Ferris IS4500ZBL3561 Operator'S Manual Download Page 1

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23469

Revision 02

Rev. Date: 4/2005

TP 100-7174-02-45-F

IS4500Z Series

Zero-Turn Riding Mower

Ferris Industries
5375 North Main Street
Munnsville, NY 13409
800-933-6175

OPERATOR’S

MANUAL

Models:

IS4500ZC28D61
IS4500ZC28D61CE
IS4500ZBL3561

Summary of Contents for IS4500ZBL3561

Page 1: ...2 Rev Date 4 2005 TP 100 7174 02 45 F IS4500Z Series Zero Turn Riding Mower Ferris Industries 5375 North Main Street Munnsville NY 13409 800 933 6175 OPERATOR S MANUAL Models IS4500ZC28D61 IS4500ZC28D61CE IS4500ZBL3561 ...

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Page 3: ...rols 8 Control Functions 8 Operation 10 General 10 Checks Before Starting 10 Priming the Fuel System diesel model only 11 Starting the Engine 12 Stopping the Tractor and Engine 12 Driving the Tractor 13 Mowing 13 Pushing the Rider by Hand 13 Zero Turn Driving Practice 14 Storage 16 17 Starting After Long Term Storage 16 17 Diesel Fuel Recommendations 16 Regular Maintenance 18 Maintenance Schedule ...

Page 4: ... 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 TRAINING 1 Read understand and follow all instructions in the manual and on the unit before starting If the opera tor 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 operati...

Page 5: ...tting 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 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 equipmen...

Page 6: ...Clean up oil or fuel spillage 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 14 Carefully release pressure from components with stored energy 15 Discon...

Page 7: ...nual S SA A M M P PL LE E Identification Tag Identification Numbers Identification Numbers Model No kW Engine RPM LpA Vibration Wheels Vibration Seat Ferris Industries Inc Munnsville NY USA 13409 XXX XXX XXXXXXXXXX XXX XXXX XX dB A XXX XXX 200X CE IDENTIFICATION TAG MARKINGS A Manufacturer s Identification Number B Power Rating in Kilowatts C Maximum Engine Speed in Rotations per Minute D Sound Pr...

Page 8: ...or power equipment manufacturing Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effec tively we have placed several safety labels on the unit to remind you of this important information while you are operating your unit Decal Danger Part No 1704276 Decal Danger Part No 1704277 ...

Page 9: ...t 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 SAFETY ICONS Warning Read Operator s Manual Read and understand the Operator s Manual before using this machine Danger Thrown Objects This machine is capable of throwing objects and debris Keep bystanders away Warning Remove Key Be...

Page 10: ...ward position the seat as desired and release the lever to lock the seat in position Figure 1 CONTROL FUNCTIONS The information below briefly describes the function of 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 various tasks see the OPERATION s...

Page 11: ...t 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 re...

Page 12: ...king 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 flame smoking or m...

Page 13: ...he engine fuel filter 2 3 revolutions 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...

Page 14: ...operators seat engage the park ing brake and make sure the PTO switch is disen gaged and the motion control handles are locked in the NEUTRAL position 2 NOTE A warm engine may not require choking Set the engine throttle control to FAST throttle posi tion Then fully close the choke by pulling the knob OUT fully 3 Insert the key into the ignition switch and turn it to START 4 After the engine starts...

Page 15: ...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 See the Lawn Care Section for tips on mowing patterns lawn care and trouble shooting information...

Page 16: ... 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 neces sary top speed can be balance adjusted see the Speed Balancing Adjustment in the Adjustments section located on page 26 Reverse Travel Practice LOOK DOWN BEHIND then gradually move both ground speed contr...

Page 17: ...me more familiar and experi enced 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 simultaneou...

Page 18: ...au thorized 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 t...

Page 19: ...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 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 Antifreez...

Page 20: ... 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 See Before Before Every Every Every Spring SAFETY ITEMS Page First Use Each Use 5 Hours 25 Hours 100 Hours Fall Check Safety Interlock System 7 Check Rider Brakes 30 Check Mower Blade Stopping Time 34 ...

Page 21: ...before draining the fuel filter 3 Place a container under the drain valve A Figure 12 and turn the drain valve approximately 1 2 turns 4 Allow the filter to drain until all water and debris have drained out 5 Turn the drain valve to close it when finished drain ing WARNING Diesel fuel is highly flammable and must be handled with care Never fill the tank when the engine is still hot from recent ope...

Page 22: ... 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 WARNING Gasoline is highly flammable and must be handled w...

Page 23: ...ill 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 15 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 cont...

Page 24: ...ine coolant specifications 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 1 Raise ...

Page 25: ...Oil 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 fit tings and surfaces clean both before and after lubri cation Figure 18 Deck Lift Pivots Figure 19 Mule Drive Idler Arm Figure 20 Deck Lubrication Use needle nozzle later models RE PACK RE PACK BEARINGS BEARINGS ANUALLY ANUALLY RE PACK BEARINGS AN...

Page 26: ...minal C Retainer Strap 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 FRONT C B A ANTI SCALP DECK CASTERS The anti scalp deck casters A Figure ...

Page 27: ... 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 28 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 inj...

Page 28: ...1 Engage parking brake 2 PTO electric clutch switch 2 Place in OFF position in ON position 3 Out of fuel 3 If engine is hot allow it to cool 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 bl...

Page 29: ...ower cut is rough looking 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 Clean or replace belt as necessary because it is oily or worn 5 Blades not properly fastened 5 See Servicing the Mower Blades to spindles Engine stalls easily with 1 Engine speed ...

Page 30: ...ition the handle either up or down from its original 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 posi tion the top speed of each of these levers can be bal anced by turning the adjustment bolt s A Figure 31 Only adjust the speed of the wh...

Page 31: ...al position lock the levers in the neutral position and measure the reverse return spring B Figure 32 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 Figure 32 Neutral Spring Return Adjustment A Reverse Return Bolt B Reverse Return Spring C Spring Position Nut D Jam Nut A B D C NE...

Page 32: ... 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 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 tir...

Page 33: ... 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 6 Refer to Figure 38 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 meas urements are NOT e...

Page 34: ...d the deck is still resting on the 2 x 4 s Tighten jam nuts See Figure 42 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 42 6 Remove all 2 x 4 blocks and spacers from under the mower deck Adjust Here Adjust Here Figure 42 Deck Level Adjustment Troubleshooting Adjustment...

Page 35: ...mount of pre load applied to the springs This allows the operator to customize the ride according to operator s weight and or operating conditions Less Pre Load Light operator weight Softer more cushioned ride Best for relatively flat terrain More Pre Load Heavy operator weight Stiffer more rigid ride Better handling and greater stability on hilly terrain ...

Page 36: ...Troubleshooting Adjustment Service 34 WARNING To avoid serious injury perform adjustments only with engine stopped key removed and tractor on level ground B A C ...

Page 37: ...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 47 While holding the breaker bar firmly install the belts in the left hand pump pulley grooves and the two stationary idler pul leys grooves 5 Carefully release the tension on the break...

Page 38: ...ey 5 Carefully release the tension on the wrench 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 flo...

Page 39: ...Pulley Center Spindle Pulley FRONT IMPORTANT V side of belt must contact v groove pulleys Flat side of belt must contact flat pulleys Figure 49 PTO Belt Routing NOTE Gray areas indicate the flat side of the belt Figure 50 Spindle Drive Belt Removal A Idler Arm B Trim Side Spindle Pulley Figure 51 Spindle Drive Belt Removal A Spindle Pulley B Idler Pulley C Drive Belt B A C B A A A ...

Page 40: ... 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 JUMP STARTING WITH AUXILIARY BOOSTER BATTERY Jump ...

Page 41: ...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 flammable and explosive Do not allow battery acid to contact skin eyes fabri...

Page 42: ...Inflation Pressure 25 psi 1 72 bar TRANSMISSIONS HydroGear BDP 21 Parker TF 040 Type Pump and Wheel Motor Hydraulic Fluid Mobil 1 15W 50 synthetic oil or Castrol Syntec 5W 50 oil Speeds Forward 0 10 MPH 0 16 1 km h 3400 rpm Reverse 0 5 MPH 0 8 05 km h Continuous Torque 483 ft lbs 654 N m Output Maximum Weight 3000 lbs 1360 Kg on Axle DIMENSIONS Overall Length 86 1 2 220 cm Overall Width 75 191 cm ...

Page 43: ...porates 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 you have watered is to place several empty tin cans low shallow cans work best in various spots around the lawn and check the depth of water in the can during the watering process HOW TO FERTILIZE YOUR...

Page 44: ... 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 gr...

Page 45: ......

Page 46: ...vy 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 mowing...

Page 47: ...aterial 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 prefabricated bin from a garden store The bin should also have venting on each side and from the bottom to the top 2 Fill the bin with alternating layers of yard waste Follow this recipe First layer 3 4 inch...

Page 48: ... misadjustment or damage to mower blades CAUSE SOLUTION Deck is not leveled correctly Level the deck correctly Tires are not properly inflated Check and inflate 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 ...

Page 49: ...Deck is plugged with grass Clean out the mower Uneven Cutting Uneven cutting is waviness or smooth troughs in the lawn surface Uneven cutting is usually caused by mower deck damage or misadjustment CAUSE SOLUTION Deck is not leveled correctly Level the deck correctly Blades are dull or worn Sharpen or replace the blades Blades are damaged Replace the blades Deck is clogged with grass clippings Cle...

Page 50: ...illustrations 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 included in these manuals For the applicable manuals currently available for your model contact your local dealer Have the information listed in the box at the right available when making your requ...

Page 51: ... 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 necessar...

Page 52: ...ustries 5375 North Main Street Munnsville NY 13409 800 933 6175 www ferrisindustries com Copyright 2005 Ferris Industries All Rights Reserved Printed in USA IS4500Z Series Zero Turn Riding Mower OPERATOR S MANUAL ...

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