Ferris 5100/72 Operator'S Manual Download Page 48 | Manualshive

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Troubleshooting, Adjustment & Repair

Belt Removal & Replacement

Mower Drive Belt Removal & Replacement

1. Park the tractor on a smooth, level surface such

as a concrete floor. Disengage the PTO, engage
the parking brake, turn off the engine, and remove
the ignition key.

2. Remove the height adjustment pin (A, Figure 47)

and lower deck.

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

guards and remove the guards.

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

WARNING

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

Figure 47. Lower the Mower Deck
A. Height Adjustment Pin

A

4.

61” Side Discharge:

Using a breaker bar

rotate the spring-loaded idler pulley (A, Figure
48) COUNTER-CLOCKWISE to release the belt
tension.

4a.

72” Side Discharge:

Using a 3/4” combination

wrench, rotate the spring-loaded idler pulley
(A, Figure 48) CLOCKWISE to release the belt
tension.

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

idler pulley (C) and carefully release the tension on
the wrench until the spring tension is completely
released.

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

7. Install the drive belt on the gearbox pulley, the

spindle pulleys and idler pulleys.

8.

61” Side Discharge:

Rotate the spring-

loaded idler pulley (A, Figure 48) COUNTER-
CLOCKWISE and slide the drive belt over the
edge of the stationary idler pulley (C). Make sure
the V-side of the belt runs in the pulley grooves
(Figure 49). Carefull release the tension on the
breaker bar.

8.

72” Side Discharge:

Rotate the spring-loaded

idler pulley (A, Figure 48) CLOCKWISE and slide
the drive belt over the edge of the stationary
idler pulley (C). Make sure the V-side of the belt
runs in the pulley grooves (Figure 49). Carefully
release the tension on the wrench.

Figure 48. Mower PTO Belt
A. Spring-loaded Idler Pulley
B. Idler Spring
C. Stationary Idler Pulley

B

A

C

A

B

C

61” Side Discharge Model

72” Side Discharge Model

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Summary of Contents for 5100/72

Page 1: ...ase en contacto con su distribuidor Ferris o www ferrisindustries com 5102954 Rev D IS5100Z Series Zero Turn Riding Mower OPERATOR S MANUAL 61 Model Model Description 5901013 IS5100ZC33D Zero Turn Rider w Caterpillar Diesel 61 Mower Deck 72 Models Zero Turn Rider 5901011 IS5100ZC33D Caterpillar Diesel Mower Deck 5900591 5100 72 72 Side Discharge Mower Deck 5900592 5100 72RD 72 Rear Discharge Mower...

Page 2: ...Briggs Stratton Corporation Milwaukee WI USA All rights reserved FERRIS is a trademark of Briggs Stratton Corporation Milwaukee WI USA Contact Information Briggs Stratton Power Products Group LLC 5375 N Main St Munnsville NY 13409 4003 800 933 6175 www ferrisindustries com See Page 11 for the location of Identification Numbers WARNING Engine exhaust from this product contains chemicals known to th...

Page 3: ...heck Hydraulic Oil Level 29 Hydraulic Oil Filter Change 29 Check Engine Coolant Level 30 Change Engine Coolant 30 Clean Radiator Screen Oil Cooler 30 Lubrication 31 Cleaning the Battery Cables 32 Servicing the Mower Blades 33 Troubleshooting Adjustments Repair 34 Troubleshooting the Rider 34 Troubleshooting the Mower 35 Troubleshooting Common Cutting Problems 36 Hood Latch Operation 37 Floor Pan R...

Page 4: ... 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...

Page 5: ...g 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 ...

Page 6: ...wn 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 ma...

Page 7: ...e 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 ...

Page 8: ...top blades if not mowing 22 Use care when loading or unloading the machine into a trailer or truck TRAINING 1 Read understand and follow all instructions in the manual and on the unit before starting If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 2 Become familiar with the safe operation of the equipment operator controls and ...

Page 9: ...ing on slopes See attaching a trailer under OPERATION 3 Never allow children or others in or on towed equipment 4 On slopes the weight of the towed equipment may cause loss of traction and loss of control 5 Travel slowly and allow extra distance to stop 6 Do not shift to neutral and coast down hill CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Childre...

Page 10: ...ing 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 ...

Page 11: ... or by drilling additional holes BEFORE FIRST TIME USE Inspect the ROLL BAR structure and mounting hardware for 1 Check to make sure the machine GVW Gross Vehicle Weight including attachments restrained payload fuel and operator is not in excess of the maximum weight specified on the ROLL BAR label 2 Make sure there isn t any missing damaged or loose mounting hardware 3 Make sure the ROLL BAR has ...

Page 12: ... the seat belt does not pass all of the following tests it should be replaced BEFORE EACH USE Conduct the following inspections maintenance of the seat belt and retraction mechanism 1 Check for dirt or debris in the retraction mechanism If dirt or debris is found it should be removed 2 Check to make sure the retraction mechanism retracts easily and completely 3 Check for damage to any part of the ...

Page 13: ...ymbol is used to identify safety information about hazards that can result in personnal injury A signal word DECAL WARNING or CAUTION is used with the alert symbol to indicate the likelihood and the potential severity of the injury In addition a hazard icon maybe used to represent the type of hazard An explanation of hazard levels and icons are as follows DANGER This indicates a hazard which if no...

Page 14: ...and warnings are for your safety To avoid a personal injury or damage to the unit understand and follow all safety decals WARNING If any safety decals become worn or damaged and cannot be read order replacement decals from your local dealer A B B C C G G E F D Located on pump plate on the rear of the machine Decals are located behind the ROPS on the frame of the machine ...

Page 15: ...ot 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 T...

Page 16: ...rake NOTE To start the unit the parking brake must be engaged E Seat Adjustment Lever The seat can be adjusted forward and back Move the lever to the left position the seat as desired and release the lever to lock the seat in position F S N 2016098451 Above Removable Floor Plate The floor plate can be removed for easy access to the mower deck To remove the plate remove the black knob and tilt the ...

Page 17: ...olant temperature If the indicator lamp is ON it will turn the PTO OFF F Oil Pressure Indicator Lamp that indicates a low oil pressure condition If the indicator lamp is ON it will turn the PTO OFF G Hour Meter The hour meter measures the number of hours the PTO has been engaged The hour meter has a self contained power source so the total hours are always visible H Voltage Gauge Gauge measures th...

Page 18: ...unit Before leaving the operator s position for any reason engage the parking brake disengage the PTO stop the engine and remove the key To reduce fire hazard keep the engine tractor and mower free of grass leaves and excess grease Do not stop or park tractor over dry leaves grass or combustible materials Gasoline is highly flammable and must be handled with care Never fill the tank when the engin...

Page 19: ...ent 3 Tighten the vent screw to 4 5 ft lbs 6 N m DO NOT OVER TIGHTEN On the engine injector pump 1 Using a 13 mm wrench loosen the vent screw D on the fuel inlet 2 3 revolutions 2 Operate the hand pump up and down until fuel that is free of air flows from the vent 3 Tighten the vent screw to 4 5 ft lbs 6 N m DO NOT OVER TIGHTEN 4 Tighten the priming fuel pump finger tight 5 Start the engine See ST...

Page 20: ...d control levers to the middle position will stop tractor movement Pivot the levers outward and lock them in neutral 2 Disengage the PTO 3 Engage the parking brake 4 Move the throttle control to SLOW and allow the engine to cool down for a short time 5 Turn the ignition key to OFF Remove the key Driving the Rider 1 Sit in the seat and adjust the seat so that you can comfortably reach all of the co...

Page 21: ...ior to moving the control levers inward BASIC DRIVING Forward Travel Practice Gradually move both ground speed control levers evenly FORWARD from neutral Slow down and repeat NOTE Straight forward travel takes practice If necessary top speed can be balance adjusted see the Speed Balancing Adjustment in the Adjustments section Reverse Travel Practice LOOK DOWN BEHIND then gradually move both ground...

Page 22: ...you become more familiar and experienced with operating the Zero Turn rider you will learn more maneuvers that will make your mowing time easier and more enjoyable Remember the more you practice the better your control of the Zero Turn will be Practice Turning In Place To turn in place Zero Turn gradually move one ground speed control lever forward from neutral and one lever back from neutral simu...

Page 23: ...nts 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 Cu...

Page 24: ... are mowing too fast using a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems Use an appropriate ground speed for the thickness and height of the grass you are cutting 3rd gear or slower for manual gear models If you hear the engine slowing down you are mowing too fast use a slower ground speed Mowing Methods Proper Broadcast Mowing Br...

Page 25: ...nditions 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...

Page 26: ...manual for additional safety information Figure 9 Trailer Weight Recommendations A Clevis Pin B Clip A B Figure 8 Hydraulic Release Valve Location A Hydraulic Release Valve Right hand side shown Pushing the Rider by Hand 1 Refer to Figure 8 for hydraulic release valve location 2 To open the dump valves turn the right hand release valve which is located on top of the right hand pump counter clockwi...

Page 27: ...r pins B 2 Push or pull the top of the roll bar C forward against the rubber stops D and remove the retainer pins B 3 Lower the roll bar and reinstall the retainer pins and hair pin clips to secure the roll bar in the down position see insert Figure 10 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 s...

Page 28: ...t and apply paint or rust preventative to any areas where paint is chipped or damaged 10 Be sure the battery is filled to the proper level with water and is fully charged Battery life will be increased if it is removed put in a cool dry place and fully charged about once a month If battery is left in unit disconnect the negative cable 11 Drain fuel system completely or add a diesel fuel stabilizer...

Page 29: ... loose hardware Every 100 Hours or Annually Check Gearbox Oil Level Clean Deck Check Replace Mower Blades Lubricate Rider Mower Clean Battery Cables Check Tire Pressure Check Hydraulic Oil Every 250 Hours or Annually Change Hydraulic Oil Filter Whichever comes first More often in hot over 85 F 30 C weather or dusty operating conditions Change gearbox oil after first 100 hours and every 500 hours t...

Page 30: ...erature 3 Place a container under the fuel filter tube and turn the drain valve B Figure 13 approximately 1 turn 4 Allow the filter to drain until all water and debris have drained out 5 Turn the drain valve to close it when finished draining WARNING Diesel fuel is highly flammable and must be handled with care Never fill the tank when the engine is still hot from recent operation Do not allow ope...

Page 31: ... oil filter from the filter base will drain the oil reservoir Have a suitable container ready to catch any spilled oil Ferris recommends this be a dealer only service item 1 Locate the hydraulic oil filter A Figure 16 behind the battery 2 Fill the new filter with oil Lubricate the new filter seal with a few drops of oil 3 Remove the oil filter and quickly thread the new filter onto the filter base...

Page 32: ... side of the radiator Clean Radiator Screen Oil Cooler Clean the radiator screen and oil cooler fins before each use or as required depending on conditions to allow proper air flow through radiator and hydraulic oil cooler 1 Raise the seat plate 2 Lift the radiator screen straight up to remove the screen Flush the screen with water or blow clean with air Flush the radiator core with water or blow ...

Page 33: ... 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 19 Deck Lift Linkage Pivots Figure 20 Deck Lubrication Figure 23 Front Caster Wheel A 1 4 28 Bolt Figure 21 Control Handle Pivots Seat Pivots Figure 22 Gearbox Drive Idler Pivot A Lubricating the Front Casters Interv...

Page 34: ...with a wire brush until shiny 4 Reinstall the battery and reattach the battery cables positive cable first A 5 Coat the cable ends and battery terminals with petroleum jelly or non conducting grease WARNING Be careful when handling the battery Avoid spilling electrolyte Keep flames and sparks away from the battery When removing or installing battery cables disconnect the negative cable FIRST and r...

Page 35: ...gure 26 Center the blade s hole on a nail lubricated with a drop of oil A balanced blade will remain level 5 Reinstall each blade with the tabs pointing up toward deck as shown in Figure 27 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...

Page 36: ...e is hot allow it to cool then refill the fuel tanks Prime the fuel system Ground speed control levers not locked in neutral position Lock handles in neutral position Operator not in seat Assume operator s position in seat Glow plugs not pre heated Pre heat glow plugs Fuse blown Replace fuse Battery terminals require cleaning Clean the battery terminals Battery discharged or dead Recharge or repla...

Page 37: ... Leak in the hydraulic system See authorized service dealer Engine stall easily with mower engaged Engine speed too slow Set to full throttle Ground speed too fast Decrease ground speed Cutting height set too low Cut tall grass at maximum cutting height during first pass Discharge chute jamming wiht cut grass Cut grass with discharge pointing toward previously cut area Excessive mower vibration Bl...

Page 38: ...pped Cutting Deck is not leveled correctly Level the deck correctly Tires are not properly inflated Check and inflate the tires Blades are damaged Replace the blades Deck shell is damaged Repair or replace the deck Mower spindle is bent or loose Repair or replace the spindle Blades are installed incorrectly Reinstall the blades correctly Uneven Cutting Deck is not leveled correctly Level the deck ...

Page 39: ...etter access to the mower deck Removing the Floor Pan 1 Loosen and remove the knob A Figure 29 that secures the floor pan B to the frame of the unit 2 Tilt the back end of the floor pan up and then remove it from the unit Reinstalling the Floor Pan 1 Reverse the removal procedure Figure 29 Floor Pan Removal Installation A Knob B Floor Pan A B Figure 28 Hood Latch Operation A Hood Latch A Seat Adju...

Page 40: ...rest against the cutting height adjustment pin Figure 31 Mowing Height Adjustment A Cutting Height Adjustment Pin B Hydraulic Mower Lift Switch C Deck Lift Lock Lever D Deck Lift Foot Pedal A C B D Deck Lift Lock Lever Lockout Plate Operation Models S N 2016098451 Above The Deck Lift Lock Lever Lockout Plate A Figure 32 can be used to prevent the mower deck from locking the deck in the TRANSPORT p...

Page 41: ...position You will need to readjust the handle alignment as described above Speed Balancing Adjustment If the rider veers to the right or left when the ground speed control levers are in the maximum forward position the top speed of each of these levers can be balanced by turning the adjustment bolt s A Figure 34 Only adjust the speed of the wheel that is traveling faster To Reduce the Speed of the...

Page 42: ...g brake and turn off the engine 2 Move the ground speed control levers in the operating position pull levers rearward and release 3 Move the ground speed control levers towards the neutral position If the levers do not align with the notches in the neutral lock plate it is necessary to adjust the reverse return bolts A Figure 36 Neutral Position Adjustment 1 Loosen the jam nut D Figure 36 locked a...

Page 43: ...fuel tanks 3 With the parking brake engaged measure the compressed spring length The spring should be 2 2 1 8 5 0 5 4cm when compressed 4 If adjustment is required disengage the parking brake and turn the adjustment nut B 5 Engage the parking brake and re measure the spring FRONT Figure 37 Parking Brake Adjustment A Upper Brake Spring B Adjustment Nut A CAUTION Do not adjust the spring to be short...

Page 44: ...e distance from the carpenters square to the top of the tire A Figure 38 Measure and record the distance from the carpenters square to the bottom of the tire B Subtract the bottom measurement from the top measurement and reference the chart below for the number of shims that are needed If the measurement is greater than 75 1 91 cm contact your dealer Installing the camber shims 1 Park the machine ...

Page 45: ...o adjust the spring pre load 1 Park machine on a flat level surface Disengage the PTO stop the engine and engage the parking brake 2 Using the supplied spanner wrench p n 5022853 insert the tip of the wrench into the notch in the pre load adjuster While holding the wrench with both hands turn CLOCKWISE to decrease the pre load turn COUNTER CLOCKWISE to increase the pre load Make sure that for each...

Page 46: ... up the mower deck until all hanger chains are slack 8 Refer to Figure 43 To adjust the inner lift rod loosen the jam nut on the front ball joint then remove the 1 2 hardware fastening the ball joint the the lift pivot arm Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise to lengthen the distance between the rod pivots Reinstall the ball joint on the ...

Page 47: ... are tight and the deck is still resting on the 2 x 4 s Tighten jam nuts See Figure 45 5 Loosen the jam nuts A Figure 45 and turn the adjustment bolts B until the chains are tight and the rear of the deck is resting on the 2 x 4 s Tighten the jam nuts 6 Remove all 2 x 4 blocks from under the mower deck 7 See Figure 46 Position the outside mower blades so they face front to back 8 Measure from the ...

Page 48: ...e belt tension 4a 72 Side Discharge Using a 3 4 combination wrench rotate the spring loaded idler pulley A Figure 48 CLOCKWISE to release the belt tension 5 Slide the drive belt over the edge of the stationary idler pulley C and carefully release the tension on the wrench until the spring tension is completely released 6 Remove the old belt and replace with a new one 7 Install the drive belt on th...

Page 49: ...Belt Idler Spring Length inch cm 61 Mower Deck 7 17 8 72 Mower Deck 6 1 4 15 9 A D E B C 2 Measure the coil length E Figure 50 of the mower belt tensioner spring A The measurement should equal the measurement as indicated in the chart If the measurement does not equal the measurement as indicated in the chart adjust the mower belt spring length Adjusting the Mower Belt Spring Length 1 Loosen the j...

Page 50: ...exerted from the idler arm 6 Remove the belts from the gearbox drive pulley D 7 Carefully release the tension on the breaker bar until the idler arm stops 8 Remove the clutch belts from the clutch pulley grooves and pull around the idler pulley Clutch Belt Replacement 1 Install the clutch belts over the top of the clutch into the grooves of the crankshaft pulley and around the idler pulley 2 Caref...

Page 51: ...elt 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 20 While holding the breaker bar firmly install the b...

Page 52: ...drive pulley on the gearbox so the drain plug is aligned with the opening between the pulley spokes 3 Place a container under the gearbox drain hole and remove the drain plug B 4 Replace drain plug and fill with SAE 80 90 weight gear oil until oil starts to seep from hole then replace fill plug 5 Using a parts solvent thoroughly clean any excess oil from the pulley faces and groove 6 Reinstall the...

Page 53: ...guage reads a high temperature Move the ground speed control levers to the neutral position disengage the PTO switch engage the parking brake and reduce to half throttle speed Leave the engine running so the radiator fan will continue to run and coolant will continue to circulate Check the engine coolant level See Check Engine Coolant Level Add coolant if necessary Check to see if the radiator scr...

Page 54: ...er charged is to measure the specific gravity of a cell once per hour The battery is fully charged when the cells are gassing freely at low charging rate and less than 0 003 change in specific gravity occurs over a three hour period Jump Starting With Auxiliary Booster Battery Jump starting is not recommended However if it must be done follow these directions Both booster and dis charged batteries...

Page 55: ...or explode If a frozen battery is suspected examine all fill vents on the battery If ice can be seen or if the electrolyte fluid cannot be seen do not attempt to start with jumper cables as long as the battery remains frozen WARNING For your personal safety use extreme care when jump starting Never expose battery to open flame or electric spark battery action generates hydrogen gas which is flamma...

Page 56: ...9 2 L Total Rear Wheels Tire Size 26 x 12 00 12 Inflation Pressure 15 psi 1 03 bar Front Wheels Tire Size 13 x 6 50 6 Inflation Pressure 25 psi 1 72 bar TRANSMISSIONS PUMP Hydro Gear PW 1ACC LH S N All Hydro Gear PW 1DCC RH S N All WHEEL MOTOR Parker TF0405UB080AADD LH RH S N 2016098450 Below Parker TG0335UB080AAKZ LH S N 2016098451 Above Parker TG0335UB081AAKZ RH S N 2016098451 Above Type Pump an...

Page 57: ...N o t f o r R e p r o d u c t i o n Notes ...

Page 58: ...ANTY We welcome warranty repair and apologize to you for being inconvenienced Warranty service is available only through FERRIS Authorized Service Dealers Most warranty repairs are handled routinely but sometimes requests for warranty service may not be appropriate This warranty only covers defects in materials or workmanship It does not cover damage caused by improper use or abuse improper mainte...

Page 59: ... that it is identical in all material respects to the engine described in the manufacturer s application for certification The warranty period begins on the date the engine is originally purchased The warranty on emissions related parts is as follows Any warranted part that is not scheduled for replacement as required maintenance in the owner s manual supplied is warranted for the warranty period ...

Page 60: ...N o t f o r R e p r o d u c t i o n IS5100Z Series Zero Turn Riding Mower OPERATOR S MANUAL ...

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