OPERATOR’S
MANUAL
IS4500Z Series
Zero-Turn Riding Mower
Model Number:
5901178
5901179
5901180
5901181
5900626
5900621
Description
IS4500ZBL35, 35HP Zero-Turn Riding Mower
IS4500ZBL3561, 35HP, 61” Cut Zero-Turn Riding Mower
IS4500ZC28D61, 28HP, 61” Cut Zero-Turn Riding Mower
IS4500ZC28D61CE, 28HP, 61” Cut Zero-Turn Riding Mower (Export)
IS4500ZC28D61SDCE, 28HP, 61” Cut Zero-Turn Riding Mower (Export)
4500/72, 72” Mower Deck
Ferris Industries
5100798
5375 North Main Street
Munnsville, NY 13409
800-933-6175
Revision 01
Rev. Date: 9/2006
TP 100-7306-01-45-F
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Table of Contents
Safety Rules & Information ................................2
Identification Numbers .....................................11
Safety Decals.....................................................12
Safety Icons .......................................................13
Safety Interlock System....................................14
Features & Controls..........................................15
Control Functions..................................................15
Operation ...........................................................17
General .................................................................17
Checks Before Starting.........................................17
Priming the Fuel System (diesel model only).......18
Starting the Engine ...............................................19
Stopping the Tractor and Engine...........................19
Driving the Tractor.................................................20
Pushing the Rider by Hand...................................20
Zero Turn Driving Practice ....................................21
Attaching a Trailer .................................................23
Raise & Lower the Roll Bar ..................................23
Mowing..................................................................24
Mowing Recommendations...................................24
Mowing Methods...................................................25
Storage..................................................................27
Starting After Long Term Storage .........................27
Diesel Fuel Recommendations.............................27
Regular Maintenance ........................................30
Maintenance Schedule .........................................30
Checking Tire Pressures.......................................30
Checking/Adding Fuel (diesel model)...................31
Fuel Filter (diesel model) ......................................31
Checking/Adding Fuel (gas model).......................32
Fuel Filter (gas model)..........................................32
Check / Add Engine Oil.........................................33
Check / Change Air Filter......................................33
Check Hydraulic Oil Level.....................................33
Hydraulic Oil Filter Change...................................33
Check Engine Coolant Level.................................34
Change Engine Coolant........................................34
Clean Radiator, Screen & Oil Cooler....................34
Lubrication ............................................................35
Battery Maintenance.............................................36
Anti-Scalp Deck Casters.......................................36
Servicing the Mower Blades .................................37
Troubleshooting, Adjustments & Service.......38
Troubleshooting the Rider.....................................38
Troubleshooting the Mower...................................39
Troubleshooting Common Cutting Problems ........40
Seat Adjustment....................................................41
Ground Speed Control Lever Adjustment.............41
Speed Balancing Adjustment................................41
Neutral Position & Return Spring Adjustment.......42
Neutral Adjustment ...............................................42
Parking Brake Adjustment ....................................43
Mowing Height Adjustment ...................................43
Deck Lift Rod Timing Adjustment..........................44
Deck Leveling Adjustment.....................................45
Deck Lift Spring.....................................................45
Suspension Adjustment ........................................46
PTO Clutch Adjustment ........................................47
Belt Removal & Replacement...............................48
Battery Service .....................................................51
Specifications....................................................53
NOTE: In this manual, “left” and “right” are referred to as
seen from the operating position.
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Safety Rules & Information
Operating Safety
Congratulations on purchasing a superior-quality piece of lawn
and garden equipment. Our products are designed and
manufactured to meet or exceed all industry standards for safety.
Do not operate this machine unless you have been trained.
Reading and understanding this operator’s manual is a way to
train yourself.
Power equipment is only as safe as the operator. If it is misused,
or not properly maintained, it can be dangerous! Remember, you
are responsible for your safety and that of those around you.
Use common sense, and think through what you are doing. If
you are not sure that the task you are about to perform can be
safely done with the equipment you have chosen, ask a
professional: contact your local authorized dealer.
Read the Manual
The operator’s manual contains important safety
information you need to be aware of BEFORE you
operate your unit as well as DURING operation.
Safe operating techniques, an explanation of the
product’s features and controls, and maintenance
information is included to help you get the most out of
your equipment investment.
Be sure to completely read the Safety Rules and
Information found on the following pages. Also
completely read the Operation section.
Children
Tragic accidents can occur with children. Do
not allow them anywhere near the area of
operation. Children are often attracted to the
unit and mowing activity. Never assume that
children will remain where you last saw them.
If there is a risk that children may enter the
area where you are mowing, have another
responsible adult watch them.
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Safety Rules & Information
Slope Operation
Operation on slopes can be dangerous. Using the unit on a slope
that is too steep where you do not have adequate wheel traction
(and control) can cause sliding, loss of steering, control, and
possible rollover. You should not operate on a slope greater than a
3.5 foot rise over a 20 foot length (10 degrees).
Always mow across slopes, not up and down (to maintain traction
on the wheels) and avoid sudden turns or rapid speed changes.
Reduce speed and use extreme caution on ALL slopes.
Also, note that the surface condition you are on can greatly impact
your ability to safely operate this machine. Operating on wet or
slippery slopes can cause sliding and loss of steering and control.
Do not operate on slopes that are slippery, wet, or have soft soil
conditions.
If you feel unsure about operating the unit on a slope, don’t do it.
It’s not worth the risk.
Thrown Objects
This unit has spinning mower blades. These blades can pick up and
throw debris that could seriously injure a bystander. Be sure to clean
up the area to be mowed and remove objects that could be thrown by
the blade BEFORE you start mowing.
Do not operate this unit without the entire grass catcher or discharge
guard (deflector) in place.
Also, do not allow anyone in the area while the unit is running! If
someone does enter the area, shut the unit off immediately until they
leave.
Moving Parts
This equipment has many moving parts that can injure
you or someone else. However, if you stay in the operator
zone (stay seated in the seat), and follow the safety rules
in this operator’s manual, the unit is safe to operate.
The mower deck has spinning mower blades that can
amputate hands and feet. Do not allow anyone near the
unit while it is running! Keep safety devices (guards,
shields, and switches) in place and working.
To help you, the operator, use this equipment safely, it is
equipped with an operator-present safety system. Do NOT
attempt to alter or bypass the system. See your dealer
immediately if the system does not pass all the safety
interlock system tests found in this manual.
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Safety Rules & Information
Roll Bar Use
Keep the roll bar in the raised position and fasten the
seat belt. There is no roll over protection when the
roll bar is down! Do not jump off if the mower tips (it is
safer to be secured by the seat belt with the roll bar
raised.)
Lower the roll bar only when necessary (such as to
temporarily clear a low overhanging obstacle) and
NEVER remove it. Do NOT use the seat belt when
the roll bar is down. Raise the roll bar as soon as
clearance permits.
Retaining Walls, Drop-
offs, and Water
Retaining walls and drop-offs around steps and
water are a common hazard. Give yourself a
minimum of two mower widths of clearance
around these hazards and hand-trim with a walk
behind mower or string trimmer. Wheels
dropping over retaining walls, edges, ditches,
embankments, or into water can cause rollovers,
which may result in serious injury, death, or
drowning.
Overhead Obstacles
Check for overhead clearances before driving
under any objects. Do not allow the roll bar to
contact low overhanging obstacles such as tree
branches and guide wires.
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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
any other enclosed area that is not well ventilated.
Gasoline spills should be cleaned up promptly and before
operation begins.
Gasoline should be stored only in sealed containers
approved for fuel.
Proper maintenance is critical to the safety and
performance of your unit. Keep the unit free of grass,
leaves, and excess oil. Be sure to perform the
maintenance procedures listed in this manual, especially
periodically testing the safety system.
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.
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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.
2. Mow only in the daylight or with good artificial
light, keeping away from holes and hidden
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.
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 drop-
offs.
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.
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.
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.
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.
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.
OPERATION
1. Never run an engine in an enclosed area.
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Safety Rules & Information
23. Use care when approaching blind corners, shrubs,
trees or other objects that may obscure vision.
24. To reduce fire hazard, keep unit free of grass,
leaves & excess oil. Do not stop or park over dry
leaves, grass or combustible materials.
25. The engine in this unit is not factory equipped with
a spark arrester. It is a violation of California
Public Resource Code Section 4442 to use or
operate the engine on or near any forest-covered,
brush-covered, or grass-covered land unless the
exhaust system is equipped with a spark arrester
meeting any applicable local or state laws. Other
states or federal area may have similar laws.
26. OSHA regulations may require the use of hearing
protection when exposed to sound levels greater
than 85 dBA for an 8 hour time period.
Do Not
1. Avoid starting, stopping, or turning on a slope. If
tires lose traction (i.e. machine stops forward
motion on a slope), disengage the blade(s) (PTO)
and drive slow off the slope.
2. Do not turn on slopes unless necessary, and then,
turn slowly and gradually uphill, if possible. Never
mow down slopes.
3. Do not mow near drop-offs, ditches, or
embankments. The operator could lose footing or
balance or mower could suddenly turn over if a
wheel is over the edge of a cliff or ditch, or if an
edge caves in.
4. Do not mow on wet grass. Reduced footing or
traction could cause sliding.
5. Do not try to stabilize the unit by putting your foot
on the ground. (ride-on units)
6. Do not mow excessively steep slopes.
7. Do not use grass catcher on steep slopes.
8. Do not mow slopes if you cannot back up them.
CAUTION
This machine produces sound levels
in excess of 85 dBA at the operator’s
ear and can cause hearing loss
TOWED EQUIPMENT (RIDE-ON UNITS)
1. Tow only with a machine that has a hitch designed
for towing. Do not attach towed equipment except
at the hitch point.
2. Follow the manufacturer’s recommendations for
weight limit for towed equipment and towing on
slopes. See attaching a trailer under OPERATION.
3. Never allow children or others in or on towed
equipment.
4. On slopes, the weight of the towed equipment
may cause loss of traction and loss of control.
5. Travel slowly and allow extra distance to stop.
6. Do not shift to neutral and coast down hill.
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.
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.
WARNING
Never operate on slopes greater than 17.6
percent (10°) which is a rise of 3-1/2 feet (106
cm) vertically in 20 feet (607 cm) horizontally.
1. Keep children out of the mowing area and under
the watchful care of another responsible adult.
2. Be alert and turn unit off if children enter the area.
3. Before and during reverse operation, look behind
and down for small children.
4. Never carry children, even with the blade(s) off.
They may fall off and be seriously injured or
interfere with safe unit operation. Children who
have been given rides in the past may suddenly
appear in the mowing area for another ride and be
run over or backed over by the machine.
5. Never allow children to operate the unit.
6. Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
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.
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. 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.
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.
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Safety Rules & Information
mufflers, and engine to prevent fires. Clean up oil
or fuel spillage.
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.
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.
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.
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.
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.
17. Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
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.
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.
Maintenance and Storage
1. Always observe safe refueling and fuel handling
practices when refueling the unit after
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.
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,
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Safety Rules & Information
27. Models equipped with an engine radiator:
WARNING: Stored energy device. To prevent
serious bodily injury from hot coolant or steam
blow-out, never attempt to remove the radiator cap
while the engine is running. Stop the engine and
wait until it is cool. Even then, use extreme care
when removing the cap.
• Never alter the ROLL BAR by welding anything to
it or by drilling additional holes.
• BEFORE FIRST TIME USE - Inspect the ROLL
BAR structure and mounting hardware for:
1) Check to make sure the machine GVW (Gross
Vehicle Weight), including attachments,
restrained payload, fuel and operator, is not in
excess of the maximum weight specified on
the ROLL BAR label.
ROLL BAR INSTRUCTIONS
For models equipped with factory-installed Roll Over
Protection System (ROPS).
2) Make sure there isn’t any missing, damaged,
or loose mounting hardware.
WARNING
3) Make sure the ROLL BAR has been correctly
and completely installed.
In order to avoid serious injury or death from
roll over, it is important to follow the warnings
listed below.
• EVERY 100 HOURS - Inspect the ROLL BAR
structure and mounting hardware for:
1) Any cracks in the structure (structural
members and/or welds).
OPERATIONAL WARNINGS
• Always use the seat belt when the roll bar is in the
raised position.
2) Significant corrosion on any part of the ROLL
BAR structure or hardware.
• Never use the seat belt when the roll bar is in the
down position.
• Remember there is no roll over protection when
the roll bar is in the down position so it is very
important to always keep the roll bar in the raised
position whenever possible.
• Lower the roll bar to the down position only when
it is absolutely necessary.
3) Missing, damaged, or loose mounting
hardware
4) Mounting hardware that is of a grade lesser
than specified.
• Check for overhead clearances before driving
under any objects. Do not allow roll bar to contact
low overhanging obstacles such as tree branches
and guide wires.
• Never remove the roll bar from the vehicle.
• Do not exceed the machine weight rating of the
roll bar.
• Read and follow all of the instructions shown
below regarding the inspection and maintenance
of the roll bar structure and the seat belt.
5) Machine GVW (Gross Vehicle Weight),
including attachments, restrained payload, fuel
and operator, in excess of the maximum weight
specified on the ROLL BAR label.
6) Any modifications that have been made, such
as unauthorized welds and holes.
7) Any permanent deformation or twisting of the
ROLL BAR structure.
8) That the ROLL BAR label is still in place and is
readable.
WARNING
Failure to properly inspect and maintain the
ROLL BAR protective structure can cause
serious injury or death.
9) That the ROLL BAR on-product warning labels
are still on the ROLL BAR and are readable.
• If there is any doubt as to the condition of the
ROLL BAR, remove the machine from service and
contact your dealer for assistance.
INSPECTION OF THE ROLL BAR PROTECTIVE
STRUCTURE
A ROLL BAR, like any other safety device, needs to be
periodically inspected to verify that the integrity of the
device has not been compromised through normal
machine use, misuse, age degradation, modifications,
or a roll over.
To maintain operator roll over protection and roll bar
effectiveness:
• If a ROLL BAR becomes damaged for any reason,
such as a collision, roll over or impact, the ROLL
BAR must be replaced. Small undetectable
cracks can reduce the effectiveness of the ROLL
BAR. Never weld, straighten, or repair the ROLL
BAR.
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Safety Rules & Information
INSPECT BUCKLE
& LATCH
WARNING
Failure to properly inspect and maintain the
seat belt can cause serious injury or death.
INSPECTION AND MAINTENANCE OF
THE ROLL BAR SEAT BELT
• The seat belt like the ROLL BAR, needs to be
periodically inspected to verify that the integrity
has not been compromised through normal
machine use, misuse, age degradation,
modifications, or a roll over. If the seat belt does
not pass all of the following tests, it should be
replaced.
INSPECT WEBBING
• BEFORE EACH USE – Conduct the following
inspections/maintenance of the seat belt and
retraction mechanism:
1) Check for dirt or debris in the retraction
mechanism. If dirt or debris is found, it should
be removed.
2) Check to make sure the retraction mechanism
retracts easily and completely.
3) Check for damage to any part of the seat belt
such as nicks, cuts, loose stitching, or fraying.
4) Check that the buckle and latch operate
properly and that the latch plate is not
excessively worn, deformed, or the buckle is
damaged or cracked. The seat belt should
latch and release easily.
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Identification Numbers
Identification Numbers
All Models
Identification
Tag
CE Models
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.
CE IDENTIFICATION TAG
MARKINGS
A. Manufacturer’s Identification Number
B. Power Rating in Kilowatts
I
A
B
H
J
C
D
C. Maximum Engine Speed in Rotations per Minute
D. Sound Pressure at Operator’s Position in Decibels
**
E
F
E. Vibration at the Wheels *
F. Vibration at the Seat *
G. Manufacturer’s Address
H. Year of Manufacture
K
G
I. CE Compliance Logo
J. Sound Power in Decibels ***
K. Mass of Unit in Kilograms
CE Models:
Place copy of
Identification Tag here.
This unit complies with European Harmonized Lawn Mower
Standard EN 836, European Machinery Directive 98/37/EC,
and European EMC Directive 89/336/EC
* Tested according to EN 836:1997/A2:2001, EN 1032:
1996, EN 1033:1995
** Tested according to EN836:1997/A2:2001
*** Tested according to 2000/14/EC
11
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Safety Decals
SAFETY DECALS
This unit has been designed and manufactured to
provide you with the safety and reliability you would
expect from an industry leader in outdoor power
equipment manufacturing.
NORTH AMERICAN MODELS
1
2
Although reading this manual and the safety
instructions it contains will provide you with the
necessary basic knowledge to operate this equipment
safely and effectively, we have placed several safety
labels on the unit to remind you of this important
information while you are operating your unit.
All DANGER, WARNING, CAUTION and
3
4
instructional messages on your mower should be
carefully read and obeyed. Personal bodily injury can
result when these instructions are not followed. The
information is for your safety and it is important! The
safety decals below are on your unit.
5
6
If any of these decals are lost or damaged, replace
them at once. See your local dealer for
replacements.
7
These labels are easily applied and will act as a
constant visual reminder to you, and others who may
use the equipment, to follow the safety instructions
necessary for safe, effective operation.
8
9
(Gas model only.)
8
10
11
11
1
12
13
13
14
2
CE MODELS (EXPORT)
1
7
2
3
10
4,5
6,7
12
9
14
3
4
8,10
9
5
11,12
13,14
6
2
12
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Safety Icons
Warning: Read Operator’s
Manual.
Read and understand the
Operator’s Manual before using
this machine.
Danger: Fire Hazard.
Keep unit free of grass, leaves and
excess oil. Do not add fuel while
engine is hot or running. Stop
engine and allow to cool for at
least 3 minutes prior to adding fuel. Do not add fuel
indoors, in an enclosed trailer, garage or other
enclosed areas. Clean up spilled fuel. Do not smoke
while operating this machine.
Danger:Thrown Objects.
This machine is capable of
throwing objects and debris. Keep
bystanders away.
Warning: Avoid Serious Injury or
Death from Roll Over
Warning: Remove Key Before
Servicing.
Do NOT jump off if the mower tips.
Read and follow all operating
Remove the key and consult
technical literature before
instructions and warnings in the operator’s manual.
performing repairs or maintenance.
DANGER
result in serious injury or death.
Danger: Machine Rollover.
This indicates a hazard which, if not avoided, will
Operating on steep slopes can
cause sliding and loss of steering,
control and rollover. Do not use
this machine on slopes greater
than 10°.
WARNING
This indicates a hazard which, if not avoided, could
Danger: Machine Rollover.
result in serial injury or death.
Do not operate on any slopes
when wet or slippery. Do not
operate near drop-offs or near
water.
CAUTION
result in minor or moderate injury.
This indicates a hazard which, if not avoided, might
Danger: Dismemberment.
This machine can amputate limbs.
Keep bystanders and children
away when engine is running.
CAUTION or NOTICE
These messages presented without the alert symbol
indicate a situation where the unit or property could
be damaged.
Danger: Dismemberment.
This mower deck can amputate
limbs. Keep hands and feet away
from blades.
NORTH AMERICAN SAFETY ICONS
Safety
Icon
Safety
Icon
Hazard
Hazard
Danger: Dismemberment.
This machine can crush and cut.
Keep hands away from belts and
pulleys.
Amputation
Foot in
Alert
Blade
Danger: Dismemberment.
This machine can crush and cut.
Keep hands away from deck lift
rod.
Thrown
Objects
Toxic
Fumes
Danger: Carbon Monoxide
Poisoning.
Maintain a
safe
distance
Read the
Manual
Do not operate the engine in an
unventilated area.
Warning: Avoid Serious Injury or
Death from Roll Over
Keep roll bar in the raised position
and use seat belt. Do NOT use
seat belt when the roll bar is down
Keep
children
away
Open flame
hazard
Hot
Fire
surface
Hazard
Warning: Avoid Serious Injury or
Death from Roll Over
Keep roll bar in the raised position
Wear
Protective
Gear
Amputation
Rotating
Parts
Amputation
Hand in
Blade
and use seat belt. There is no roll
over protection when roll bar is down. Lower roll bar
only when necessary and NEVER remove it. Raise
the roll bar as soon as clearance permits.
Pinch
Point
Warning: Low Overhanging
Obstacles Hazard
Check for overhead clearances
Rollover
Hazard
Overhead
Obstacles
before driving under any objects.
Stay clear. Do NOT allow roll bar to contact low
overhanging obstacles, such as tree branches and
guide wires. Read and follow all operating
instructions and warnings in the operator’s manual.
13
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Safety Interlock System
SAFETY INTERLOCK
SYSTEM
This unit is equipped with safety interlock switches.
These safety systems are present for your safety, do
not attempt to bypass safety switches, and never
tamper with safety devices. Check their operation
regularly.
Operational SAFETY Checks
Test 1 — Engine should NOT crank if:
• PTO switch is engaged, OR
• Parking brake is not engaged, OR
• Motion control handles are not in the NEUTRAL
position, OR
• Operator is not on the seat.
Test 2 — Engine SHOULD crank if:
• PTO switch is NOT engaged, AND
• Parking brake is engaged, AND
• Motion control handles are locked in the
NEUTRAL position, AND
• Operator is on the seat.
Test 3 — Engine should SHUT OFF if:
• Operator rises off seat with PTO engaged, OR
• Operator rises off seat with parking brake
disengaged.
• Operator moves motion control handles inward
before disengaging parking brake.
Test 4 — Blade Brake Check
Mower blades and mower drive belt should come to a
complete stop within seven (7) seconds after electric
PTO switch is turned off (or operator rises off seat). If
mower drive belt does not stop within seven (7)
seconds, see your dealer.
NOTE: Once the engine has stopped, PTO switch
must be turned off, parking brake must be engaged,
and the motion control handles must be locked in the
NEUTRAL position after the operator returns to the
seat in order to start the engine.
WARNING
If the unit does not pass a safety test, do not
operate it. See your authorized dealer. Under
no circumstance should you attempt to defeat
the purpose of the safety interlock system.
14
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Features & Controls
Figure 1. CONTROL FUNCTIONS
The information below briefly describes the function of the individual controls. Starting, stopping, driving, and
mowing require the combined use of several controls applied in specific sequences. To learn what combination
and sequence of controls to use for various tasks see the OPERATION section.
Ignition Switch
Ground Speed Levers
The ignition switch starts and stops the engine, it has
four positions:
These levers control the ground speed of the rider.
The left lever controls the left rear drive wheel and the
right controls the right rear drive wheel.
Moving a lever forward increases the FORWARD
speed of the associated wheel, and pulling back on a
lever increases the REVERSE speed.
Note: The further a lever is moved away from the
neutral position the faster the drive wheel will turn.
Heats the glow plugs (diesel model only)
Stops the engine and shuts off the
electrical system.
Allows the engine to run and powers the
electrical system.
See the Operating the Zero Turn Rider section for
steering instructions.
Cranks the engine for starting.
NOTE: Never leave the ignition switch in the ON
position with the engine stopped–this drains the
battery.
Seat Adjustment Lever
The seat can be adjusted forward and back. Move the
lever forward, position the seat as desired, and
release the lever to lock the seat in position.
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Features & Controls
PTO (Power Take Off) Switch
The PTO switch engages and disengages the mower.
Pull UP on the switch to engage the mower, and push
DOWN to disengage the mower.
Glow Plug Indicator (diesel model
only)
Lamp that indicates that the glow plugs are heating.
Hold the ignition key in the “HEAT” position until
indicator lamp turns off, then turn the key to start.
Throttle Control
Voltage Indicator
Lamp that indicates a low voltage condition.
Moving the throttle control fully forward is FULL
throttle position. Always operate the unit at FULL
throttle when mowing.
Oil Pressure Indicator
Lamp that indicates a low oil pressure condition.
Choke (gas model only)
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.
Water Temperature Gauge
Measures the engine coolant temperature.
Parking Brake
Fuel Tank Cap
To remove the cap, turn counterclockwise.
DISENGAGE
ENGAGE
Releases the parking brake.
Locks the parking brake.
Fuel Level Gauge
Displays the fuel level in the tank.
Pull the parking brake lever back to engage the
parking brake. Move the lever fully forward to
disengage the parking brake. NOTE: To start the unit
the parking brake must be engaged.
Power Outlet
Unit is equipped with a +12VDC, 20A power outlet.
Deck Lift Pedal, Cutting
Height Adjustment Pin & Deck Lift Lock
Lever
These control the cutting height of the mower deck.
Depress the pedal until it locks into the 6” (15,2 cm)
position. Place the adjustment pin in the desired
cutting height and release the lift lock lever.
Hour Meter / Maintenance Reminder
Measures the time of the PTO being engaged. The
hour meter measures the number of hours the PTO
has been engaged. The hour meter will flash an
initial oil change indicator at 5 hours, and a lubrication
reminder every 50 hours. These reminders display for
approximately two hours and will automatically reset
themselves.
Note: The hour meter will register the passage of time
only when the PTO is engaged. The hour meter has
a self contained power source so the total hours are
always visible.
16
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Operation
GENERAL OPERATING SAFETY
CHECKS BEFORE STARTING
• Check that crankcase is filled to full mark on
dipstick. See the engine Operators Manual for
instructions and oil recommendations.
Before first time operation:
• Be sure to read all information in the Safety and
Operation sections before attempting to operate
this tractor and mower.
• Check the radiator fluid level. See engine
operator’s manual for instructions.
• Become familiar with all of the controls and how to
stop the unit.
• Check the hydraulic oil level. Refer to REGULAR
MAINTENANCE section.
• Drive in an open area without mowing to become
accustomed to the unit.
• Make sure all nuts, bolts, screws and pins are in
place and tight.
• Adjust the seat position, and make certain you
can reach all controls from the operators position.
WARNING
• Fill the fuel tanks with fresh fuel. Refer to engine
manual for fuel recommendations.
Never allow passengers to ride on the unit.
Before leaving the operator’s position for any
reason, engage the parking brake, disengage
the PTO, stop the engine and remove the key.
WARNING
Never operate on slopes greater than 17.6
percent (10°) which is a rise of 3-1/2 feet (106
cm) vertically in 20 feet (607 cm) horizontally.
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.
Select slow ground speed before driving onto a
slope. Use extra caution when operating on
slopes with a rear-mounted grass catcher.
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.
Mow across the face of slopes, not up and
down,use caution when changing directions
and DO NOT START OR STOP ON SLOPE.
WARNING
Do not load this zero-turn rider on a trailer or
truck using two separate ramps. Only use a
single ramp that is at least one foot wider than
the width of the rear wheels of this rider. This
rider has a zero turning radius and the rear
wheels could fall off the ramps, or the rider
could tip over injuring the operator or
bystanders.
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Operation
PRIMING THE FUEL SYSTEM
Diesel Model Only
B
A
Priming the fuel system fills the fuel filters and
removes any air bubbles from the fuel system. This
must be performed before the first use, after any fuel
filter maintenance or if the fuel system is run dry.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire. To help
prevent possible injury, turn the ignition switch
off when changing fuel filter or water separator
element. Clean up fuel spills immediately.
To prime the fuel system:
C
On the water separator:
1. Using a 1/2” wrench, loosen the vent screw (A) on
the water separator 2-3 revolutions.
2. Unscrew the priming hand pump (B) located on
top of the water separator. Operate the hand
pump up and down until fuel that is free of air
flows from the vent.
3. Tighten the vent screw (A) to 4.5 ft.lbs. (6 N.m.).
DO NOT OVER TIGHTEN!
On the engine fuel filter:
Figure 2. Fuel System Priming
A. Water Separator Vent Screw
B. Priming Hand Pump
1. Using a 9/16” wrench, loosen the vent screw (C)
on the engine fuel filter 2-3 revolutions.
C. Engine Fuel Filter Vent Screw
2. Operate the hand pump (B) up and down until fuel
that is free of air flows from the vent.
3. Tighten the vent screw (C) to 4.5 ft.lbs. (6 N.m.).
DO NOT OVER TIGHTEN!
4. Tighten the priming hand pump finger tight.
5. Start the engine. (See STARTING THE ENGINE).
If the engine will not start, further priming is
necessary. If the engine starts but misfires or
continues to emit smoke, further priming is
necessary.
6. If the engine starts but runs rough, continue to run
the engine at low idle until the engine runs
smoothly.
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Operation
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.
STARTING THE ENGINE
(Gas Model)
STARTING THE ENGINE
(Diesel Model)
1. While sitting in the operators seat, engage the
parking brake and make sure the PTO switch is
disengaged and the motion control handles are
locked in the NEUTRAL position.
1. While sitting in the operators seat, engage the
parking brake and make sure the PTO switch is
disengaged and the ground speed control levers
are locked in the neutral position.
2. NOTE: A warm engine may not require choking.
2. Set the throttle to middle position (set throttle to
FULL when starting in cold weather)
Set the engine throttle control to FAST throttle
position. Then fully close the choke by pulling the
knob OUT fully.
3. Turn the key to the HEAT position. Hold the key to
turn the glow plug indicator light on and activate
the glow plugs.
3. Insert the key into the ignition switch and turn it to
START.
4. Wait until the glow plug indicator light turns off,
then turn the key to START. If the engine does not
start immediately, move the throttle control to
FULL.
4. After the engine starts, gradually open the choke
(push knob down fully). Warm up the engine by
running it for at least a minute.
NOTE: Do not crank the engine continuously for
more than 30 seconds. Allow the starter motor to
cool for two minutes before cranking the engine
again.
5. Move the throttle to FULL before engaging the
PTO switch or driving the machine.
In the event of an emergency the engine can be
stopped by simply turning the ignition switch to
STOP. Use this method only in emergency situations.
For normal engine shut down follow the procedure
given in STOPPING THE RIDER.
5. After the engine starts, move the engine throttle
control to SLOW. Warm up the engine by running
it for at least a minute.
6. Move the throttle to FULL before engaging the
PTO switch or driving the machine.
In the event of an emergency the engine can be
stopped by simply turning the ignition switch to
STOP. Use this method only in emergency situations.
For normal engine shut down follow the procedure
given in STOPPING THE TRACTOR.
STOPPING THE TRACTOR &
ENGINE
1. Returning the ground speed control levers to the
middle position will stop tractor movement. Pivot
the levers outward and lock them in neutral.
2. Disengage the PTO.
3. Engage the parking brake.
4. Move the throttle control to SLOW and allow the
engine to cool down for a short time.
5.Turn the ignition key to OFF. Remove the key.
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Operation
DRIVING THE TRACTOR
PUSHING THE RIDER BY HAND
1. Sit in the seat and adjust the seat so that you can
comfortably reach all of the controls and see the
instrument and gauge panels.
DO NOT TOW RIDER
Towing the unit will cause hydraulic pump
and wheel motor damage. Do not use
another vehicle to push or pull this unit.
2. Engage the parking brake.
3. Make sure the PTO switch is disengaged and the
ground speed control levers are locked in the
neutral position.
1. Refer to Figure 3 for hydraulic release valve
location.
4. Start the engine (see STARTING THE ENGINE).
2. To open the release valves, turn the right-hand
release valve, which is located on engine side of
the right-hand pump, counter-clockwise 2 full turns
MAX. Then turn the left-hand release valve, which
is located on the outer side of the left-hand pump,
counter-clockwise 2 full turns MAX
5. Disengage the parking brake and pivot the ground
speed control levers inward.
6. Move the levers evenly forward to travel forward.
Return them to the neutral position to stop. Note
that the further the levers are moved forward the
faster the tractor will travel.
3. Disengage the parking brake. The tractor can now
be pushed by hand.
7. Stop the tractor by returning the control levers to
the neutral position, pivoting the levers outward to
lock into the neutral position, engaging the parking
brake, and stopping the engine (see STOPPING
THE TRACTOR AND ENGINE).
4. After moving the tractor, engage the parking
brake. Re-engage the pumps (drive position) by
turning the release valves clockwise and tighten to
80-120 in/lbs (9-13.5 N.m.)
NOTE: See the ZERO-TURN DRIVING PRACTICE
section on pages 16 & 17 for detailed instructions on
driving the tractor.
A
Figure 3. Hydraulic Release Valve Location
A. Hydraulic Release Valve (Right-hand side
shown)
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Operation
Smooth Travel
ZERO TURN
The lever controls of
the Zero Turn rider are
responsive.
DRIVING PRACTICE
The lever controls of the Zero Turn rider are
responsive, and learning to gain a smooth and
efficient control of the rider’s forward, reverse, and
turning movements will take some practice.
The BEST method of
handling the ground
speed control levers is
in three steps — as
shown in Figure 3.
Spending some time going through the maneuvers
shown and becoming familiar with how the unit
accelerates, travels, and steers — before you begin
mowing —is absolutely essential to getting the most
out of the Zero Turn rider.
FIRST place your
hands onto the levers
as shown.
Locate a smooth, flat area of your lawn — one with
plenty of room to maneuver. (Clear the area of
objects, people and animals before you begin.)
Operate the unit at mid-throttle during this practice
session (ALWAYS operate at full throttle when
mowing), and turn slowly to prevent tire slippage and
damage to your lawn.
SECOND, to go
forward gradually push
the levers forward with
your palms.
THIRD, to speed up
move the levers farther
forward. To slow down
smoothly, slowly move
the levers toward
neutral.
We suggest you begin with the Smooth Travel
procedure to the right, and then advance through the
forward, reverse, and turning maneuvers.
You must release the parking brake prior to moving
the control levers inward.
Figure 3. Move Control
Levers Gradually
BASIC DRIVING
Forward Travel Practice
Reverse Travel Practice
Gradually move both ground speed control levers —
evenly FORWARD from neutral. Slow down and
repeat.
LOOK DOWN & BEHIND, then gradually move both
ground speed control levers evenly BACK from
neutral. Slow down and repeat.
NOTE: Straight forward travel takes practice. If
necessary, top speed can be balance-adjusted — see
the Speed Balancing Adjustment in the Adjustments
section near the back of this manual.
NOTE: Practice backing up for several minutes before
attempting to do so near objects. The rider turns
sharply in reverse as well as forward, and backing up
straight takes practice.
Forward
Travel
Reverse
Travel
Figure 4. Forward Travel
Figure 5. Reverse Travel
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Operation
Practice Turning Around a Corner
Practice Turning In Place
While traveling forward allow one handle to gradually
return back toward neutral. Repeat several times.
To turn in place, “Zero Turn,” gradually move one
ground speed control lever forward from neutral and
one lever back from neutral simultaneously. Repeat
several times.
NOTE: To prevent pivoting directly on the tire tread, it
is best to keep both wheels going at least slightly
forward.
NOTE: Changing the amount each lever is pulled—
forward or back, changes the “pivot point” you turn on.
Turning
In-Place
Executing
Turns
Figure 6. Turning Around a Corner
Figure 7. Turning in Place
ADVANCED DRIVING
Executing an End-Of-Row Zero
Turn
Your Zero Turn Rider’s unique ability to turn
in place allows you to turn around at the
end of a cutting row rather than having to
stop and Y-turn before starting a new row.
For example, to execute a left end-of row
zero turn:
1. Slow down at the end of the row.
2. Move the RIGHT ground speed control
lever forward slightly while moving the
LEFT ground speed control lever back to
center and then slightly back from
center.
3. Begin mowing forward again.
This technique turns the rider LEFT and
slightly overlaps the row just cut —
eliminating the need to back up and re-cut
missed grass.
As you become more familiar and
experienced with operating the Zero Turn
rider, you will learn more maneuvers that
will make your mowing time easier and
more enjoyable.
Remember, the more you practice, the
better your control of the Zero Turn will
be!
Figure 8. Executing an End-Of-Row Turn
22
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Operation
ATTACHING A TRAILER
A
The maximum weight of a towed trailer should be less
than 300 lbs (138kg). Secure the trailer with a
appropriately sized clevis pin (A, Figure 10) and clip
(B).
Excessive towed loads can cause loss of traction and
loss of control on slopes. Reduce towed weight when
operating on slopes. The surface being driven on
greatly impacts traction and stability. Wet or slippery
surfaces can greatly reduce traction and the ability to
stop or turn. Carefully evaluate the surface conditions
before operating the unit and trailer, and never
operate on slopes greater than 10°. See SLOPE
OPERATION and TOWED EQUIPMENT in the safety
section of this manual for additional safety
B
information.
Figure 10. Trailer Weight Recommendations
A. Clevis Pin
B. Clip
RAISE & LOWER THE ROLL BAR
To lower the roll bar:
1. Pull the hair pin clips (A, Figure 12) out of the
retainer pins (B).
C
2. Push or pull the top of the roll bar (C) forward
against the rubber stops (D) and remove the
retainer pins (B).
D
C
3. Lower the roll bar and reinstall the retainer pins
and hair pin clips to secure the roll bar in the
down position (see insert, Figure 12).
To raise the roll bar:
1. Pull the hair pin clips (A) out of the retainer pins
(B) and remove the retainer pins.
2. Raise the roll bar (C) until the rubber stops (D)
contact the upright tubes.
A
3. Push or pull the top of the roll bar forward against
the rubber stops and reinstall the retainer pins and
hair pin clips to secure the roll bar in the raised
position.
D
B
WARNING
Figure 12. Raise & Lower the Roll Bar
A. Hair Pin Clip
B. Retainer Pin
AVOID SERIOUS INJURY OR DEATH FROM
ROLL OVER:
C. Roll Bar
D. Rubber Stop
Keep roll bar in the raised position and use
seat belt.
THERE IS NO ROLL OVER PROTECTION WHEN
THE ROLL BAR IS DOWN
Lower the roll bar only when necessary and
NEVER remove it.
Do NOT use seat belt when the roll bar is down.
Raise the roll bar as soon as clearance permits.
Do NOT jump off if mower tips.
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Operation
MOWING
1. Engage the parking brake. Make sure the PTO
switch is disengaged, the motion control handles
are locked in the NEUTRAL position and the
operator is on the seat.
2. Start the engine (see STARTING THE ENGINE).
3. Set the mower cutting height.
4. Set the throttle to FULL.
5. Engage the PTO by pulling up on the PTO switch.
6. Begin mowing.
7. When finished, slow engine down and shut off the
PTO.
8. Stop the engine (see STOPPING THE TRACTOR
AND ENGINE).
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.
MOWING RECOMMENDATIONS
Don’t cover the grass surface with a heavy layer of
clippings. Consider using a grass collection system
and starting a compost pile.
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
Cut Here On
Cut
First Pass
Here On
Second
Pass
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).
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Operation
When and How Often to Mow
The time of day and condition of the grass greatly
affect the results you’ll get when mowing. For the best
results, follow these guidelines:
1. Mow when the grass is between three and five
inches high.
2. Mow with sharp blades. Short clippings of grass
one inch or shorter decompose more quickly than
longer blades. Sharp mower blades cut grass
cleanly and efficiently, preventing frayed edges
which harm the grass.
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.
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.
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.
1. Cut long straight strips overlapping slightly.
2. Where possible, change patterns occasionally to
eliminate matting, graining or a corrugated
appearance.
MOWING METHODS
3. For a truly professional cut, mow across the lawn
in one direction, then recut the lawn by mowing
perpendicular to the previous cut.
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.
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.
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
25
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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 (side-
discharging) or grass bagging operation.
ENGINE SPEED & GROUND SPEED FOR
BROADCASTING
Use full engine throttle matched with a slow ground
speed so that clippings will be finely cut. Ground
speed while mulching should be HALF of the speed
that would be used when broadcasting (side
discharging) under similar conditions. Since mulching
requires more horsepower than broadcasting, using a
slower ground speed is vitally important for proper
mulching operation.
HOW MUCH GRASS TO MULCH
The best mulching action typically results from cutting
only the top 1/2 inch to 3/4 inch of grass blade. This
provides short clippings which decompose properly
(much more quickly than longer clippings). The ideal
cutting height will vary with climate, time of year, and
quality of your lawn. We recommend that you
experiment with both the cutting height and ground
speed until you achieve the best cut. Start with a high
cutting height and using progressively lower settings
until you find a cutting height that is matched to your
mowing conditions and preferences.
26
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Operation
STORAGE (Diesel Model)
WARNING
Temporary Storage (30 Days Or Less)
Remember, the fuel tank will still contain some fuel, so
never store the unit indoors or in any other area where
fuel vapor could travel to any ignition source. Fuel vapor
is also toxic if inhaled, so never store the unit in any
structure used for human or animal habitation.
Never store the unit, with diesel fuel in engine
or fuel tank, in a heated shelter or in enclosed,
poorly ventilated enclosures. Diesel fumes
may reach an open flame, spark or pilot light
(such as a furnace, water heater, clothes dryer,
etc.) and cause an explosion.
Here is a checklist of things to do when storing your unit
temporarily or in between uses:
Handle diesel fuel carefully. It is highly
flammable and careless use could result in
serious fire damage to your person or property.
• Keep the unit in an area away from where children
may come into contact with it. If there’s any chance
of unauthorized use remove the ignition key.
• If the unit can’t be stored on a reasonable level
surface, chock the wheels.
• Clean all grass and dirt from the mower.
• If temperature is expected to drop below 35 degrees,
refer to Long Term Storage, Item 2.
Drain fuel outdoors into an approved container
and away from open flame or sparks.
NOTE: Diesel fuel, if permitted to stand unused for
extended periods (30 days or more), may develop
gummy deposits which can adversely affect the fuel
pump and injector tubes and cause engine malfunction.
To avoid this condition, add a diesel fuel stabilizer to the
fuel tank and run the engine a few minutes, or drain all
fuel from the unit before placing it in storage.
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.
STARTING AFTER
LONG TERM STORAGE
2. Use an Antifreeze tester to check the cooling
system’s level of protection. Read the instructions on
the Antifreeze container for the appropriate ratio of
water to Antifreeze for your geographical area.
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.
3. Prepare the mower deck for storage as follows:
a. Remove mower deck from the unit.
b. Clean underside of mower deck.
4. Fill the fuel tank with fresh fuel. See engine manual
for recommendations.
c. Coat all bare metal surfaces with paint or light coat
of oil to prevent rusting.
5. See engine owner’s manual and follow all
instructions for preparing engine after storage.
4. Clean external surfaces and engine.
6. Check crankcase oil level and add proper oil if
necessary. If any condensation has developed
during storage, drain crankcase oil and refill.
5. Prepare engine for storage. See engine owner’s
manual.
6. Clean any dirt or grass from cylinder head, engine
housing and air cleaner element.
7. 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.
7. Cover air cleaner and exhaust outlet tightly with
plastic or other waterproof material to keep out
moisture, dirt and insects.
8. Completely grease and oil unit as outlined in the
Regular Maintenance section.
DIESEL FUEL RECOMMENDATIONS
Fuel companies provide fuel tailored to meet the existing
weather conditions. These fuels change at the start of
the predominant season according to regional weather
trends.
9. Clean up unit and apply paint or rust preventative to
any areas where paint is chipped or damaged.
10. Be sure the battery is filled to the proper level with
water and is fully charged. Battery life will be
increased if it is removed, put in a cool, dry place
and fully charged about once a month. If battery is
left in unit, disconnect the negative cable.
Winter fuels are tailored to give ease of starting for cold
weather. Summer fuel may be somewhat heavier than
winter fuel resulting in slightly better fuel economy and
power. Spring and fall fuel is an average blend between
winter and summer blend.
11. Drain fuel system completely or add a diesel fuel
stabilizer to the fuel system. If you have chosen to
use a fuel stabilizer and have not drained the fuel
system, follow all safety instructions and storage
precautions in this manual to prevent the possibility
of fire from the ignition of diesel fumes. Remember,
diesel fumes can travel to distant sources of ignition
and ignite, causing risk of explosion and fire.
For these reasons an effort should be made to purchase
fuels in such quantities that they are not carried over into
the next season. Using the wrong blend of fuel can
cause problems with the engine.
Refer to the engine manufacturer’s manual for specific
fuel recommendations.
27
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Operation
STORAGE (Gas Model)
WARNING
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.
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.
Here is a checklist of things to do when storing your unit
temporarily or in between uses:
Handle gasoline carefully. It is highly flammable
and careless use could result in serious fire
damage to your person or property.
• 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.
Drain fuel outdoors into an approved container
and away from open flame or sparks.
• If the unit can’t be stored on a reasonable level
surface, chock the wheels.
• Clean all grass and dirt from the mower.
• If temperature is expected to drop below 35 degrees,
refer to Long Term Storage, Item 2.
11. 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.
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.
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.
2. Use an Antifreeze tester to check the cooling
system’s level of protection. Read the instructions on
the Antifreeze container for the appropriate ratio of
water to Antifreeze for your geographical area.
3. Prepare the mower deck for storage as follows:
a. Remove mower deck from the unit.
b. Clean underside of mower deck.
STARTING AFTER
LONG TERM STORAGE
Before starting the unit after it has been stored for a long
period of time, perform the following steps.
c. Coat all bare metal surfaces with paint or light coat
of oil to prevent rusting.
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. Clean external surfaces and engine.
5. Prepare engine for storage. See engine owner’s
manual.
6. Clean any dirt or grass from cylinder head cooling
fins, engine housing and air cleaner element.
4. Fill the fuel tank with fresh gasoline. See engine
manual for recommendations.
7. Cover air cleaner and exhaust outlet tightly with
plastic or other waterproof material to keep out
moisture, dirt and insects.
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.
8. Completely grease and oil unit as outlined in the
Regular Maintenance section.
7. Inflate tires to proper pressure.
9. Clean up unit and apply paint or rust preventative to
any areas where paint is chipped or damaged.
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
10. Be sure the battery is filled to the proper level with
water and is fully charged. Battery life will be
increased if it is removed, put in a cool, dry place
and fully charged about once a month. If battery is
left in unit, disconnect the negative cable.
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Operation
Notes
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Regular Maintenance
MAINTENANCE SCHEDULE & PROCEDURES
The following schedule should be followed for normal care of your rider and mower. You will need to keep a
record of your operating time. Determining operating time is easily accomplished by observing the hour meter.
Before Every Every
Every
100
Hours
Every Spring &
SAFETY ITEMS
Each
Use
5
25
250
Fall
Hours Hours
Hours
•
•
•
•
Check Safety Interlock System
Check Rider Brakes
Before Every Every
Each
Use
Every
100
Hours
Every Spring &
RIDER MAINTENANCE
5
25
250
Hours
Fall
Hours Hours
•
•
Check Gearbox Oil Level ****
•
Check Rider / Mower for loose hardware
•
•
Clean Deck & Check / Replace Mower
Blades**
Lubricate Rider & Mower **
•
•
•
Clean Battery & Cables
Check Tire Pressure
Check Hydraulic Oil
•
Change Hydraulic Oil Filter **
Before Every Every
Every
100
Hours
Every Spring &
ENGINE MAINTENANCE
Each
Use
5
25
250
Fall
Hours Hours
Hours
•
Check Engine Oil Level / Engine Coolant
Level
•
Check / Clean Cooling Fins & Intake **
Service Air Filter *
Change Oil & Filter *
Check / Replace Spark Plugs *
•
Check Fuel Filter / Drain Water Separator*
Check & Clean Radiator Screens
Check Coolant Level
•
•
•
•
Change Coolant
* 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.
**** Service after the first 25 hours, then after every 100 hours.
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.
Tire
Front
Rear
Pressure
25 psi (1,72 bar)
18 psi (1,24 bar)
Figure 12. Checking Tire Pressure
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Operation
CHECKING / ADDING FUEL (Diesel)
To add fuel:
1. Remove the fuel cap (A, Figure 13).
A
2. Fill the tank to the bottom of the fill tube. This will
leave room in the tank for fuel expansion. Refer to
your engine manual for specific fuel
recommendations.
3. Install and hand tighten the fuel cap.
4. Repeat same process for opposite tank.
NOTE: The fuel tanks are tied together through a
“tee” in the supply lines. By filling only one tank, the
level will balance between the two tanks, effectively
having 1/2 tank of fuel for each side. The fuel
transfer through the “tee” is slow, so it is
recommended that both tanks have fuel added to
them.
Figure 13. Fuel Tank Fill
A. Fuel Tank Cap
FUEL FILTER
This unit is equipped with two fuel filters. One is a
water separator/filter mounted to the frame, under the
seat and the other is located on the engine. The
water separator should be drained every 25 hours or
whenever water is visible in the bowl. Replace the
fuel filters every 500 hours of operation or as
required.
To drain the fuel filter:
1. Turn the engine off, set the parking brake, remove
the ignition key, and wait for all moving parts to
stop.
A
Figure 14. Drain Fuel Filter
A. Drain Valve
2. Allow the engine to cool for five (5) minutes before
draining the fuel filter.
3. Place a container under the drain valve (A, Figure
14) and turn the drain valve approximately 1-2
turns.
Do not use Kerosene in place of diesel
fuel. Kerosene will damage the engine.
Consult the engine manufacturer’s manual
for specific fuel recommendations.
4. Allow the filter to drain until all water and debris
have drained out.
5. Turn the drain valve to close it when finished
draining.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire. To help
prevent possible injury, turn the ignition switch
off when changing fuel filters or water
separator elements. Clean up fuel spills
immediately.
WARNING
Diesel fuel is highly flammable and must be
handled with care. Never fill the tank when the
engine is still hot from recent operation. Do
not allow open flame, smoking or matches in
the area. Avoid over-filling and wipe up any
spills.
The water separator is under suction
during normal engine operation. Ensure
the drain valve is tightened securely to
help prevent air from entering the fuel
system.
Do not drain or replace fuel filter when engine
is hot, as spilled fuel may ignite. Make sure the
filter drain valve is fully closed before returning
the unit to service.
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Regular Maintenance
CHECKING / ADDING FUEL (Gas)
To add fuel:
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.
1. Remove the fuel cap (see A, Figure 13).
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.
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.
3. Install and hand tighten the fuel cap.
4. Repeat same process for opposite tank.
NOTE: The fuel tanks are tied together through a
“tee” in the supply lines. By filling only one tank, the
level will balance between the two tanks, effectively
having 1/2 tank of fuel for each side.
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.
FUEL FILTER
The fuel filter is located in the fuel line between fuel
shut off valve and fuel pump, behind the hydraulic
reservoir. If filter is dirty or clogged, replace as
follows:
1. Shut off the fuel tank selection valve.
2. Disconnect the negative battery cable.
3. Place a container below the filter to catch spilled
fuel.
4. Using a pliers, open and slide hose clamps from
fuel filter.
5. Remove hoses from filter.
6. Install new filter in proper flow direction in fuel line.
7. Secure with hose clamps.
8. Reconnect the negative battery cable when
finished.
32
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Regular Maintenance
CHECK / ADD ENGINE OIL
Refer to Figure 15 for dipstick and oil fill locations.
Diesel Model
Refer to the engine owners manual for specific engine
oil check and fill procedures. Also refer to the engine
owners manual for specific engine oil and filter
change procedures.
A
B
A
B
CHECK / CHANGE AIR FILTER
Refer to the engine owners manual for specific air
filter service procedures.
Gas Model
CHECK HYDRAULIC OIL LEVEL
NOTE: Do not open the hydraulic oil reservoir unless
oil is being added.
Figure 15. Change Oil & Filter
A. Oil Fill Cap
B. Crankcase Dip Stick
1. Visually check that the hydraulic oil level is filled to
the recess area (A, Figure 16) of the hydraulic oil
reservoir.
A
2. If necessary, remove the reservoir cap (B) and
add either Mobil 1™, 15W-50 synthetic oil or
Castrol Syntec™ 5W-50 oil. DO NOT use
conventional oils. Make sure area around the filler
neck is free of dust, dirt, or other debris.
B
HYDRAULIC OIL FILTER CHANGE
Change Interval: Every 500 Hours
Filter Part Number: 5021357
NOTE: Removing the oil filter from the filter base will
drain the oil reservoir. Have a suitable container
ready to catch any spilled oil. Ferris recommends this
be a dealer-only service item.
Figure 16. Hydraulic Oil Reservoir
A. Tank Recess (“FULL” level)
B. Cap
1. Locate the hydraulic oil filter (A, Figure 17) behind
the oil reservoir.
2. Fill the new filter with oil. Lubricate the new filter
seal with a few drops of oil.
3. Remove the oil filter and quickly thread the new
filter onto the filter base until the gasket makes
contact, then tighten 3/4 of a turn more.
A
4. Refill reservoir with fresh oil to replace any oil lost
during filter change.
5. Raise the rear of the unit and secure with
jackstands. Chock the front wheels to prevent the
unit from rolling. Run the unit for several minutes
to purge any air from the hydraulic system and
check the hydraulic oil level.
Figure 17. Hydraulic Oil Filter Location
A. Oil Filter
IMPORTANT NOTE: Use caution after changing the
filter; air in the hydraulic system may affect the
responsiveness of the control levers. Repeat step 5
until the air is out of the system.
33
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Regular Maintenance
CHECK ENGINE COOLANT LEVEL
The engine coolant level and quality should be
checked before each use, when the engine is cool
and off.
1. Remove the radiator pressure cap (A, Figure 18)
to check the fluid level.
WARNING
PRESSURIZED SYSTEM
Hot coolant can cause serious burns. To open
the cooling system filler cap, stop the engine
and wait until the cooling system components
are cool. Loosen the cooling system pressure
cap slowly in order the relieve the pressure.
2. Coolant level should be 1/2” (13mm) below the
bottom of the filler tube. If coolant level is low, add
coolant until level is 1/2” (13mm) below the bottom
of the filler tube. Proper coolant mix is a 50/50
mixture of ethylene glycol and distilled water. See
engine owners manual for engine coolant
specifications.
C
3. Check the coolant level in the radiator expansion
tank (Figure 19). If coolant level is low, remove
the cap add coolant until level is at the “FULL” line.
Proper coolant mix is a 50/50 mixture of ethylene
glycol and distilled water. See engine owners
manual for engine coolant specifications.
A
B
CHANGE ENGINE COOLANT
See engine owners manual for specific engine coolant
procedures. The drain valve is located at the base of
the right-hand side of the radiator.
CLEAN RADIATOR, SCREEN & OIL
COOLER
Clean the radiator, screen and oil cooler fins before
each use, or as required (depending on conditions) to
allow proper air-flow through radiator and hydraulic oil
cooler.
Figure 18. Radiator & Oil Cooler
(Diesel model shown)
A. Radiator Pressure Cap
B. Radiator Screen
C. Hydraulic Oil Cooler
1. Raise the seat plate.
2. Lift the radiator screen straight up to remove the
screen. Flush the screen with water or blow clean
with air. Flush the radiator core with water or blow
clean with air. See engine owners manual for
proper radiator cleaning procedures.
3. Clean all dirt, grass, and debris from the oil cooler
fins.
4. Reinstall the radiator screen. Make sure the
screen is fully seated in the carrier.
5. Lower the seat plate.
Figure 19. Radiator Expansion Tank
34
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Regular Maintenance
LUBRICATION
Lubricate the unit at the locations shown in Figure 20
through 25.
*
*
Grease:
Use grease fittings when present. Disassemble
parts to apply grease to moving parts when
grease fittings are not installed.
Not all greases are compatible. Ferris Red Grease
(P/N 5022285) is recommended, automotive-type
high-temperature, lithium grease may be used when
this is not available.
Oil:
Figure 22. Deck Lubrication
* - Use needle nozzle
Generally, all moving metal parts should be oiled
where contact is made with other parts. Keep oil
and grease off belts and pulleys. Remember to
wipe fittings and surfaces clean both before and
after lubrication.
Figure 23. Control Handle Pivots & Seat Pivots
Figure 24. Center Lift Link
Figure 20. Deck Lift Pivots
Figure 21. Mule Drive Idler Arm
Figure 25. Casters, Wheels & Suspension Arms
35
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Regular Maintenance
BATTERY MAINTENANCE
B
NOTE: This unit is equipped with a maintenance-free
BCI58 battery)
C
Cleaning the Battery and Cables
1. Disconnect the cables from the battery, negative
cable first (A, Figure 26).
2. Remove the battery retainer strap (C).
3. Remove the battery and clean the tray and
surrounding areas with a solution of baking soda
and water.
A
4. Clean the battery terminals and cable ends with a
wire brush until shiny.
5. Reinstall the battery and reattach the battery
cables, positive cable first (B).
Figure 26. Battery Compartment
A. Negative (-) Cable & Terminal
B. Positive (+) Cable & Terminal
C. Retainer Strap
6. Secure the battery with the retainer strap (C).
7. Coat the cable ends and battery terminals with
petroleum jelly or non-conducting grease.
WARNING
Be careful when handling the battery. Avoid
spilling electrolyte. Keep flames and sparks
away from the battery.
When removing or installing battery cables,
disconnect the negative cable FIRST and
reconnect it LAST. If not done in this order, the
positive terminal can be shorted to the frame
by a tool.
ANTI-SCALP DECK CASTERS
The anti-scalp deck casters (A, Figure 27) will aid in
preventing the mower deck from scalping or gouging
the turf while mowing or turning.
C
B
The casters can be adjusted in 1/2” (1,3 cm)
increments with the spacers (B). The desired position
is just below the leading edge of the deck.
IMPORTANT NOTE: These casters are not intended
to be in contact with the ground at all times. If you
are mowing at a low cut height, adjust the casters up
to prevent the casters from carrying the weight of the
deck.
B
A
Figure 27. Anti-Scalp Deck Casters
A. Deck Caster
B. Spacer
C. Lynch Pin
36
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Regular Maintenance
SERVICING THE MOWER BLADES
1. Blades should be sharp and free of nicks and
dents. If not, sharpen blades as described in
following steps.
2. To remove blade for sharpening, use a 1” wrench
on the flats of the spindle shaft while removing the
blade mounting bolt with a 15/16” wrench (Figure
28).
3. Use a file to sharpen blade to fine edge. Remove
all nicks and dents in blade edge. If blade is
severely damaged, it should be replaced.
4. Balance the blade as shown in Figure 29. Center
the blade’s hole on a nail lubricated with a drop of
oil. A balanced blade will remain level.
Figure 28. Removing the Blade
5. Reinstall each blade with the tabs pointing up
toward deck as shown in Figure 30. Secure with a
bolt and flat washer and torque bolts to 70 ft.lbs.
(94 N.m.).
WARNING
Mower blades are sharp. For your personal
safety, do not handle mower blades with bare
hands. Careless or improper handling of
blades may result in serious injury.For your
personal safety, blade mounting bolts must
each be installed with a flat washer then
securely tightened. Torque blade mounting
bolts to 70 ft.lbs. (94 N.m.)
Nail
Figure 29. Balancing The Blade
A
Figure 30. Installing The Blade
A. Blade Bolt
B. Flat Washer
37
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Troubleshooting, Adjustment & Service
TROUBLESHOOTING
WARNING
To avoid serious injury, perform maintenance
on the tractor or mower only when the engine
is stopped and the parking brake engaged.
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.
Always remove the ignition key to prevent
accidental starting of the engine.
See the information on the following pages for
instructions on how to perform most of these minor
adjustments and service repairs yourself. If you prefer,
all of these procedures can be performed for you by
your local authorized dealer.
TROUBLESHOOTING THE RIDER
PROBLEM
CAUSE
REMEDY
Engine will not turnover or start.
1. Parking brake not engaged.
2. PTO (electric clutch) switch
in ON position.
1. Engage parking brake.
2. Place in OFF position.
3. Out of fuel.
3. If engine is hot, allow it to cool, then refill
the fuel tanks. Prime the fuel system.
4. Lock handles in neutral position.
4. Motion Control Handles not
locked in neutral position.
5. Operator not in seat.
6. Glow plugs not pre-heated.
7. Fuse blown.
5. Assume operator’s position in seat.
6. Pre-heat glow plugs.
7. Replace fuse.
8. Battery terminals require
cleaning.
8. Clean the battery terminals
9. Battery discharged or dead.
10. Wiring loose or broken.
9. Recharge or replace.
10. Visually check wiring & replace broken or
frayed wires. Tighten loose connections.
11. Repair or replace. See authorized
service dealer
11. Solenoid or starter motor faulty.
12. Safety interlock switch
faulty.
12. Replace as needed. See authorized
service dealer.
13. Water in fuel.
14. Fuel is old or stale.
13. Drain fuel & refill with fresh fuel.
14. Drain fuel & replace with fresh fuel.
Engine starts hard or runs poorly. 1. Fuel mixture too rich.
1. Clean air filter.
2. Air in fuel system.
2. Prime the fuel system.
Engine knocks.
1. Low oil level.
2. Using wrong grade oil.
1. Check/add oil as required.
2. See engine manual.
Excessive oil consumption.
1. Engine running too hot.
2. Using wrong weight oil.
3. Too much oil in crankcase.
1. Clean radiator screens and air cleaner.
2. See engine manual.
3. Drain excess oil.
Engine exhaust is black.
1. Dirty air filter.
2. Air in fuel system
1. Replace air filter. See engine manual.
2. Prime the fuel system.
38
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Troubleshooting, Adjustment & Service
Rider Troubleshooting Continued.
PROBLEM
CAUSE
REMEDY
Engine runs, but rider will
not drive.
1. Hydraulic dump valve(s)
in “open” position.
2. Belt is broken.
1. Turn dump valve(s) clockwise to close.
Torque to 80-120 in.lbs. (9-13.5 N.m.)
2. See Drive Belt Replacement.
3. Drive belt slips.
4. Brake is not fully released.
3. See problem and cause below.
4. See authorized service dealer
Hydraulic pump drive belt slips.
Brake will not hold.
1. Pulleys or belt greasy or oily.
2. Belt stretched or worn.
1. Clean as required.
2. Replace belt.
1. Brake is incorrectly adjusted.
2. Brake caliper pads worn.
1. See Brake Adjustment.
2. Replace with new brake pads.
Rider steers or handles poorly.
1. Steering linkage is loose.
2. Improper tire inflation.
1. Check and tighten any loose connections.
2. See Regular Maintenance Section.
TROUBLESHOOTING THE MOWER
PROBLEM
CAUSE
REMEDY
Mower will not raise.
1. Lift linkage not properly attached 1. See authorized service dealer for repair.
or damaged.
Engine stalls easily with
mower engaged.
1. Engine speed too slow.
2. Ground speed too fast.
3. Cutting height set too low.
1. Set to full throttle.
2. Decrease Ground Speed.
3. Cut tall grass at maximum cutting
height during first pass.
4. Discharge chute jamming
with cut grass.
4. Cut grass with discharge pointing toward
previously cut area.
Excessive mower vibration.
1. Blade mounting bolts
are loose.
1. Tighten to 70 ft.lbs. (94 N.m.).
2. Mower blades, spindles,
or pulleys are bent.
3. Mower blades are out
of balance.
2. Check and replace as necessary.
3. Remove, sharpen, and balance blades.
See Maintenance Section.
4. Belt installed incorrectly.
4. Reinstall Correctly.
Excessive belt wear or breakage. 1. Bent or rough pulleys.
1. Repair or replace.
2. Using incorrect belt.
2. Replace with correct belt.
Mower drive belt slips or fails to
drive.
1. Idler pulley spring broken or not
1. Repair or replace as needed.
properly attached.
2. Mower drive belt broken.
2. Replace drive belt.
39
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Troubleshooting, Adjustment & Service
TROUBLESHOOTING COMMON CUTTING PROBLEMS
PROBLEM
CAUSE
REMEDY
Streaking.
1. Blades are not sharp.
2. Blades are worn down to far.
3. Engine speed is too slow.
4. Ground speed is too fast.
5. Deck is plugged with grass
6. Not overlapping cutting rows
enough.
1. Sharpen your blades.
2. Replace your blades.
3. Always mow at full throttle.
4. Slow down.
5. Clean out the mower.
6. Overlap your cutting rows.
7. Not overlapping enough when
turning.
7. When turning your effective cutting width
decreases–overlap more when turning.
Scalping.
1. Lawn is uneven or bumpy.
2. Mower deck cutting height is
set too low.
1. Roll or level the lawn.
2. Raise the cutting height.
3. Ground speed is too fast.
4. Deck is not leveled correctly.
5. Tire pressure is low or uneven
3. Slow down.
4. Correctly level the deck.
5. Check and inflate the tires.
Stepped Cutting.
1. Deck is not leveled correctly.
2. Tires are not properly inflated.
3. Blades are damaged.
1. Level the deck correctly.
2. Check and inflate the tires.
3. Replace the blades.
4. Deck shell is damaged.
5. Mower spindle is bent or loose.
6. Blades are installed incorrectly.
4. Repair or replace the deck.
5. Repair or replace the spindle.
6. Reinstall the blades correctly.
Uneven Cutting.
1. Deck is not leveled correctly.
2. Blades are dull or worn.
3. Blades are damaged.
1. Level the deck correctly.
2. Sharpen or replace the blades.
3. Replace the blades.
4. Deck is clogged with grass
clippings.
4. Clean out the deck.
5. Deck shell is damaged.
6. Mower spindle is bent or loose.
7. Blades are installed incorrectly.
8. Tires are not properly inflated.
5. Repair or replace the deck.
6. Repair or replace the spindle.
7. Reinstall the blades correctly.
8. Check and inflate the tires.
Stingers.
1. Blades are not sharp or nicked.
2. Blades are worn down too far.
3. Engine speed is too slow.
4. Ground speed is too fast.
5. Deck is plugged with grass.
1. Sharpen your blades.
2. Replace your blades.
3. Always mow at full throttle.
4. Slow down.
5. Clean out the mower.
40
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Troubleshooting, Adjustment & Service
Seat
Adjustment
Lever
SEAT ADJUSTMENT
See Figure 31. The seat can be adjusted fore and
aft. Move the lever forward, position the seat as
desired, and release the lever to lock the seat into
position.
GROUND SPEED CONTROL LEVER
ADJUSTMENT
The control levers can be adjusted in three ways. The
alignment of the control levers, the placement of the
levers (how close the ends are to one another) and
the height of the levers can be adjusted.
Figure 31. Seat Adjustment
C
Handle Alignment
Loosen the mount hardware (A, Figure 32) and pivot
the lever(s) (C, Figure 32) fore or aft to align with
each other.
Handle Placement
Loosen the jam nuts and adjust the placement bolt
(B, Figure 32) in or out to properly adjust the lever
end spacing.
A
B
Handle Height
Remove the mounting hardware (A, Figure 32) and
reposition the handle either up or down from its
original position. You will need to readjust the handle
alignment as described above.
Figure 32. Control Lever Adjustment
A. Alignment Hardware
B. Placement Hardware
C. Ground Speed Control Lever
SPEED BALANCING ADJUSTMENT
If the rider veers to the right or left when the ground
speed control levers are in the maximum forward
position, the top speed of each of these levers can be
balanced by turning the adjustment bolt(s) (A, Figure
33). Only adjust the speed of the wheel that is
traveling faster.
To Reduce the Speed of the Faster Wheel
1. Loosen the flange nuts.
A
2. turn the top speed adjustment bolt COUNTER-
CLOCKWISE to reduce the speed.
B
3. Retighten the flange nuts when adjustment is
complete.
WARNING
DO NOT adjust the tractor for a faster overall
speed forward or reverse than it was designed
for.
Figure 33. Top Speed Adjustment
A. Top Speed Adjustment Bolt
B. Flange Nut
41
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Troubleshooting, Adjustment & Service
NEUTRAL POSITION AND RETURN
SPRING ADJUSTMENT
To determine if it is necessary to adjust the neutral
position, perform the following steps.
NEUTRAL ADJUSTMENT
If the tractor “creeps” while the ground speed control
levers are locked in NEUTRAL, then it may be
necessary to adjust the control linkage.
NOTE: Perform this adjustment on a hard, level
surface such as a concrete floor. The neutral position
MUST be checked and adjusted BEFORE performing
a neutral adjustment.
1. Disengage the PTO, engage the parking brake
and turn off the engine.
2. Move the ground speed control levers in the
operating position, pull levers rearward and
release.
1. Disengage the PTO, engage the parking brake
and turn off the engine.
3. Move the ground speed control levers towards the
neutral position. If the levers do not align with the
notches in the neutral lock plate, it is necessary to
adjust the reverse return bolts (A, Figure 34).
2. Loosen the jam nuts (B, Figure 35) and turn the
adjustment linkage (A) to adjust. If the machine
creeps forward, turn the linkage CLOCKWISE
(while standing at the rear of the machine, facing
forward), if the machine creeps backward, turn the
linkage COUNTER-CLOCKWISE.
Neutral Position Adjustment
1. Loosen the jam nut (D, Figure 34) locked against
the clevis.
3. Lock the jam nuts (B) when neutral is achieved.
2. Turn the reverse return bolt (A) clockwise to adjust
handle rearward, counter-clockwise to adjust
handle forward.
NOTE: This adjustment should NOT be performed
while the machine is running. It may take several
attempts to achieve neutral, depending upon how
much the machine creeps.
4. Pull lever rearward and release to check position
again. Adjust as necessary to align levers with
notches.
It is important to note that after every adjustment of
the reverse return bolt, the lever must be pulled
rearward and released to properly check the neutral
position.
5. Once the lever alignment has been adjusted, lock
jam nut against the clevis.
Return Spring Adjustment
After adjusting the neutral position, lock the levers in
the neutral position and measure the reverse return
spring (B, Figure 34) length. This should be 2-3/8”
(6,03 cm) long. If not, hold the reverse return bolt (A)
with a wrench while turning the spring position nut (C)
until the measurement is achieved.
B
A
B
Figure 35. Neutral Adjustment
(Left-hand side shown)
A. Control Linkage
B
A
B. Jam Nuts
D
C
Figure 34. Neutral Spring Return Adjustment
A. Reverse Return Bolt
B. Reverse Return Spring
C. Spring Position Nut
D. Jam Nut
42
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Troubleshooting, Adjustment & Service
PARKING BRAKE ADJUSTMENT
1. Disengage the PTO, stop the engine, block the
front wheels, remove the ignition key, and engage
the parking brake.
B
2. Jack up the rear of the machine and secure with
jackstands. Remove both drive tires.
A
3. With the parking brake engaged, measure the
compressed spring length (see Figure 36). The
spring should be 2-1/8” - 2-1/4” (5,4 - 5,7 cm) long
when compressed.
4. If the spring does not measure 2-1/8” - 2-1/4” (5,4
- 5,7 cm), release the parking brake and turn the
adjustment nut (B) to adjust the spring length
5. Engage the parking brake and remeasure the
spring length. Continue to adjust the nut as
required.
Figure 36. Parking Brake Adjustment
A. Brake Spring
B. Adjustment Nut
CAUTION
Do not adjust the spring to be shorter than
2-1/8” (5,4 cm) when compressed. This may
damage the brake caliper.
6. With the parking brake engaged, adjust the set
collar position until 3/16” (4,7 mm) gap is
measured between the set collar and brake link.
7. Reinstall the drive tires. Torque the lug bolts to
85-95 ft/lbs. (115-129 Nm). Remove the
jackstands from under the machine.
MOWING HEIGHT ADJUSTMENT
B
The cutting height adjustment pin (A, Figure 37)
controls the mower cutting height. The cutting height
is adjustable between 1-1/2” (3,8 cm) and 6” (15,2
cm) in 1/4” (0,64 cm) increments.
A
1. Depress the deck lift foot pedal (B, Figure 35) until
it locks into the 6” (15,2 cm) position.
C
2. Place the cutting height adjustment pin in the
desired cutting height.
3. Depress the deck lift foot pedal then push the lock
lever (C) towards the right to release the lock.
4. Release the deck lift foot pedal until it comes to
rest against the cutting height adjustment pin.
Figure 37. Mowing Height Adjustment
A. Cutting Height Adjustment Pin
B. Deck Lift Foot Pedal
C. Deck Lift Lock lever
43
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Troubleshooting, Adjustment & Service
DECK LIFT ROD TIMING
ADJUSTMENT
1. Park machine on a flat, level surface. Disengage
the PTO, stop the engine and engage the parking
brake. Rear tires must be inflated to 18 psi (1,24
bar); front tires to 25 psi (1,72 bar).
2. Install the cutting height adjustment pin in the 3-
3/4” (9,5 cm) position. See Figure 38.
Figure 38. Deck Height Pin Position
3. To check the lift rod timing, measure and record
the distance between the lift pivots and the rod
pivots. Repeat for other side of unit. See Figure
39.
4. 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”
(3,17mm) difference), adjustment is required,
continue with Step 5.
5. Refer to Figure 39. To adjust the lift rods, adjust
the 5/8” hex nuts on either side of the front lift
pivot until the measurements are equal. Repeat
for other side. Make sure the nylon lock nut on
the end of the rod towards the rear of the machine
is loose to allow the rod to turn in the rear lift
pivot.
Figure 39. Measure & Adjust Lift Rod Timing
6. Refer to Figure 40. Measure the distance from
the front lift pivot to the ground and from the front
chain anchor bolt to the ground. If the
measurements are equal, no further adjustment is
required. If the measurements are NOT equal
(greater than 1/8” (3,17mm) difference),
adjustment is required, continue with Step 7.
7. Raise the seat plate to access the center lift link
(A, Figure 41).
8. Loosen the jam nut (C) on the lift clevis (D) and
turn the adjuster bolt (B) until the measurements
are equal. Tighten the jam nut against the lift
clevis.
Figure 40. Measure Front Lift Pivot
A
B
C
D
Figure 41. Center Lift Link Adjustment
A. Center Lift Link
B. Adjuster Bolt
C. Jam Nut
D. Lift Clevis
44
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Troubleshooting, Adjustment & Service
DECK LEVELING ADJUSTMENT
NOTE: Before adjusting the deck level, the deck lift
rod timing must be checked and/or adjusted.
1. Park machine on a flat, level surface. Disengage
the PTO, stop the engine and engage the parking
brake. Rear tires must be inflated to 18 psi (1,24
bar); front tires to 25 psi (1,72 bar).
2. Install the cutting height adjustment pin in the
4” (10,2 cm) position. See Figure 42.
Figure 42. Deck Height Pin Position
3. Place 2 x 4 blocks under each corner of the
mower deck with the 3-1/2” sides being vertical.
Place a 1/4” (0,64 cm) thick spacer on top of the
rear 2 x 4 blocks. See Figure 43.
4. Adjust the front eyebolts until the chains are tight
and the deck is still resting on the 2 x 4’s. Tighten
jam nuts. See Figure 44.
5. Loosen the nuts and allow the rear of the deck to
rest on the 2 x 4’s and 1/4” spacers. Slide the
chains in the slots until the chains are tight and
tighten the nuts. See Figure 44.
6. Remove all 2 x 4 blocks and spacers from under
the mower deck.
Figure 43. 2 x 4 Locations
Figure 44. Deck Level Adjustment
DECK LIFT SPRING
The deck lift springs (A, Figure 45) are factory set to
provide optimal lifting performance.
A
Although it is fastened with an adjustable anchor, this
is NOT AN ADJUSTMENT POINT.
DO NOT attempt to adjust the spring length or lifting
performance will be compromised.
Figure 45. Deck Lift Spring Location
A. Deck Lift Spring
45
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Troubleshooting, Adjustment & Service
To adjust the spring pre-load:
SUSPENSION ADJUSTMENT
This unit is equipped with adjustable shock
assemblies. The shocks can be adjusted to vary the
amount of pre-load applied to the springs. This allows
the operator to customize the ride according to
operator’s weight and/or operating conditions.
1. Locate the pe-load adjuster collar on the shock
assembly. See Figure 46.
2. Using the supplied spanner wrench (p/n
5022853), insert the tip of the wrench into the
notch in the pre-load adjuster. While holding the
wrench in place with one hand, turn COUNTER-
CLOCKWISE to increase the pre-load, turn
CLOCKWISE to decrease the pre-load. Make
sure that both front shocks are set to the same
amount of pre-load. Make sure that both rear
shocks are set to the same amount of pre-load.
Less Pre-Load:
• Light operator weight
• Softer, more cushioned ride
• Best for relatively flat terrain
NOTE: Spanner wrench is located under the seat, in
between the water separator and the brake cable.
More Pre-Load:
NOTE: It is recommended that the rear suspension
be adjusted stiffer due to the added weight of the
collection system.
• Heavy operator weight
• Stiffer, more rigid ride
• Better handling and greater stability on hilly terrain
T
REAR
Figure 46. Adjust Spring Pre-Load
46
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Troubleshooting, Adjustment & Service
A
B
B
B
C
Figure 48. Adjust PTO Clutch
A. Window
B. Adjustment Nut
A
B
C. .016”-.018” (0,40 - 0,45 mm) Feeler Gauge
Figure 47. PTO Clutch Adjustment
A. Adjustment Window (Qty. 3, one shown)
B. Adjustment Nut
WARNING
To avoid serious injury, perform adjustments
only with engine stopped, key removed and
tractor on level ground.
PTO CLUTCH ADJUSTMENT
Check the PTO clutch adjustment after the initial 25
hour break-in period and then after every 100 hours
of operation. Also perform the following procedure if
the clutch is slipping or will not engage, or if a new
clutch has been installed.
Blade Brake Check
Mower blades and mower drive belt should come to a
complete stop within seven (7) seconds after electric
PTO switch is turned off.
1. Remove key from ignition switch to prevent the
possibility of accidental starting while the PTO is
being adjusted.
1. With parking brake engaged, PTO disengaged
and an operator in the seat, start the engine
engine.
2. See Figure 47. Note the position of the 3
adjustment windows (A) in the side of the brake
plate and the nylock adjustment nuts (B).
2. Have an assistant observe the mower drive belt
through the open end of the left-hand arbor cover.
Engage the PTO and wait several seconds.
Disengage the PTO and check the amount of time
it takes for the mower drive belt to stop.
3. Insert a .016”-.018” (0,40 - 0,45 mm) feeler gauge
(C) through each window, positioning the gauge
between the rotor face and the armature face as
shown in Figure 48.
3. If the mower drive belt does not stop within seven
(7) seconds, perform the PTO Clutch Adjustment.
If the belt still does not stop within seven (7)
seconds, see your dealer.
4. Alternately tighten the adjustment nuts (B, Figure
47) until the rotor face and armature face just
contacts the gauge.
5. Check the windows for an equal amount of
tension when the gauge is inserted and removed,
and make any necessary adjustments by
tightening or loosening the adjustment nuts.
NOTE: The actual air gap between the rotor and
armature may vary even after performing the
adjustment procedure. This is due to dimensional
variations on component parts, and is an acceptable
condition.
6. Check the mower blade stopping time. The
mower blades and mower drive belt should come
to a complete stop within seven (7) seconds after
the electric PTO switch is turned off.
47
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Troubleshooting, Adjustment & Service
BELT REMOVAL & REPLACEMENT
B
WARNING
If servicing the belts after the engine has been
running, use extreme caution when raising the
hood or lowering the rear shield. The surface
of the hood and rear shield can be hot from the
muffler and exhaust manifold.
Pump Drive Belt Removal
1. Park the tractor on a smooth, level surface such
as a concrete floor. Disengage the PTO, engage
the parking brake, turn off the engine, and remove
the ignition key.
A
Figure 49. Pump Belt Removal & Replacement
A. Pump Drive Idler Arm
B. Spring
2. Remove the PTO drive belt from the clutch (see
PTO DRIVE BELT REMOVAL for instructions).
3. Using a 1/2” breaker bar, place the square end in
the square hole located in the middle of the idler
arm (A, Figures 49). Carefully rotate the breaker
bar COUNTER-CLOCKWISE, which will relieve
the tension on the belts exerted from the idler
arm.
To avoid damaging belts, DO NOT
PRY BELTS OVER PULLEYS.
4. Remove the belts from the right-hand and left-
hand pump drive pulley grooves.
WARNING
5. Carefully release the tension on the breaker bar.
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.
6. Unhook the spring (B) from the anchor bolt on the
idler arm.
7. Remove the belts from the crankshaft pulley
grooves and pull out from behind the clutch.
Pump Drive Belt Replacement
1. Place the belts under clutch into the crankshaft
pulley grooves.
2. Wrap the belts around the top side of the idler arm
pulley and install the belts in the right-hand pump
pulley grooves.
3. Reinstall the spring onto the anchor bolt on the
idler arm.
4. Carefully rotate the idler arm with the breaker bar
counter-clockwise (see Figure 49). While holding
the breaker bar firmly, install the belts in the left-
hand pump pulley grooves and the two stationary
idler pulleys grooves.
5. Carefully release the tension on the breaker bar.
6. Inspect the belt path making sure that all belts are
properly seated in the pulley grooves.
7. Reinstall the PTO drive belt from the clutch (see
PTO DRIVE BELT REPLACEMENT for
instructions).
48
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Troubleshooting, Adjustment & Service
PTO Drive Belt Removal
1. Park the tractor on a smooth, level surface such
as a concrete floor. Disengage the PTO, engage
the parking brake, turn off the engine, and remove
the ignition key.
2. Release the hood cam latches and raise the hood
until it locks in place.
3. Release the rear guard cam latches and lower or
remove the rear guard.
4. Using a 3/4” box end wrench on the nut of the
spring-loaded idler pulley (A, Figure 50), rotate the
wrench CLOCKWISE to release the tension on
the PTO drive belt.
A
B
Figure 50. PTO Drive Belt Removal
A. Spring Loaded Idler Pulley
B. Stationary Idler Pulley
WARNING
Use extreme caution when rotating the idler
pulley with the wrench, due to the increased
tension in the spring as the idler pulley is being
rotated. Injury may result if the wrench is
prematurely released while the spring is under
tension.
Spindle Drive Belt Removal &
Replacement
1. Park the tractor on a smooth, level surface such
as a concrete floor. Disengage the PTO, engage
the parking brake, turn off the engine, and remove
the ignition key.
5. Remove the belt from the stationary idler pulley
(B, Figure 50).
2. Remove the PTO drive belt from the center
spindle pulley (see PTO DRIVE BELT REMOVAL
for instructions).
6. Carefully release the tension on the wrench.
7. Remove the belt from the PTO clutch pulley,
spring-loaded idler pulley and center spindle
pulley.
3. Using a 1/2” breaker bar, place the square end in
the square hole located near the end of the idler
arm
8. Pull the belt towards the rear of the machine until
free of the guide pulleys and belt keeps on the
rear of the mower deck.
(A, Figures 52). Carefully rotate the breaker bar
CLOCKWISE, which will relieve the tension on the
belts exerted from the idler arm.
PTO Drive Belt Replacement
WARNING
1. From the rear of the mower deck, route the new
belt through the guide pulleys and belt keeps.
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.
2. Install the belt on the center spindle pulley. Follow
the illustration in Figure 51 carefully. Make sure
the belt twists in the correct direction.
3. Install the belt over the PTO clutch pulley and the
spring loaded idler pulley. Again, follow the
illustration in Figure 51 carefully and make sure
the belt twists in the correct direction.
4. Remove the belt from the trim side spindle pulley
(B, Figure 52).
4. Using a 3/4” box end wrench on the nut of the
idler pulley (A, Figure 50), rotate the wrench
CLOCKWISE and install the belt on the stationary
idler pulley.
5. Carefully release the tension on the breaker bar.
6. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves (Figure 53).
5. Carefully release the tension on the wrench.
7. Install the belt on all of the pulleys, except for the
trim side spindle pulley. Carefully rotate the
breaker bar CLOCKWISE and install the belt on
the trim side spindle pulley. Carefully release the
tension on the breaker bar.
8. Reinstall the PTO drive belt.
49
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Troubleshooting, Adjustment & Service
Figure 51. PTO Belt Routing
NOTE: Gray areas indicate the flat side of the
belt.
C
B
B
A
A
A
A
Figure 52. Spindle Drive Belt Removal
A. Idler Arm
B. Trim Side Spindle Pulley
Figure 53. Spindle Drive Belt Removal
A. Spindle Pulley
B. Idler Pulley
C. Drive Belt
50
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Troubleshooting, Adjustment & Service
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.
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
JUMP STARTING WITH AUXILIARY
(BOOSTER) BATTERY
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.
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 54.
A dead battery or one too weak to start the engine
may not mean the battery needs to be replaced. For
example, it may mean that the alternator is not
charging the battery properly. If there is any doubt
about the cause of the problem, see your dealer. If
you need to replace the battery, follow the steps
under Cleaning the Battery & Cables in the Regular
Maintenance Section.
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.
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.
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.
3. Always unplug or turn the charger off before
attaching or removing the clamp connections.
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.
4. Carefully attach the clamps to the battery in
proper polarity (usually red to [+] positive and
black to [-] negative).
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.
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.
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.
51
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Troubleshooting, Adjustment & Service
Figure 54. Jump Starting
WARNING
Any procedure other than the preceding could
result in:
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.
(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.
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.
52
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Specifications
NOTE: Specifications are correct at time of printing and are subject to change without notice.
ENGINE:
TRANSMISSIONS:
HydroGear BDP-21 / Parker TF-040
28 HP* Caterpillar
Type
Pump and Wheel Motor
Make
Model
Caterpillar
3011C
28 @ 3600 rpm
69 Cu. in (1131 cc)
12 Volt, 40 amp. Alternator, Battery: 500
Hydraulic Fluid
Mobil 1™ 15W-50 synthetic oil or
Castrol Syntec™ 5W-50 oil
Forward: 0-10 MPH (0-16.1 km/h)
Reverse: 0-5 MPH (0-8.05 km/h)
483 ft. lbs. (654 N.m.)
Horsepower
Displacement
Electrical System
CCA
Speeds
@ 3400 rpm
Continuous Torque
Output
Oil Capacity
5.2 US qt. (4.9 L) w/ Filter
Maximum Weight
on Axle
3000 lbs. (1360 Kg)
35 HP* Briggs
Make
Briggs & Stratton
613177
35 @ 3600 rpm
61 Cu. in (993 cc)
12 Volt, 20 amp. Alternator, Battery: 500
DIMENSIONS:
Model
Overall Length
Overall Width
86-1/2” (220 cm)
Horsepower
Displacement
Electrical System
CCA
75” (191 cm) - side discharge model
62” (158 cm) - rear discharge model
52” (132 cm)
Height
Weight (apx..)
With Side Discharge
Mower Deck
Oil Capacity
2.4 US qt. (2.25 L) w/ Filter
1846 lbs. (837 kg)
With Rear Discharge 1868 lbs. (847 kg)
Mower Deck
CHASSIS:
Fuel Tanks
Capacity: 15 Gallons (56.8 L) Total
Tire Size: 24 x 12.00 -12
Rear Wheels
Inflation Pressure: 18 psi (1,24 bar)
Tire Size: 13 x 6.50 - 6
Front Wheels
Inflation Pressure: 25 psi (1,72 bar)
Engine Power Rating Information
The gross power rating labels for individual gas engine models meet or exceed SAE (Society of Automotive
Engineers) code J1940 (Small Engine Power & Torque Rating Procedure) and rating performance has been
obtained and corrected in accordance with SAE J1995 (Revision 2002-05). Actual gross engine power may be
lower and is affected by, but not limited to, ambient operating conditions and engine to engine variability. Given
both the wide array of products on which engines are placed, and the variety of environmental issues applicable
to operating the equipment, the gas engine will not develop the rated gross power when used in a given piece of
power equipment (actual “on-site” or net horsepower). This difference is due to a variety of factors including, but
not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application
limitations, ambient operating conditions (temperature, humidity, altitude), and engine to engine variability.
53
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Ferris Industries - a division of Simplicity Manufacturing Inc.
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' instruc-
tions.
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 pur-
chaser 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 limi-
tations.
Covered Parts
All Mowers
Warranty Period
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
And Hoses, Battery, Blades
90 days from date of retail purchase by the original purchaser
*Attachments
*Engine
1 year from date of retail purchase by the original purchaser
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 man-
ufacturer'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 assis-
tance 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 PROD-
UCT 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 WAR-
RANTIES, 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 LIABILI-
TIES 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.
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OPERATOR’S
MANUAL
IS4500Z Series
Zero-Turn Riding Mower
Product Quick Specs:
ENGINE:
BELTS AND BLADES:
TRACTOR
28 HP* Caterpillar
Pump Drive Belt
5023388
Make
Caterpillar
Model
Oil Capacity
3011C
5.2 US qt. (4.9 L) w/ Filter
61” SIDE DISCHARGE MOWER DECK -
DIESEL MODELS
35 HP* Briggs
Deck Drive Belt
PTO Drive Belt
Mower Blade
5023297
5023304
5020842
Make
Briggs & Stratton
613177
Model
Oil Capacity
2.4 US qt. (2.25 L) w/ Filter
61” SIDE DISCHARGE MOWER DECK -
DIESEL MODELS (EXPORT)
CHASSIS:
Fuel Tanks
Capacity: 15 Gallons (56.8 L) Total
Tire Size: 24 x 12.00 -12
Inflation Pressure: 18 psi (1,24 bar)
Tire Size: 13 x 6.50 - 6
Deck Drive Belt
PTO Drive Belt
Mower Blade
5023297
5023304
5023272
Rear Wheels
Front Wheels
Inflation Pressure: 25 psi (1,72 bar)
61” SIDE DISCHARGE MOWER DECK -
GASOLINE MODELS
Deck Drive Belt
PTO Drive Belt
Mower Blade
5023297
5100003
5020842
61” REAR DISCHARGE MOWER DECK -
DIESEL MODELS (EXPORT)
Deck Drive Belt
PTO Drive Belt
Mower Blade
5023297
5100014
5023272
72” SIDE DISCHARGE MOWER DECK
Deck Drive Belt
PTO Drive Belt
Mower Blade
5100046
5100655
5022476
Ferris Industries
5375 North Main Street
Munnsville, NY 13409
800-933-6175
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