Ferris IS2500Z Series Operator'S Manual Download | Manualshive

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49

Troubleshooting, Adjustment & Repair

Hydraulic Pump Drive Belt Replacment

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 hardware (A, Figure 54) that secures

the pump guard plate (B) to the frame. Remove
the pump guard plate from the machine.

3. Using a 1/2” breaker bar, place the square end in

the square hole located in the end of the idler arm
(A, Figure 55). Carefully rotate the breaker bar
CLOCKWISE, which will relieve the tension on the
belt exerted from the idler arm.

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

pump drive pulley (C). Carefully release the
tension on the breaker bar.

5. Loosen and remove the two drive shaft collar bolts

(A, Figure 56) from the drive shaft universal joint
(B).

6. Pull the drive shaft universal away from the drive

shaft spindle (D) and pivot out of the way.

7. Remove the old belt (E) and replace with a new

one. Install the belt on the left pump drive pulley
and the drive shaft spindle pulley. Make sure
the V-side of the belt runs in the pulley grooves
(Figure 55).

8. Using the two (2) drive shaft collar bolts (A)

reinstall the drive shaft universal joint to the drive
shaft spindle.

A

B

Figure 55. Removing the Tension on the Belt
A. Idler Arm
B. Right Pump Drive Pulley
C. Pump Drive Belt

C

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

WARNING

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

Figure 56. Removing the Spindle Shaft
A.  Drive Shaft Collar Bolts
B.  Drive Shaft Universal Joint
C. Pump Drive Belt
D.  Drive Shaft Spindle

Figure 54. Remove the Pump Drive Belt Guard
A. Hardware
B. Pump Guard Plate

A

B

A

A

B

D

C

Not

for

Reproduction

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Summary of Contents for IS2500Z Series

Page 1: ... Model Number Description 5900798 IS2500ZY20D52 52 Cut Zero Turn Riding Mower 5900799 IS2500ZY24D61 61 Cut Zero Turn Riding Mower 5900943 IS2500ZY20D52HT 52 Cut Zero Turn Riding Mower 5900500 IS2500ZY24D52 52 Cut Zero Turn Riding Mower N o t f o r R e p r o d u c t i o n ...

Page 2: ...e Briggs Stratton Power Products Group LLC Copyright 2012 Briggs Stratton Corporation Milwaukee WI USA All rights reserved FERRIS is a trademark of Briggs Stratton Corporation Milwaukee WI USA Contact Information Briggs Stratton Power Products Group LLC 5375 N Main St Munnsville NY 13409 4003 800 933 6175 www ferrisindustries com See Page 11 for the location of Identification Numbers WARNING Engin...

Page 3: ...Engine Coolant Level 31 Change Engine Coolant 31 Clean Radiator Screen 31 Lubrication 32 Cleaning the Battery Cables 34 Servicing the Mower Blades 35 Fuse Location 37 Gearbox Maintenance 37 Troubleshooting Adjustments Service 38 Troubleshooting the Tractor 38 Troubleshooting the Mower 39 Troubleshooting Common Cutting Problems 40 Seat Adjustment 41 Ground Speed Control Lever Adjustment 41 Speed Ba...

Page 4: ...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 t...

Page 5: ... 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 u...

Page 6: ...arance 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 ...

Page 7: ...hile 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 ...

Page 8: ... when loading or unloading the machine into a trailer or truck TRAINING 1 Read understand and follow all instructions in the manual and on the unit before starting If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 2 Become familiar with the safe operation of the equipment operator controls and safety signs 3 All operators and mec...

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

Page 10: ... 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 re...

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

Page 12: ...the following tests it should be replaced BEFORE EACH USE Conduct the following inspections maintenance of the seat belt and retraction mechanism 1 Check for dirt or debris in the retraction mechanism If dirt or debris is found it should be removed 2 Check to make sure the retraction mechanism retracts easily and completely 3 Check for damage to any part of the seat belt such as nicks cuts loose s...

Page 13: ...s 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 in Figure 1 Identification Numbers Figure 1 Identification Tag Locations A Tractor Identification Tag A Tractor Identification Tag SAM PLE SAM PLE N o t f o r R e p r o d u c t i o n ...

Page 14: ...unit All DANGER WARNING CAUTION and instructional messages on your rider and mower should be carefully read and obeyed Personal bodily injury can result when these instructions are not followed The information is for your safety and it is important The safety decals on this page are on your rider and mower If any of these decals are lost or damaged replace them at once See your local dealer for re...

Page 15: ...s injury or death WARNING This indicates a hazard which if not avoided could result in serial injury or death CAUTION This indicates a hazard which if not avoided might result in minor or moderate injury NOTICE These messages presented without the alert symbol indicate a situation where the unit or property could be damaged North American Safety Icons Alert Toxic Fumes Read the Manual Open Flame H...

Page 16: ...aged OR Operator rises off seat with parking brake disengaged Operator moves motion control handles out of their neutral positions 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...

Page 17: ...eel will turn See the Operating the Zero Turn Rider section for steering instructions Seat Adjustment Lever The seat can be adjusted forward and back S N 2014582798 Below Move the lever forward position the seat as desired and release the lever to lock the seat in position S N 2014582799 Above Move the lever towards the left position the seat as desired and release the lever to lock the seat in po...

Page 18: ...cap turn counterclockwise Fuel Level Gauge Displays the fuel level in the tank PTO Power Take Off Switch The PTO switch engages and disengages the mower Pull UP on the switch to engage the mower and push DOWN to disengage the mower Throttle Control Moving the throttle control fully forward is FULL throttle position Always operate the unit at FULL throttle when mowing Parking Brake DISENGAGE Releas...

Page 19: ...engage the parking brake disengage the PTO stop the engine and remove the key To reduce fire hazard keep the engine tractor and mower free of grass leaves and excess grease Do not stop or park tractor over dry leaves grass or combustible materials Gasoline is highly flammable and must be handled with care Never fill the tank when the engine is still hot from recent operation Do not allow open flam...

Page 20: ... performing maintenance on the fuel system such as changing the fuel filter or replacing a fuel system component To prime the fuel system 1 Make sure that there is fuel in the fuel tanks and that both fuel tank shut off valves A Figure 2 are open 2 Turn the key to the ON position not the start position for 10 to 15 seconds The electric fuel pump feeds fuel to the system WARNING Fuel leaked or spil...

Page 21: ...vers are locked in the neutral position 2 Set the throttle to middle position set throttle to FULL when starting in cold weather 3 S N 2015276814 Below Turn the key to the HEAT position S N 2014276815 Above Turn the key to the HEAT RUN position Hold the key to turn the glow plug indicator light on and activate the glow plugs 4 Wait until the glow plug indicator light turns off then turn the key to...

Page 22: ...C 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 near the back of this manual Reverse Travel Practice LOOK DOWN and BEHIND then gradually move both ground speed cont...

Page 23: ...ro 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 Around a Corner While traveling forward allow one handle to gradually return back toward neutral Repeat several times NOTE To prevent pivoting directly on the tire tread it is best to keep both wheels ...

Page 24: ...aged 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 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 ti...

Page 25: ...l cut mow across the lawn in one direction then recut the lawn by mowing perpendicular to the previous cut Mowing Methods Proper Broadcast Mowing Broadcasting side discharging disperses fine clippings evenly over the entire lawn Many golf courses use this method Your mower has a deep dish deck to allow freer circulation of clippings so they are broadcast evenly over the lawn ENGINE SPEED GROUND SP...

Page 26: ...ting 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 The ideal cutting height will vary with climate time of year and quality of your lawn We recommend that you experiment with both the...

Page 27: ...hair pin clips A Figure 11 out of the retainer pins B 2 Push or pull the top of the roll bar C forward against the rubber stops D and remove the retainer pins B 3 Lower the roll bar and reinstall the retainer pins and hair pin clips to secure the roll bar in the down position see insert Figure 11 To raise the roll bar 1 Pull the hair pin clips A out of the retainer pins B and remove the retainer p...

Page 28: ...authorized use remove the ignition key If the unit can t be stored on a reasonable level surface chock the wheels Clean all grass and dirt from the mower If temperature is expected to drop below 35 degrees refer to Long Term Storage Item 2 Long Term Storage Longer Than 30 Days Before you store your unit for the off season read the Maintenance and Storage instructions in the Safety Rules section th...

Page 29: ...or Annually Check Gearbos 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 ENGINE MAINTENANCE Before Each Use Check Engine Oil Level Check Engine Coolant Level Check Clean Radiator Screens Check Clean Cooling Fins Intake Every 25 Hours Check Fuel Filter Drain Wa...

Page 30: ...ocated in the engine compartment on the right side of the engine The water separator should be drained every 25 hours or whenever water is visible in the bowl Replace both fuel filters every 500 hours of operation or as required A C B A Figure 14 Replacing the Fuel Filter A Water Seperator B Fuel Pump C Fuel Filter Checking Adding Fuel To add fuel 1 Remove the fuel cap A Figure 13 2 Fill the tank ...

Page 31: ...edures Change Engine Oil Filter 1 Warm engine by running for a few minutes Refer to the engine operator s manual for oil filter replacement instructions 2 Remove the dipstick A Figure 15 to vent the crankcase and allow the engine oil to drain easily 3 Place a small pan under the oil drain cap D to catch the oil Using the appropriate tools remove the oil drain cap and drain the engine oil 3 After d...

Page 32: ... filter onto the filter base until the gasket makes contact then tighten 3 4 of a turn more 5 Run the unit for several minutes and check the transmission oil level IMPORTANT NOTE Use caution after changing the filter air in the hydraulic system may affect the responsiveness of the control levers Repeat step 5 until the air is out of the system Check Hydraulic Oil Level 1 Before removing the reserv...

Page 33: ...radiator Clean Radiator Screen Clean the radiator A Figure 19 and screen 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 B 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 ...

Page 34: ...compatible Ferris Red Grease p n 5022285 is recommended automotive type high temperature lithium grease may be used when this is not available Oil control handle pivots seat plate pivots deck lift pivots discharge chute hinge Generally all moving metal parts should be oiled where contact is made with other parts Keep oil and grease off belts and pulleys Remember to wipe fittings and surfaces clean...

Page 35: ... 1 4 28 grease fitting 3 Grease the drive shaft 4 Remove the 1 4 28 grease fitting and reinstall the plug Lubricating the Front Casters Maintenance Interval Annually 1 Remove the 1 4 28 bolt A Figure 27 screwed into the caster and install a 1 4 28 grease fitting 2 Grease the front caster 3 Remove the 1 4 28 grease fitting and reinstall the 1 4 28 bolt 4 Repeat the process for the other side of the...

Page 36: ... battery terminals with petroleum jelly or non conducting grease Reinstall the Floor Pan 1 All Models 2014696070 Below Insert the floor pan so that the right locking pins go into the holes in the right side of the frame Push the floor pan to the right until it stops and then lower the floor pan into place All Models 2014696071 Above Insert the floor pan onto the machine and install the two hair pi...

Page 37: ...ON Avoid injury Mower blades are sharp Always wear gloves when handling mower blades or working near blades DANGER Avoid injury A worn or damaged blade can break and a piece of the mower blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the mower blade every 25 hours or at least once a year If the mower blade hits a solid object sto...

Page 38: ...s 2 See Figure 33 Put the mower blade on a nail in a vise and turn the blade to the horizontal position 3 Check the balance of the mower blade If either end of the mower blade moves downward sharpen the heavy end until the mower blade is balanced See SHARPENING THE MOWER BLADES for proper sharpening instructions 4 Repeat the process until the mower blade remains in the horizontal position Reinstal...

Page 39: ...the first 100 hrs or 30 days of operation then after 500 hours or 12 months 1 Remove the mower deck drive belt see MOWER DRIVE BELT REMOVAL REPLACEMENT for instructions 2 Rotate the the mower deck drive pulley on the gearbox so the drain plug is aligned with the opening between the pulley spokes 3 Place a container under the gearbox drain hole and remove the drain plug B 4 Replace drain plug and f...

Page 40: ...then refill the fuel tanks Prime the fuel system 4 Motion Control Handles not 4 Lock handles in neutral position locked in neutral position 5 Operator not in seat 5 Assume operator s position in seat 6 Glow plugs not pre heated 6 Pre heat glow plugs 7 Fuse blown 7 Replace fuse 8 Battery terminals require 8 Clean the battery terminals cleaning 9 Battery discharged or dead 9 Recharge or replace 10 W...

Page 41: ...oo low 3 Cut tall grass at maximum cutting height during first pass 4 Discharge chute jamming 4 Cut grass with discharge pointing toward with cut grass previously cut area Excessive mower vibration 1 Blade mounting bolts are loose 1 Tighten to 70 ft lbs 94 N m 2 Mower blades arbors 2 Check and replace as necessary or pulleys are bent 3 Mower blades are out 3 Remove sharpen and balance blades of ba...

Page 42: ... are not properly inflated 2 Check and inflate the tires 3 Blades are damaged 3 Replace the blades 4 Deck shell is damaged 4 Repair or replace the deck 5 Mower spindle is bent or loose 5 Repair or replace the spindle 6 Blades are installed incorrectly 6 Reinstall the blades correctly Uneven Cutting 1 Deck is not leveled correctly 1 Level the deck correctly 2 Blades are dull or worn 2 Sharpen or re...

Page 43: ...lever s C to align with each other To Adjust the Handle Placement Loosen the jam nuts and adjust the placement bolt B Figure 38 in or out to properly adjust the lever end spacing To Adjust the Handle Height Remove the mounting hardware and reposition the handle either up or down from its original position You will need to readjust the handle alignment as described above Speed Balancing Adjustment ...

Page 44: ...B against the ball joint when neutral is achieved NOTE This adjustment should not be performed while the machine is running It may take several attempts to achieved neutral depending upon how much the machine creeps Return to Neutral Adjustment To determine if it is necessary to adjust the neutral return perform the following steps 1 Disengage the PTO engage the parking brake and turn off the engi...

Page 45: ...ength The spring should be 1 1 8 2 9 cm when compressed 5 If the spring is not within this range release the parking brake and turn the adjustment nut B to compress or release the spring 6 Engage the parking brake and remeasure the spring 7 Position the set collar C 1 4 0 25 cm away from the parking brake bracket D and tighten If this does not correct the braking problem see your Ferris dealer Tro...

Page 46: ...rk machine on a flat level surface Disengage the PTO stop the engine and engage the parking brake 2 See Figure 43 Using the supplied spanner wrench p n 5022853 insert the tip of the wrench into the notch in the pre load adjuster While holding the wrench with both hands turn CLOCKWISE to decrease the pre load turn COUNTER CLOCKWISE to increase the pre load Make sure that for each pair of shocks tha...

Page 47: ...ing 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 Foot Pedal Adjustment The deck lift foot pedal can be adjusted to accommodate the operator s height for optimal comfort To adjust pedal position...

Page 48: ...n and lower the mower deck 6 To ensure that the deck is in the lowest position push the pedal by hand towards the rear of the unit and install the height adjustment pin in the 3 7 6cm position to hold in place 7 Block up the mower deck until all hanger chains are slack 8 Refer to Figure 48 To adjust the inner lift rod loosen the jam nut on the front ball joint then remove the 1 2 hardware fastenin...

Page 49: ...ls Only Loosen the nuts and allow the front of the deck to rest of the 2 x 4 s Slide the chains down in the slots until the chains and tight and tighten the nuts See Figure 50 4a 61 Models Only Adjust the front eyebolts until the chains are tight and the deck is still resting on the 2 x 4 s Tighten the jam nuts See Figure 50 5 Loosen the nuts and allow the rear of the deck to rest on the 2 x 4 s S...

Page 50: ...just the deck height until the front measurement equals 4 10 2 cm and the back measurement equals 4 10 2 cm Turn the bolt CLOCKWISE to raise the deck Turn the bolt COUNTER CLOCKWISE to lower the deck 2 Position the outside mower blades so that they face front to back 3 Re measure from the front tip of the blade from the cutting edge to the ground Measure from the rear tip of the blade from the cut...

Page 51: ...al away from the drive shaft spindle D and pivot out of the way 7 Remove the old belt E and replace with a new one Install the belt on the left pump drive pulley and the drive shaft spindle pulley Make sure the V side of the belt runs in the pulley grooves Figure 55 8 Using the two 2 drive shaft collar bolts A reinstall the drive shaft universal joint to the drive shaft spindle A B Figure 55 Remov...

Page 52: ...for about 5 minutes to break in the new belt Idler Arm Spring Adjustment 1 Measure the coil length of the idler arm spring A Figure 57 as shown in Figure 57 The measurement should equal 3 5 16 8 4 cm 2 If the measurement does not equal 3 5 16 8 4 cm loosen the jam nut B and turn the nylock flange nut C Turn the nylock flange nut CLOCKWISE to increase the length of the measurement Turn the nylock f...

Page 53: ...lutch E and the idler pulley F Carefully rotate the breaker bar CLOCKWISE and install the pulley on the gearbox pulley D Carefully release the tension on the breaker bar 9 Reinstall the PTO clutch bolt B 10 Reconnect the PTO clutch wire harness G 11 Close the hood and secure with hood latches 12 Run the mower under no load condition for about 5 minutes to break in the new belt Idler Arm Spring Adj...

Page 54: ... Figure 60 5 Install the drive belt on the PTO pulley the spindle pulleys and all idler pulleys except the stationary pulley B Figure 59 Carefully rotate the breaker bar counter clockwise and install the belt on the stationary idler pulley B Carefully release the tension on the breaker bar 6 Run the mower under no load condition for about 5 minutes to break in the new belt To avoid damaging belts ...

Page 55: ...own module that will automatically shut down the mower deck if the engine looses oil pressure or begins to overheat What to do if the deck shuts down during operation Immediately check your dash panel to see if the oil pressure indicator lamp A Figure 62 is lit or the water temperature gauge B is reading a high temperature If the oil pressure indicator lamp is lit Shut the unit off immediately and...

Page 56: ...c gravity of a cell once per hour The battery is fully charged when the cells are gassing WARNING Keep open flames and sparks away from the battery the gasses coming from it are highly explosive Ventilate the battery well during charging 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 start...

Page 57: ...if the electrolyte fluid cannot be seen do not attempt to start with jumper cables as long as the battery remains frozen WARNING For your personal safety use extreme care when jump starting Never expose battery to open flame or electric spark battery action generates hydrogen gas which is flammable and explosive Do not allow battery acid to contact skin eyes fabrics or painted surfaces Batteries c...

Page 58: ...11 00 10 61 Deck Inflation Pressure 18 psi 1 24 bar Front Wheels Tire Size 13 x 5 00 6 Inflation Pressure 25 psi 1 72 bar TRANSMISSIONS S N 2014390038 Below LH Hydro Gear HGM 18E 3056 5022975L Hydro Gear PK 3HBQ FV1F XXXX 5102174 RH Hydro Gear HGM 18E 3052 5022975R Hydro Gear PK 3KBQ FV1F XXXX 5102175 S N 2014390039 Above LH Parker TF0240LS080AAKZ 5102682 Hydro Gear PK 3HBQ FV1F XXXX 5102174 RH Pa...

Page 59: ...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 ...

Page 60: ...IS2500Z Series Zero Turn Riding Mower OPERATOR S MANUAL N o t f o r R e p r o d u c t i o n ...

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