01 Regular Maintenance OIL & FIL TER CHANGE Ref er to Figure 16 f or oil filter , dipstick and filler neck locations. T o drain the oil: 1. Place a drain pan below the engine oil pan. 2. Remove the oil dr ain plug and allow the engine oil to completely drain. 3. Remove and replace the oil filter 4. Reinstall the oil drain plug. 5. Refill the[...]

24 05 Regular Maintenance Figure 19. Radiator & Oil Cooler A. Radiator Pressure Cap B. Radiator Screen C . Screen K eeper Handle (LH side hidden) D . Hydraulic Oil Cooler E. Wing Bolt CHECK ENGINE COOLANT LEVEL (Diesel Model) The engine coolant le vel and quality should be chec ked bef ore each use, when the engine is cool and off . 1. Remove t[...]

25 05 Regular Maintenance CHECK ENGINE COOLANT LEVEL (Gas Model) The engine coolant le vel and quality should be chec ked bef ore each use, when the engine is cool and off . 1. Check the coolant in the ov erflow reser voir (A, Figure 21). Coolant should be between the “FULL ” and “LO W” mar ks on the tank. 2. If coolant lev el is below the [...]

26 03 Regular Maintenance LUBRICA TION Lubricate the unit at the locations shown in FIgure 23 through 29 as well as the f ollowing lubrication points. Grease: • front caster wheel axles • rear suspension a-arms • rear deck mounts • deck lift piv ots • deck lift f oot pedal • blade spindles Use grease fittings when present. Disassemble p[...]

27 03 Regular Maintenance Figure 29. Rear Suspension Lubrication (Both upper & lower a-arms) Figure 28. Fr ont Caster & Wheel Figure 27. Gearbo x Drive Idler Pivot Figure 26. Contr ol Handle Pivots & Seat Piv ots[...]

28 00[...]

29 05 LOOSEN A C B TIGHTEN Figure 31. Remo ving the Blade Figure 32. Balancing The Blade Figure 33. Installing The Blade A. 4x4 Wood Block C . Blade Bolt B. Flat W asher Nail SER VICING THE MO WER BLADES 1. Blades should be shar p and free of nicks and dents. If not, shar pen blades as described in f ollowing steps. 2. T o remov e blade f or shar p[...]

30 00 T roubleshooting Adjustments & Service TR OUBLESHOO TING While normal care and regular maintenance will extend the lif e of your equipment, prolonged or constant use ma y e ventually require that service be performed to allow it to continue oper ating properly . The troubleshooting guide belo w lists the most common problems , their cause[...]

31 00 Rider Troubleshooting Continued. PROBLEM CA USE REMED Y Engine runs, b ut rider will 1. Hydraulic dump v alve(s) 1. T urn dump valve(s) cloc kwise to close. not drive. in “open” position. T orque to 80-120 in.lbs. (9-13.5 N.m.) 2. Belt is broken. 2. See Drive Belt Replacement. 3. Drive belt slips . 3. See problem and cause below . 4. Brak[...]

32 00 SEA T ADJUSTMENT See Figure 34. The seat can be adjusted f ore and aft. Mov e the lev er f orward, position the seat as desired, and release the le ver to loc k the seat into position. GR OUND SPEED CONTROL LEVER ADJUSTMENT The control le vers can be adjusted in three w ays. The alignment of the control le vers , the placement of the le vers [...]

33 00 T roubleshooting, Adjustment & Service NEUTRAL ADJUSTMENT If the tractor “creeps” while the ground speed control le vers are loc ked in NEUTRAL, then it ma y be neces- sar y to adjust the control linkage. NO TE: P erform this adjustment on a hard, le vel surf ace such as a concrete floor . 1. Disengage the PTO , engage the parking bra[...]

34 01 T roubleshooting, Adjustment & Service P ARKING BRAKE ADJUSTMENT 1. Disengage the PTO , stop the engine, b lock the front wheels, remo ve the ignition k ey , and engage the parking brake . 2. Locate the upper brake spring (A, Figure 39). 3. With the par king brake engaged, measure the com- pressed spring length. The spr ing should be 2”[...]

35 00 T roubleshooting, Adjustment & Service FR ONT SUSPENSION ADJUSTMENT The shock assemb ly can be adjusted to var y the amount of pre-load applied to the springs. This allows the oper- ator to customize the ride according to operator’ s weight and/or operating conditions. Less Pre-Load: • Light operator weight • Softer , more cushioned[...]

36 00 T roubleshooting, Adjustment & Service MO WING HEIGHT ADJUSTMENT See Deck Le veling Adjustment to ensure that the actual cutting height is consistent with the cutting height adjust- ment pin placement. The cutting height adjustment pin (A, Figure 43) controls the mower cutting height. The cutting height is adjustable betw een 1-1/2” (3,[...]

37 00 T roubleshooting, Adjustment & Service 5. See Figure 46. Measure the distance between the rear lift pivots and the suspension-mounted lift piv ots. Add or remov e 5/8” SAE washers from in betw een the deck lift rod and the lift link until measurements are equal.[...]

38 05 T roubleshooting, Adjustment & Service BEL T REMO V AL & REPLA CEMENT Mower Drive Belt Remo val & Replacement 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PTO , engage the parking brake , tur n off the engine, and remo ve the ignition ke y . 2. See Figure 48. Remov e the hair pin clip a[...]

39 05 T roubleshooting, Adjustment & Service Clutch Belt Remo val 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PTO , engage the parking brake , tur n off the engine, and remo ve the ignition ke y . 2. Remove the rear skid plate b y removing the bolts that f asten the skid plate to the bumper and slid[...]

40 00 T roubleshooting, Adjustment & Service Pump Drive Belt Remov al 1. Park the tractor on a smooth, le vel surf ace such as a concrete floor . Disengage the PTO , engage the parking brake , tur n off the engine, and remo ve the ignition ke y . 2. Remove the clutch belts (see CLUTCH BEL T REMO V AL f or instructions). 3. Using a 1/2” breake[...]

41 00 T roubleshooting, Adjustment & Service To p Front Figure 54. Gearbo x Oil Level A. Fill Plug B. Drain Plug A B GEARBO X MAINTENANCE Check Gearbo x Oil Level 1. Remove fill plug (A, Figure 54) on gearbo x. 2. Once plug is removed, oil should seep out of fill plug hole. If no oil drains out, fill with SAE 80-90 weight gear oil until oil sta[...]

42 00 T roubleshooting, Adjustment & Service B A TTER Y SER VICE Checking Battery V oltage A voltmeter can be used to determine condition of bat- ter y . When engine is off , the voltmeter sho ws batter y voltage , which should be 12 volts. When engine is run- ning, the voltmeter sho ws voltage of charging circuit which nor mally is 13 to 14 v [...]

43 00 To Starter Switch Starting V ehicle Battery T o Ground To Starter Switch Dischar ged V ehicle Battery Engine Block THIS HOOK-UP FOR NEGA TIVE GROUND VEHICLES MAKE CERT AIN VEHICLES DO NO T T OUCH Jumper Cab le Jumper Cab le W ARNING Any pr ocedure other than the preceding could result in: (1) personal injury caused by electr olyte squirting o[...]

44 01 Common Replacement Parts COMMON REPLA CEMENT P ARTS Listed below are par ts numbers f or the more common replacement par ts. Use only genuine F erris replace- ment par ts to assure optimum perf or mance and safety . 72” Deck Belt (Gearbox to Spindle) .....................22439 72” Deck Blades (Set of 3) ................................224[...]

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LC-2 Lawn Care & Mowing Information HO W HIGH T O MO W THE GRASS Often cutting height is a matter of personal prefer- ence. Typically, you should mow the grass when it is is between three and five inches high. The proper cutting height range for a specific lawn will depend upon several factors, including the type of grass, the amount of rainfal[...]

LC-3 Lawn Care & Mowing Information Where possible, make one or two passes around the outside of the area discharging the grass INTO the lawn to keep the cut grass off fences and walks. WHEN AND HO W OFTEN T O MO W The time of day and condition of the grass greatly affect the results you’ll get when mowing. For the best results, follow these [...]

LC-4 Lawn Care & Mowing Information MO WING METHODS Proper Br oadcast Mowing Broadcasting, or side-discharging, disperses fine clip- pings evenly over the entire lawn. Many golf courses use this method. Your mower has a deep dish deck to allow freer circulation of clippings so they are broadcast evenly over the lawn. ENGINE SPEED & GROUND S[...]

LC-5 Lawn Care & Mowing Information TIPS On Dealing With Clippings Clippings are beneficial to your lawn. A common mis- conception about clippings is that they automatically lead to thatch—this is untrue. Short clippings produced by broadcasting and clippings produced by mulching methods actually contribute to a healthy lawn because they: •[...]

LC-6 Lawn Care & Mowing Information Stepped Cutting Stepped cutting is sharp ridges or uneven levels left in the lawn surface. Stepped cutting is usually caused by mower deck damage or misadjustment, or damage to mower blades. CAUSE SOLUTION Deck is not leveled correctly Level the deck correctly Tires are not properly inflated Check and inflate[...]

LC-7 Lawn Care & Mowing Information Stingers Stingers are sparse patches of uncut grass left behind the mower. Stingers are usually caused by operator error or poor blade maintenance. CAUSE SOLUTION Blades are not sharp or are nicked Sharpen your blades Blades are worn down too far Replace your blades Engine speed is too slow Always mow at full[...]

LC-8 Common International Symbols T echnical Manuals Additional T echnical Literature A v ailable Operators Manuals Additional copies of this manual are available, (and as part of our product support commitment, we maintain a stock of printed operators manuals going back many years!) Parts Manuals Fully illustrated parts manuals are also available [...]

LC-9 Notes[...]

Ferris Industries 5375 Nor th Main Street Munnsville, NY 13409 800-933-6175 www .f errisindustr ies.com © Cop yright 2004 Ferris Industries All Rights Reser ved. Pr inted in USA. IS5000Z Series Zero-T urn Riding Mower OPERA TOR’S MANUAL FERRIS LIMITED W ARRANTY IMPORT ANT This warranty shall apply ONL Y if the warranty registr ation f or m has b[...]