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31

Clutch 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. Remove the rear skid plate by removing the bolts

that fasten the skid plate to the bumper and slide the
plate forward until it drops from the mounts.

3. Remove the rear belt shield and rear guard support.

4. Remove the bumper.

5. Remove the nylon lock nut (A, Figure 40) to release

the belt tension and unhook the clutch belt idler
spring (C) from the screw hook (B). Set the screw
hook aside.

6. Remove the 5/16” bolt, washers and nut (D) that fas-

ten the rubber pad to the clutch and unplug the
clutch from the electrical harness. Note the order
that the hardware is oriented before removing.

7. Loosen the four (4) nylon lock nuts (E) that mount

the gear box to the pump plate.

8. Pushing upward on the gearbox (F), remove the

clutch belts from the gearbox pulley grooves.

9. Pulling the belts over the top of the clutch, remove

the clutch belts from the clutch pulley grooves and
pull around the idler pulley.

Clutch Belt Replacement & Adjustment

1. Install the clutch belts over the top of the clutch, into

the grooves of the crankshaft pulley and around the
idler pulley.

2. Pushing upward on the gearbox (F), place the clutch

belts in the grooves of the gear box pulley.

3. Push the gearbox down as far as possible and tight-

en the four (4) nylon lock nuts (E). Make sure the
bottom pulley on the gearbox is parallel with the
frame.

4. Hook the spring clutch belt idler spring on the screw

hook and reinstall the screw hook into the anchor.
Adjust the screw hook until the spring measures
4-3/4” (12,1cm) to the outside of the loops on the
spring (see Figure 41).

5. Reinstall the clutch anchor pad to the clutch with the

hardware (D) previously removed. Make sure the
hardware is in the same order as is was before being
removed, with the smaller washer(s) between the
clutch pad and the clutch.

6. Reinstall the bumper, rear hood support, rear belt

shield and skid plate.

Figure 40. Clutch Belt Removal & Replacement

A.

3/8” Nylon Lock Nut

B.

Screw Hook

C.

Clutch Belt Idler Spring

D.

Clutch Anchor Hardware

E.

Gearbox Mount Hardware

F.

Gearbox

F

E

E

D

C

4-3/4"

(12,1cm)

Figure 41. Idler Spring Measurement

A

B

Troubleshooting, Adjustment & Service

Summary of Contents for IS4000Z/D31

Page 1: ...ower Tractor Mower Deck Models Description Models Description IS4000Z D31 IS4000Z w 31 HP B S D Engine 4000 72 72 Mower Deck IS4000Z KAV27 IS4000Z w 27 HP Kawasaki Engine 4000 61 61 Mower Deck Ferris...

Page 2: ...OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE and all other obligations or lia...

Page 3: ...tures Controls 6 Control Functions 6 Safety Interlock System 7 Operating the Zero Turn Rider 8 General 8 Checks Before Starting 8 Starting the Engine 9 Stopping the Rider 9 Mowing 9 Pushing the Rider...

Page 4: ...e of the main frame rail behind the deck height plate The Mower Deck I D tag is located under the right hand guard near the front of the deck For location of Engine Serial Number refer to the Engine O...

Page 5: ...ed 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 the unit indoors Check that operator s presence controls safe...

Page 6: ...red or interfere with safe unit operation Never allow children to operate the unit Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision TRANSPORTING AND...

Page 7: ...k components and replace with manufacturer s recom mended parts when necessary Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Check brake...

Page 8: ...f the individual controls Starting stopping driving and mow ing require the combined use of several controls applied in specific sequences To learn what combination and sequence of controls to use for...

Page 9: ...engages the mower Pull UP on the switch to engage the mower and push DOWN to disengage the mower F G Deck Lift Pedal Cutting Height Adjustment Pin These control the cutting height of the mower deck De...

Page 10: ...ure 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 Fill the fuel tanks with fresh fuel Refer to...

Page 11: ...g down on the PTO switch E Figure 1 3 Engage the parking brake by pulling the handle D Figure 1 up until it locks into position 4 Move the throttle control H Figure 1 to mid throttle position and turn...

Page 12: ...ol 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 n...

Page 13: ...ting 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 Operati...

Page 14: ...ct with it If there s any chance of unau thorized use remove the spark plug s and put in a safe place Be sure the spark plug opening is protected from foreign objects with a suitable cover If the unit...

Page 15: ...13 Notes...

Page 16: ...X Check Tire Pressure 14 X X Check Hydraulic Fluid 15 X X Check Fuel Filter 15 X Clean Battery Cables 17 X Clean Sharpen Mower Blades 18 X Inspect Spark Plug 15 X Check Coolant Level 16 X Change Cool...

Page 17: ...RAULIC OIL LEVEL NOTE Do not open the hydraulic oil reservoir unless oil is being added 1 Visually check that the hydraulic oil level is filled to the recess area C Figure 10 of the hydraulic oil rese...

Page 18: ...R SCREENS Clean the radiator screens before each use to allow proper air flow through radiator and engine compart ment 1 Open the hood 2 Slide both radiator screens A Figure 12 up and out of the mount...

Page 19: ...t installed Not all greases are compatible Ferris Red Grease P N 22285 is recommended automotive type high temperature lithium grease may be used when this is not available Oil control handle pivots f...

Page 20: ...nsion Lubrication Both upper lower a arms RE PACK RE PACK BEARINGS BEARINGS ANUALLY ANUALLY RE PACK BEARINGS ANUALLY Figure 18 Front Caster Wheel Figure 17 Gearbox Drive Idler Pivot Figure 16 Control...

Page 21: ...3 Clean the battery terminals and cable ends with a wire brush until shiny 4 Reinstall the battery and reattach the battery cables positive cable first B 5 Coat the cable ends and battery terminals wi...

Page 22: ...ve all nicks and dents in blade edge If blade is severely damaged it should be replaced 4 Balance the blade as shown in Figure 22 Center the blade s hole on a nail lubricated with a drop of oil A bala...

Page 23: ...21 Notes...

Page 24: ...e fuel tank 4 Engine flooded 4 Move throttle control out of CHOKE position 5 Fuse blown 5 Replace fuse 6 Battery terminals require 6 Clean the battery terminals cleaning 7 Battery discharged or dead 7...

Page 25: ...oking 1 Engine speed too slow 1 Set throttle to full 2 Ground speed too fast 2 Decrease Ground Speed 3 Blades are dull 3 Sharpen or replace blades See Mower Blade Service 4 Mower drive belt slipping 4...

Page 26: ...iginal 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 max...

Page 27: ...e the com pressed spring length The spring should be 2 to 2 1 8 5 0cm 5 4cm when compressed 5 If the spring is not within this range jack up the rear of the machine and secure with jackstands Remove b...

Page 28: ...arrow in Figure 30 3 Loosen the jam nuts and adjust the square head allen screw located above each spring 4 After adjusting all four 4 springs recheck the meas urements and adjust if necessary Figure...

Page 29: ...meas urements are achieved making sure the deck lift pedal arm is still resting against the quick pin 27 Troubleshooting Adjustment Service Figure 32 Height Measurement Location 72 deck shown Figure 3...

Page 30: ...t nuts B Figure 35 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 adjus...

Page 31: ...tment 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 CLOC...

Page 32: ...pulley and remove belt from all pulley grooves 5 Remove the old belt and replace with a new one Make sure the V side of the belt runs in the pulley grooves Figure 39 6 Install the drive belt on the g...

Page 33: ...ves and pull around the idler pulley Clutch Belt Replacement Adjustment 1 Install the clutch belts over the top of the clutch into the grooves of the crankshaft pulley and around the idler pulley 2 Pu...

Page 34: ...h Pump Drive Belt Replacement 1 Place the belts over the clutch into the crankshaft pulley grooves 2 Carefully rotate the idler arm with the breaker bar counter clockwise see Figure 42 and wrap the be...

Page 35: ...0 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 gear box so the drain plug is aligned...

Page 36: ...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...

Page 37: ...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 star...

Page 38: ...orates in the hot afternoon sun LC 1 HOW TO WATER YOUR LAWN The best method of watering a lawn is to imitate a slow soaking rain applying about 1 inch of water A method of verifying the amount that yo...

Page 39: ...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 Th...

Page 40: ...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 a...

Page 41: ...y 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...

Page 42: ...terial This material in turn acts as an inexpensive fertilizer for your lawn and garden How to start a healthy compost pile 1 Build a bin using bricks fencing cement blocks etc or pur chase a prefabri...

Page 43: ...e Blades are installed incorrectly Reinstall the blades correctly Stepped Cutting Streaking Streaking Streaking is when thin strips of uncut grass are left behind the mower Streaking is usually caused...

Page 44: ...tly Blades are dull or worn Sharpen or replace the blades Blades are damaged Replace the blades Deck is clogged with grass clippings Clean out the deck Deck shell is damaged Repair or replace the deck...

Page 45: ...lustrations which show the relationship of the parts and how they go together as well as giving the replace ment part numbers and quantities used Important assembly notes and special torque values are...

Page 46: ...LC 9 Notes...

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