dealer setup & adjustment...

Not for

Reprod

uctio

n

15104463

Rev F

Dealer Setup & Adjustment InstructionsThese Dealer Setup Instructions cover the following models:

5901350 - IS3200ZKAV3761 5901351 - IS3200ZBV3661 5901352 - IS3200ZKAV3772

5901353 - IS3200ZBV3672 5901412 - IS3200ZBV36 ANSI EXP 5901413 - IS3200ZBV3661 ANSI EXP

5901413 - 3200/72 ANSI EXP 5901458 - IS3200ZBVE3761 5901459 - IS3200ZBVE3772

5901354 - IS3200ZBV3261 5901355 - IS3200ZBV3272 5901359 - IS3200ZBVE37 ANSI-EXP

5901357 - IS3200ZKAV3572 5901358 - IS3200ZBVE3761 ANSI-EXP 5901533 - IS3200ZBVE2861 CAL

5901356 - IS3200ZKAV3561 5901360 - IS3200ZBVE2872 CAL 5901554 - IS3200ZBVE3761 QUEBEC

Table of ContentsSETUP PROCEDURES ......................................................3Uncrating ............................................................................3Connect Battery .................................................................4Zero-Turn Rider Assembly ...............................................4

Ground Speed Control Levers Installation .......................4Seat Installation ...............................................................5Ground Speed Control Lever Adjustment ........................5Seat Position Adjustment .................................................5

Roll Bar Installation ...........................................................6Check Fluid Levels & Tire Pressures ..............................8

Check Engine Oil Level ...................................................8Check the Hydraulic Oil Level .........................................8Check Tire Pressures ......................................................8

Check Torque - Mower Blades .........................................9Install the Mower Deck Pusher Bars (72” ANSI-EXP Models) ...............................................................................9Install the Mower Deck (72” ANSI-EXP Models) ...........10Install the Discharge Chute (72” ANSI-EXP Models) ...11Install the Mower Deck Belt (72” ANSI-EXP Models) ...11Check the Deck Lift Rod Timing ....................................12Check and Level the Mower Deck .................................13

Determining if the Deck Leveling Needsto Be Adjusted ...............................................................13Deck Leveling Adjustment .............................................13

Deck Lift Assist Spring ...................................................14Check Deck Drive Belt ....................................................15

Check / Adjust the Deck Belt TensioningSpring Length ................................................................15

Lubrication .......................................................................16Adding Fuel ......................................................................17Starting the Engine .........................................................17Perform the Safety Checks ............................................18

Functional Tests ............................................................18ADJUSTMENT PROCEDURES .......................................19Neutral Adjustment .........................................................19Return-to-Neutral Adjustment ........................................20Speed Balancing Adjustment .........................................21Parking Brake Adjustment .............................................22Suspension Adjustment .................................................23

ATTENTION SETUP PERSONNEL:

The safety warnings provided in this guide and in the operator’s manual included with the unit contain important information that must be obeyed when assembling, setting-up, operating, servicing, transporting, or storing the unit.

These warnings are highlighted by the safety alert triangle symbol shown above, which signifies that an important safety message is being provided.

You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all times while working on or around this unit and all other outdoor power equipment.

Sections and items denoted by the Setup symbol provide the information necessary to fully assemble, test, and prepare the units described above for delivery to your customers.

A Quick Setup List is provided on page 2 of this booklet to help you identify and check that the items have been performed.

Additional information concerning functional tests, general adjustment procedures, and the location of normal lubrication points are included in these instructions.

Although all required lubrication and normal adjustments on factory-assembled components are done at the factory, this additional information is provided to assist you in ensuring that each unit is delivered to the customer in proper working order.

Not for

Reprod

uctio

n

Dealer Setup Instructions

2

QUICK SETUP LIST:Page Setup Procedure Steps to Perform

3 Uncrating ❏ Remove Crate & Banding.

❏ Open the Hydraulic By-pass Valves.

❏ Release Parking Brake & Push Unit Forward Off Of Skid.

❏ Close the Hydraulic By-pass Valves.

4 Battery Setup ❏ Connect Battery Cables to Battery.

4 Zero-Turn Rider Assembly

❏ Adjust Ground Speed Control Levers.

❏ Adjust Seat.

6 Roll Bar Installation ❏ Install the Roll Bar.

8 Check Fluid Levels & Tire Pressures

❏ Check Engine Oil Level.

❏ Check Hydraulic Oil Level.

❏ Check Tire Pressure.

9 Check Mower Deck Blade Bolt Torque

❑ Check Mower Deck Blade Bolt Torque.

9 Install the 72” Mower Deck (ANSI-EXP Models Only)

❑ Install the Mower Deck Pusher Bars.

❑ Install the Mower Deck.

❑ Install the Discharge Chute.

❑ Install the Mower Deck Drive Belt.

12 Check the Mower Deck ❏ Check & Adjust Deck Lift Rod Timing.

❑ Check & Level Mower Deck.

❑ Check Deck Drive Belt.

16 Lubrication &Fuel Preparation

❏ Lubricate all grease and oil points.

❏ Add fuel.

❏ Start the engine.

18 SAFETY CHECKS ❏ Check for LOOSE HARDWARE.

❏ Check all OPERATOR CONTROLS.

❏ Perform SAFETY INTERLOCK SYSTEM CHECK.

Register Product ❏ To register the product: log onto www.thepowerportal.com, select the appropriate brand, click “My Resources,” select the “Product Registration and Rebate” icon and then the “New Product Registration / Rebate” tab. Fill out and submit the online product registration form.

Not for

Reprod

uctio

n


3

Figure 2 - Disengaging the Parking Brake(lever shown in disengaged position)

A

Uncrating

1. Locate the hydraulic bypass valves (A, Figure 1) on the transmissions of the unit. There is one hydraulic bypass valve on each transmission.

2. Open the hydraulic bypass valve. To open the bypass valves, turn the bypass valve, which is located on the side of the transmission, clockwise to the “open” position (marked “bypass” on the transmission).

3. Push down on the parking brake lever (A, Figure 2) to release the parking brake.

4. Be sure there are no nails or sharp objects on the bottom skid to puncture the zero-turn rider’s tires. Roll the zero-turn rider forward off the bottom skid.

5. After moving the zero-turn rider, re-engage the transmissions by turning the bypass valves counter-clockwise to the “closed” position (marked “run” on the transmission.

SETUP PROCEDURES

Figure 1 - Hydraulic System By-Pass

A

Not for

Reprod

uctio

n


4

Connect Battery WARNING

BATTERY SAFETY RULES• Battery acid causes severe burns. Avoid contact with skin. • Wear eye protection while handling the battery. • To avoid an explosion, keep flames and sparks away from the battery, especially while charging.• When installing the battery cables, CONNECT THE POSITIVE (+) CABLE FIRST and the negative (-) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool.

1. Connect the red positive battery cable (A, Figure 3) to the positive battery post.

2. Connect the black negative battery cable (B) to the negative battery post.

Zero-Turn Rider Assembly

Ground Speed Control Levers InstallationThis procedure is only necessary if the ground speed control levers are not factory installed on your unit.

There is a LEFT-HAND and a RIGHT-HAND control lever. When assembled to the control lever base, the control lever plate should be pointing towards the rear of the machine as shown in Figure 4.

1. Remove the ground speed control levers and mounting hardware from the handle bar box.

2. Install the ground speed control levers, (A, Figure 4) onto the control lever base using the 5/16” hardware (B) supplied in the box. Prior to tightening the bolts, align the handles with each other

Figure 3 - Connect the Battery

Figure 4 - Installing and Adjusting the Ground Speed Control Levers

A

B

C

BA

Not for

Reprod

uctio

n


5

C

B

ASeat InstallationThis procedure is only necessary if the seat is not factory installed on your unit.

There are two sets of holes in the seat plate that the seat can be installed in. Use the forward set of holes to position the operator closer to the front of the machine and the rear set of holes to position the operator towards the rear of the machine. Determining what holes to use is based on the preferred operating position of the operator.

1. Unpack the seat.

2. Install the seat (A, Figure 5) onto the seat mount plate (B) and secure with the 5/16 nylock flange nuts (C).

Ground Speed Control Lever AdjustmentThe ground speed control levers can be adjusted in three ways. The height of the levers, the alignment of the control levers, and the placement of the control levers (how close the ends are to one another) can be adjusted.

HEIGHT ADJUSTMENT 1. Remove the mounting hardware (B, Figure 4).

2. Position the ground speed control lever (A) either up or down from its original position and reinstall the mounting hardware.

3. Perform the Alignment Adjustment.

ALIGNMENT ADJUSTMENT 1. Loosen the mounting hardware (B, Figure 4).

2. Pivot the ground speed control levers forward or backwards to align with each other.

3. Once alignment is achieved, retighten the hardware.

PLACEMENT ADJUSTMENT 1. Loosen the jam nut and turn the placement bolt

(C, Figure 4) in or out to adjustment the amount of distance between the ends of the ground speed control levers.

Seat Position AdjustmentThe seat can be adjusted forwards and backwards.

1. Move the seat adjustment lever (A, Figure 5) to the left, position the seat as desired, and release the lever to lock the seat into position.

Figure 5 - Installing the Seat

Figure 6 - Seat Position Adjustment

A

Not for

Reprod

uctio

n


6

Figure 7 - Assemble the Retainer Pins

B

A C

D

Snap End

Loop End

Figure 8 - Install the Roll Bar Top Loop to the Upright Tubes

Roll Bar Installation

Assemble the Retainer Pins 1. Unpack the roll bar and hardware from the box.

2. Lock the snap end of the lanyard (A, Figure 7) through the retainer pin handle (B) and snap together.

3. Install the lanyard anchor (C) onto the lanyard.

4. Install the hair pin (D) onto the loop end of the lanyard as shown in Figure 7.

Install the Roll Bar Top Loop to the Upright Tubes 1. Assemble the top loop (A, Figure 8) to the left

upright tube (B) and right upright tube (C) by loosely installing the 1/2” bolt (D), through the retainer pin assembly (E), then through the hole in the top loop that is closest to rear of the machine, the upright tube, and then loosely install the 1/2” side lock nut (F).

2. Fold the ROPS to the down position (A, Figure 9) and lock in place using the retainer pins and hair pin clips (B).

Install the Roll Bar Assembly on the MachineThe Roll Bar Assembly is installed in the roll bar pockets which are part of the main frame of the unit and are located behind the seat and in front of the engine on both sides of the unit.

1. Make sure that no fuel lines, cables, or parts of the wire harness are in the way of the roll bar pockets.

2. From the bottom of the roll bar upright tube measure up 8” (G, Figure 8) and mark the distance with a marking tool or a piece of tape. Repeat for other upright tube.

3. Install the roll bar into the roll bar pockets. The roll bar is installed so that the safety decals are on the left side of the machine (as determined from the operator’s position) facing towards the front of the machine. When the mark you made is even with the top of the roll bar pocket, the holes are close to being lined up. If necessary, use a dead blow hammer and drift pin to assist in lining up the holes in the roll bar with the holes in the roll bar pocket.

4. Loosely install the the (4) 1/2” bolts (C, Figure 9), and 1/2” washers (D), through the frame of the unit, the roll bar, the outer frame of the unit, and loosely install the 1/2” side lock nuts (E).

C

G

A

D

E

B

F

DE

Not for

Reprod

uctio

n


7

5. Tighten the 1/2” hardware that secures the upright tubes to the frame of the unit to 82 ft. lbs (108 Nm) of torque.

6. Tighten the 1/2” bolt and side lock nuts that secure the top loop to the upright tubes. Do not over-tighten. The top loop should pivot snugly with the retainer pins removed.

7. Raise the top loop to the upright position and install the retainer pins and hair pin clips to secure the roll bar in the raised position.

Install the Safety Decals (Export Models Only) 1. Remove the black and yellow CE safety decals (A, &

B, Figure 10) from the publications packet.

2. Remove the three (3) existing English language decals (C) from the roll bar.

3. Refer to Figure 10 for decal installation locations. The long decal, part number 5100536 (A) is installed below the roll bar pivot on the angled part of the roll bar. The short decal, part number 5100537 (B), is installed above the roll bar pivot.

Figure 9 - Install the Roll Bar Assembly on the Machine

A

B

C

E

D

Figure 10 - Install the Safety Decals (Export Models)

C

B

A

Not for

Reprod

uctio

n


8

Figure 11 - Checking the Engine Oil Level

A

ED

D

E

B

C

D E

Check Fluid Levels & Tire Pressures

Check Engine Oil LevelThis series of mower has different engine options. Use Figure 11 to determine if your model is equipped with a Kawasaki FX or Kawasaki FX DFI Series (A, Figure 11), Briggs & Stratton Vanguard Big Block Series (895 cc or 993 cc) (B) or a Briggs & Stratton EFI Series (C).

1. Use the dipstick (D) to check the engine oil level. If necessary add engine oil through the engine oil fill (E). Check the engine manufacturer’s owner’s manual for oil recommendations.

Check the Hydraulic Oil LevelDo not open the hydraulic reservoirs (B, Figure 12) unless oil is being added.

Oil Type: 20W-50 conventional detergent motor oil.

1. Check the oil level when the unit is cold. The oil should be up to the “FULL COLD” mark on the transmission oil reservoirs (A). If the oil is below this level proceed to step 2.

2. Before removing the reservoir cap (C), make sure the area around the reservoir cap and fill neck of the reservoir is free of dust, dirt and other debris. Remove the transmission oil caps.

3. Add oil up to the “FULL COLD” mark. 4. Reinstall the reservoir cap.

Check Tire PressuresTire 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 the cut quality, and extend the tire life.

Tire Pressure

Front 25 psi (1,72 bar)

Rear 15 psi (1,03 bar)

Figure 12 - Checking the Hydraulic Oil Level

A

C

B

Figure 13 - Checking Tire Pressure

Not for

Reprod

uctio

n


9

A

B

TIGHTEN

Figure 14 - Check the Blade TorqueA. Blade BoltB. Flat Washer

Check Torque - Mower Blades

WARNINGMower 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. 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.)

1. Park the machine on a flat, level surface and engage the parking brake.

2. Lock the deck lift pedal in the TRANSPORT position.

3. Check that blades are installed with the tabs pointing up toward the deck as shown in Figure 14. Torque the bolts to 70 ft. lbs. (94 N.m.).

Install the Mower Deck Pusher Bars (72” ANSI-EXP Models)

There is a left-hand (A, Figure 15) and a right-hand pusher bar (B).

1. Measure the pusher bar length from the outside of the cross tube to the center of the ball joint (C). The measurement should be 16-9/16” (42.1 cm).

2. If the measurement does not equal 16-9/16” (42.1 cm), loosen the jam nut and turn the ball joint until it the measurement of 16-9/16” (42.1 cm) is achieved. Tighten the jam nut.

3. There are four plastic bushings (D) installed in the cross tube, two on each end. Make sure that all four of the plastic bushings are still installed in the cross tube.

4. Holding the pusher bar in place, insert the mount pin (E) through the mower decks mounting brackets and the pusher bar.

5. Secure the mount pin to the mower deck bracket with the 3/8-16 X 1” bolt (F), 3/8 SAE washers (G), and 3/8 hex nylock flange nut (H) that are provided.

Figure 15 - Install the Mower Deck Pusher Bars

FG

H

E

A

B

JI

D

D

C

Not for

Reprod

uctio

n


10

6. Secure the other end of the mount pin in place by installing a 3/8-16 X 1” bolt (I) and .390 X 1.50 X .109 washer (J) into the internal threads of the mount pin.

7. Repeat the process to install the right-hand pusher bar to the mower deck.

Install the Mower Deck (72” ANSI-EXP Models)

1. Park the zero-turn rider on a flat, level surface. Engage the parking brake, turn the ignition switch to OFF, and remove the key.

2. Lock the deck lift pedal in the TRANSPORT position. Place the deck height adjustment pin in the 4” (10.2 cm) position and lower the deck lift pedal until the arm contacts the pin. Secure in place if necessary.

3. Center the mower deck underneath the zero-turn rider’s frame.

4. Fasten the ball joints of the pusher bars (A, Figure 16) to the transmission cradle (B) using the 3/4-16 X 3” bolt (C), 3/4 flat washer (D), 3/4 rod end seal (E), and the 3/4 hex nylon nut (F).

5. Place 2 X 4 blocks underneath each corner of the mower deck with the 3-1/2” sides being vertical. See Figure 17.

6. Install the spacer (A, Figure 18) into the eyelit of the deck linkage (B).

7. Have an assistant use the deck lift pedal to raise or lower the deck linkages as necessary while you install the 1/2 bolt (C) and 1/2 washer (D) through the middle hole (E) of the mower deck connection points and the spacer and secure with the hex nylock flange nut (F).

The hardware used to secure the front of the mower deck to the deck linkages is routed so that the threads of the bolt face towards the center of the mower deck.

The hardware used to secure the rear of the mower deck to the deck linkages is routed so that the threads of the bolt face towards the outside of the mower deck.

8. Remove the blocking from underneath the mower deck.

A

E

E

F

D C B

Figure 16 - Installing the Mower Deck to the ZTR (Pusher Bars)

C

E

B

DF

BA

C

D

F

C

C

Figure 18 - Installing the Mower Deck to the ZTR (Deck Linkages)

FRONT

Figure 17 - 2 X 4 Locations

Not for

Reprod

uctio

n


11

Install the Discharge Chute (72” ANSI-EXP Models)

1. Install the discharge chute (A, Figure 19) onto the mower deck (B) as shown in Figure 19 using the pivot rod (C).

2. Secure the discharge chute to the mower deck using two (2) 5/16 washers (D) and nylon nuts (E).

The mower deck should never be run without the discharge chute installed and positioned in the down position.

WARNING

Amputation and Thrown Object Hazard

To avoid injury from rotating blades, stay clear of deck edge and keep others away. Do not mow without discharge chute or entire grass catcher in place.

Install the Mower Deck Belt (72” ANSI-EXP Models)

1. Lower the mower deck to it’s lowest cutting position and remove the mower deck guards and the floor pan of the machine.

2. Install the mower deck drive belt (A, Figure 20) so that the V-side of the belt rides in the grooves of the spindle pulleys (B) and the back side of the belt contacts the faces of the front stationary idler pulley (C) and the adjustable idler pulley (D).

WARNINGUse 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.

3. Use a 1/2” breaker bar and place the square end in the eight sided hole located in the idler arm (E). Carefully rotate the breaker bar clockwise, which

B

CD

E

EDA

Figure 19 - Install the Discharge Chute

ABB

FD

E

BC

72”

Figure 20 - Installing the Mower Deck Drive Belt (72” ANSI-EXP Mower Deck

Not for

Reprod

uctio

n


12

relieve the tension on the belt exerted by the idler arm.

4. Install the belt on the rear stationary idler pulley (F) and carefully release the tension on the breaker bar.

Check the Deck Lift Rod Timing

1. Park the machine on a flat, level surface. Disengage the PTO, engage the parking brake, turn off the engine and remove ignition key. Check that the tires are properly inflated.

2. To check the inner lift rod timing (A, Figure 21), measure and record the distance between the inner lift pivots (B) and the inner rod pivots (C). Repeat for other side of unit.

3. To check the outer lift rod timing (D), measure and record the distance between the outer lift pivots (E) and the outer rod pivots (F). Repeat for other side of unit.

4. If the measurements for the inner rods are equal, and the measurements for the outer rods are equal, no further adjustment is required. If the measurements are NOT equal (greater than 1/8” (3,17 mm) difference), adjustment is required, continue with Step 5.

5. Lock the deck lift pedal in the 5” (12,7 cm) position. See Figure 22. Remove the cutting height adjustment pin 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” (7.6 cm) position to hold in place.

7. Block up the mower deck until all hanger chains are slack.

8. To adjust the inner lift rod (A, Figure 23): loosen the jam nut (B) on the front ball joint (C) then remove the 1/2” hardware (D) fastening the ball joint to the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counter-clockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2” hardware previously removed. Tighten the jam nut against the lift rod.

9. To adjust the outer lift rod (E, Figure 23): loosen the jam nut (F) on the front ball joint (G) then remove the 1/2” hardware (H) fastening the ball joint to the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counter-

B

A

C

EF

D

Figure 21 - Measure the Inner & Outer Lift Rods

Figure 22 - Deck Lift Pedal & Pin Position

5”(12.7 cm)

3”(10.2 cm)

Not for

Reprod

uctio

n


13

Figure 23 - Adjust the Inner & Outer Lift Rods

clockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2” hardware previously removed. Tighten the jam nut against the lift rod.

10. Remove blocks from under the mower deck. 11. Lift mower deck and reinstall adjustment pin in

desired mowing height.

Check and Level the Mower Deck

Before adjusting the deck level, the deck lift rod timing must be checked, and if necessary, adjusted.

Determining if the Deck Leveling Needs to Be Adjusted

WARNINGAvoid Injury! Mower blades are sharp.

Always wear gloves when handling blades or working near blades.

1. Park the machine on a flat, level surface. Disengage the PTO, engage the parking brake, turn off the engine and remove ignition key. Check that the tires are properly inflated.

2. Place the deck height adjustment pin in the 4” (10,2 cm) position.

3. See Figure 24. Position the outside mower blades so they face front-to-back.

4. Measure the front tip (A, Figure 24) of the blade from the cutting edge to the ground.

5. Measure the rear tip (A) of the blade from the cutting edge to the ground.

• the front measurements should equal 4” (10,2 cm).

• the rear measurements should equal 4-1/4” (10,8 cm).

If the measurements are greater than 1/8” (3,17 mm) of what they should be, adjust the deck leveling.

Deck Leveling Adjustment 1. Place the deck height adjustment pin in the 4” (10,2

cm) position.

2. Loosen the jam nut (A, Figure 25) on the deck linkages (B).

3. Turn the hex adjusters on the deck linkages (C) clockwise to raise the mower deck or counter-

B

A

E

C

D

FG

H

A

A A

Figure 24 - Measuring the Blade Height

A

BC

D

Figure 25 - Adjusting the Deck Leveling

Not for

Reprod

uctio

n


14

clockwise to lower the mower deck.

NOTE: If you are lowering the mower deck measure the amount of visible threads (D) on the deck linkages. If the amount of visible threads shown reaches 2” (5.1 cm), do not lower the mower deck by adjusting the deck linkage any further.

4. Re-check the measurements from the tips of the mower blades to the ground. The front measurements should equal 4” (10.2 cm) and the rear measurements should equal 4-1/4” (10.8 cm).

• if the measurements equal 4” (10.2 cm) in the front and 4-1/4” (10.8 cm) in the rear, tighten the jam nuts on the deck linkages. The adjustment procedure is complete.

• If the measurements do not equal 4” (10.2 cm) in the front and 4-1/4” (10.8 cm) in the rear, the hole that the deck linkage is mounted in on the mower deck will have to be changed.

5. Place blocking underneath all four corners of the mower deck.

6. Re-position the hardware (A, Figure 26) that secures the deck linkage to the mower deck.

• If the mower deck was being raised when it was unable to achieve the 4” (10.2 cm) in the front and 4-1/4” (10.8 cm) in the rear measurement, position the hardware in the next lower hole (B) in the mower deck mount (C).

• If the mower deck was being lowered when it was unable to achieve the 4” (10.2 cm) in the front and 4-1/4” (10.8 cm) in the rear measurement, position the hardware in the next higher hole in the mower deck mount.

C

A

CC

B

Figure 26 - Deck Lift Linkages Mounting Holes

A

Figure 27 - Deck Lift Spring LocationA. Deck Lift Spring

7. Remove the blocking from under the mower deck.

8. Re-check the measurements from the tips of the mower blades to the ground. The front measurements should equal 4” (10.2 cm) and the rear measurements should equal 4-1/4” (10,8 cm).

• if the measurements equal 4” (10.2 cm) in the front and 4-1/4” (10,8 cm) in the rear, tighten the jam nuts on the deck linkages. The adjustment procedure is complete.

• If the measurements do not equal 4” (10.2 cm) in the front and 4-1/4” (10,8 cm) in the rear, turn the hex adjusters on the deck linkages until the measurements equal 4” (10.2 cm) in the front and 4-1/4” (10,8 cm) in the rear.

9. Tighten the jam nuts on the deck linkages.

Deck Lift Assist Spring

The deck lift springs (A, Figure 27) are factory set to provide optimal lifting performance.

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.

Not for

Reprod

uctio

n


15

Check Deck Drive Belt

1. Lower the mower deck to its lowest cutting position. 2. Remove the mower deck guards and floor pan to

gain access to the mower deck belt. 3. Make sure the V-side of the belt (A, Figure 28 &

Figure 29) runs in the pulley grooves of the spindle pulleys (B), and the PTO clutch pulley. Make sure that the flat side of the belt contacts the face of the front stationary idler pulley(s) (C), the adjustable idler pulley (D), and the rear stationary idler pulley (F).

WARNINGUse 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.

4. If the belt is not properly seated, use a 1/2” breaker bar, and place the square end in the square hole located in the end of the idler arm (E). Carefully rotate the breaker bar clockwise, which will relieve the tension on the belt exerted from the idler arm.

5. Re-seat belt and carefully release the tension on the breaker bar.

Check / Adjust the Deck Belt Tensioning Spring Length

Deck Belt Tensioning Spring Length

Deck Size Measurement

61” 12” (30,5 cm)

72” 11-3/4” (29,8 cm)

1. Set the mower deck to the 3-1/2” (8.9 cm) position.

2. Use the Deck Belt Tensioning Spring Length chart to determine the correct spring length for your unit.

3. Measure the coil length (A, Figure 30) of the mower belt idler tensioner spring (B). The measurement should equal the measurement as indicated in the chart. If not, continue with step #4.

4. Loosen the jam nut (C) on the eyebolt (D).

5. Turn the adjustment nut (E) until the measurement as indicated in the chart is achieved.

6. Re-tighten the jam nut.

7. Re-install the mower deck guards and the floor pan.

EE

BCB

B A

C

F D61”

Figure 28 - Mower Deck Drive Belt Routing - 61” Mower Deck

ABB

FD

E

BC

72”

Figure 29 - Mower Deck Drive Belt Routing - 72” Mower Deck

A

E CB

D

Figure 30 - Mower Deck Drive Belt Idler Tensioning Spring

Not for

Reprod

uctio

n


16

Lubrication

Lubricate the unit at the locations shown in Figure 31through Figure 34 as well as the following lubrication points.

Grease

front caster wheel axles & yokes

deck lift pivot blocks

mower deck spindles

mower deck rear pusher bars

transmission cradle pivot points

Use grease fittings when present. Disassemble parts to apply grease to moving parts when grease fittings are not installed.

Not all greases are compatible. 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 & linkages

parking brake shaft pivots

seat plate pivots

deck lift pivot points

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 31 - Lubrication Points - Mower Deck

Figure 32 - Lubrication Points - Deck Lift Linkages & Rear Suspension Cradle

Figure 33 - Control Handle Pivots & Seat Plate Pivots

Not for

Reprod

uctio

n


17

Lubricating the Front Casters:NOTE: Front casters should be lubricated annually.

1. Remove the 1/4-28 bolt (A, Figure 34) screwed into the front 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 machine.

Adding Fuel

To add fuel: 1. Remove the fuel cap (A, Figure 35).

2. Fill the tank to about 1-1/2” (3,81 cm) of 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.

3. Install and hand tighten the fuel cap.

Starting the Engine

MODELS WITH CARBURETED ENGINES 1. While sitting in the operator’s seat, engage the

parking brake and make sure the PTO switch is disengaged and the ground speed control handles are locked in the NEUTRAL position. Make sure the fuel valve (B, Figure 35) is in the “ON” position.

2. Set the engine throttle control to FAST throttle position. Then fully close the choke by pulling the knob OUT fully.

3. Insert the key in the ignition switch and turn it to START.

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 before engaging the PTO switch or driving the rider.

5. After warming the engine, ALWAYS operate the unit at FULL THROTTLE when mowing.

MODELS WITH KAWASAKI DFI ENGINES 1. While sitting in the operator’s 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. Make sure the fuel

Figure 34 - Lubrication Points - Front Caster & Wheel

A

AB

Figure 35 - Adding Fuel

valve (B, Figure 35) is in the “ON” position.

2. Insert the key into the ignition switch and turn it to START position.

3. The throttle will self-adjust to idle when starting. After the engine starts allow the engine to warm. Warm up the engine by running it for at least a minute before engaging the PTO switch or driving the rider.

4. After warming the engine always operate the unit at FULL throttle when mowing.

MODELS WITH BRIGGS & STRATTON EFI ENGINESNOTE: To prime a dry fuel system, turn key switch to ON position for one minute. Allow fuel pump to cycle and prime system. Turn key switch OFF.

1. While sitting in the operator’s 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. Position the throttle control midway between SLOW and FAST positions.

3. Insert the key into the ignition switch and turn it to START position. Release switch as soon as

Not for

Reprod

uctio

n


18

engine starts. If starter does not turn engine over, shut off key switch immediately, and consult engine operator’s manual. Warm up the engine by running it for at least a minute before engaging the PTO switch or driving the rider.

4. After warming the engine always operate the unit at FULL throttle when mowing.

Perform the Safety Checks

WARNINGDisengage the PTO, stop the engine, set the parking brake, and wait for moving parts to stop before leaving operator’s position for any reason.If the zero-turn rider does not pass the test, DO NOT operate the zero-turn rider. Under no circumstance should you attempt to defeat the purpose of the safety system.

Functional Tests 1. Check the zero-turn rider for loose bolts, screws,

nuts, etc.

2. Start the engine and check all the controls for proper operation: ground speed control levers, parking brake, throttle cable, electric PTO clutch, etc.

3. Stop the engine and check for fluid leaks: engine oil, fuel, and hydraulic oil.

4. If any control fails to operate properly during testing or seems to be out of adjustment, check and re-adjust it according to the following Adjustment Procedures section.

SAFETY INTERLOCK SYSTEM

This unit is equipped with safety interlock switches. These safety systems are present for your safety, do not attempt to bypass the safety switches, and never tamper with the 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 • Ground speed control levers are not in the

NEUTRAL position.

Test 2 — Engine SHOULD crank if: • PTO switch is NOT engaged, AND • Parking brake is engaged, AND • Ground speed control levers are locked in the

NEUTRAL position.

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 ground speed control levers out of

their neutral positions before disengaging parking brake.

Test 4 — Blade Brake CheckMower blades and the mower drive belt should come to a complete stop within seven (7) seconds after the electric PTO switch is turned off (or the operator rises off seat). If the 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 ground speed control levers must be locked in the NEUTRAL position after the operator returns to the seat in order to start the engine.

WARNINGIf 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.

Not for

Reprod

uctio

n


19

AB B CC

Figure 36 - Neutral Adjustment

ADJUSTMENT PROCEDURESIf any controls fails to operate properly during testing or seems to be out of adjustment, check and re-adjust it according to the following instructions.

Neutral Adjustment

The neutral system for this mower consists of two neutral linkage rods and a pivot that connects the ground speed control lever to the transmission. The lower rod that connects the transmission to the pivot is factory preset and should not be changed for neutral adjustment purposes. The adjustment is achieved by changing the length of the upper rod (A, Figure 36) that connects the ground speed control lever to the pivot.

Determining if Adjustment is Necessary: If the tractor “creeps” while the ground speed control levers are locked in the NEUTRAL, then it may be necessary to adjust the linkage rods.

NOTE: Perform this adjustment on a hard, level surface such as a concrete floor.

1. Disengage the PTO, engage the parking brake and turn off the engine.

2. There are two nuts (B) on the linkage rod. Loosen the nuts from the ball joints (C) and turn the linkage rod to adjust.

• If the machine creeps forward, turn the rod clockwise (while standing at the rear of the machine, facing forward);

• If the machine creeps backward, turn the rod counter-clockwise (while standing at the rear of the machine, facing forward).

3. Lock the jam nut against the ball joints when neutral is achieved.

NOTE: This adjustment should not be performed while the machine is running. It may take several attempts to achieve neutral, depending on how much the machine creeps.

Not for

Reprod

uctio

n


20

CA

B

Figure 37 - Return-to-Neutral Adjustment

Return-to-Neutral Adjustment

Prior to performing this procedure the Neutral Adjustment procedure must be completed.

WARNINGTo avoid serious injury, perform adjustments only with the engine stopped, ignition key removed, and zero-turn rider parked on level ground.

1. Lock the ground speed control lever in the neutral position.

2. Loosen the set collar (A, Figure 37) on the neutral return rod (B).

3. Position the set collar along the neutral return rod until it contacts and very lightly compresses the neutral return spring (C). Tighten the set collar.

4. Move the ground speed control levers into the operating position, pull rearward, and release.

5. Move the ground speed control levers out towards the neutral position.

• if the ground speed control lever aligns with the notch in the neutral lock plate, adjustment is complete.

• if the ground speed control lever stops it’s return motion past the notch (while standing at the rear of the machine), reposition the set collar so the neutral return spring is less compressed.

• if the ground speed control lever stops it’s return motion before the notch (while standing at the rear of the machine), re-position the set collar so that the neutral return spring is more compressed.

6. Repeat the process as necessary until the ground speed control lever aligns with the notch in the neutral lock plate.

NOTE: It is important to note that after every adjustment of the neutral return rod, the lever must be pulled rearward and released to properly check the return-to-neutral position.

Not for

Reprod

uctio

n


21

Speed Balancing AdjustmentIf 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 38). Only adjust the speed of the wheel that is traveling faster.

To Reduce the Speed of the Faster Wheel:

1. Loosen the securing nut (B).

2. Turn the top speed adjustment bolt counter-clockwise to reduce the speed.

3. Retighten the securing nut when adjustment is complete.

WARNINGDO NOT adjust the tractor for a faster overall speed forward or reverse than it was designed for.

AB BA

Figure 38 - Speed Balancing Adjustment

Not for

Reprod

uctio

n


22

Parking Brake Adjustment

The parking brake mechanism consists of two parking brake cables (A, Figure 39) that connect the parking brake lever shaft to the parking brake control arm on the transmissions. There is a parking brake spring on each parking brake cable located below the engine deck by the transmission. The position of the parking brake cable in the rear suspension cradle is factory preset and should not be changed for parking brake adjustment procedures. The adjustment is achieved by changing the compressed spring length of the parking brake springs.

1. Disengage the PTO, engage the parking brake, stop the engine, and chock the tires.

2. Locate the parking brake springs (B) by the transmissions.

3. With the parking brake engaged measure the compressed spring length. The spring should measure 2-3/4” (7 cm) when compressed.

4. If the spring length does not equal the measurement, the spring length will need to be adjusted.

5. Disengage the parking brake.

6. Loosen the set collar (C) and slide it away from the back of the parking spring bracket (D).

WARNINGDo not adjust the spring to be shorter than 2-1/2” (6.4 cm) when compressed. This may damage the brake mechanism.

7. Turn the adjustment nut (E) to compress or release the spring.

8. Engage the parking brake and re-measure the spring. Continue this process until the compressed spring length measures 2-3/4” (7 cm).

9. Position the set collar 3/8” (0.96 cm) away from the parking brake bracket and tighten.

If this does not correct the braking problem, see your dealer.

AC

EDB

2-3/4”(7 cm)

3/8”(.96 cm)

Figure 39 - Parking Brake Adjustment

Not for

Reprod

uctio

n


23

Figure 40 - Suspension Adjustment

B

C

A

12

A

3

Suspension Adjustment

The shock assemblies (A, Figure 40) can be adjusted in two ways to allow the operator to customize the ride according to the operator’s weight and/or operating conditions. You have the option of adjusting the spring pre-load and/or the upper mounting position.

Items to consider be adjusting the suspension:

• Less spring pre-load should be used with light weight operators, which will provide a softer, more cushioned ride.

• More spring pre-load should be used with heavy weight operator’s, which will provide a stiffer, more rigid ride.

• There are three positions in which the upper shock mount can be positioned in. If adjusting the spring pre-load does not achieve the ride requirement, the shock should be moved to the next numbered upper shock mounting position to achieve the desired ride requirement.

• Before adjusting the upper shock mount to a higher numbered position, you should attempt to achieve the ride height through the spring pre-load adjustment.

• Shock mounting position #3 should always be used when a rear mounted grass collection system is installed on the unit.

TO ADJUST THE SPRING PRE-LOAD: 1. Park the machine on a flat, level surface. Disengage

the PTO, stop the engine, and engage the parking brake.

2. Chock the front wheels to prevent the machine from rolling. Raise the rear of the machine and secure with jack stands.

3. Remove the rear drive tires.

WARNINGSpring loaded components can kick back causing injury. Use two hands when adjusting the shock springs. This will prevent the wrench from slipping while pressure is being applied.

4. Using the supplied spanner wrench (p/n 5022853) (B, Figure 40), 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 both shocks are set to the same amount of pre-load.

Not for

Reprod

uctio

n


24

Briggs & Stratton Power Products Group, LLC.Copyright © 2016 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.ferrismowers.com

5. Re-install the rear drive tires. Torque the lug bolts to 85-95 ft.lbs. (115-129 Nm). Remove the jack stands from under the machine.

NOTE: If a collection system is installed it is recommended that the rear suspension be adjusted stiffer due to the added weight of the collection system.

TO ADJUST THE UPPER MOUNTING POSITION (REAR SHOCKS): 1. Park the machine on a flat, level surface. Disengage

the PTO, stop the engine, and engage the parking brake.

2. Chock the front wheels to prevent the machine from rolling. Raise the rear of the machine and secure with jack stands. The jack stands must be under the bumper of the machine.

3. Position the jack underneath the rear cross member of the transmission cradle and slowly raise the rear suspension to relieve the pressure on the upper shock mounting bolts.

4. Remove the upper shock mounting hardware and pivot the shock to the next higher numbered position (see Figure 40). Adjust the jack to align the shock mounts to shocks.

5. Remove the jack from under the transmission cradle.

6. Remove the jack stands from underneath the machine.

dealer setup & adjustment...

Documents