OPERATOR’S MANUAL IS4500Z Series Zero-Turn Riding Mower Model Number: 5901178 5901179 5901180 5901181 5900626 5900621 Ferris Industries 5375 North Main Street Munnsville, NY 13409 800-933-6175 Description IS4500ZBL35, 35HP Zero-Turn Riding Mower IS4500ZBL3561, 35HP, 61” Cut Zero-Turn Riding Mower IS4500ZC28D61, 28HP, 61” Cut Zero-Turn Riding Mower IS4500ZC28D61CE, 28HP, 61” Cut Zero-Turn Riding Mower (Export) IS4500ZC28D61SDCE, 28HP, 61” Cut Zero-Turn Riding Mower (Export) 4500/72, 72” Mower Deck 510079
Thank you for purchasing this quality-built Ferris product. We’re pleased that you’ve placed your confidence in the Ferris brand. When operated and maintained according to the instructions in this manual, your Ferris product will provide many years of dependable service. This manual contains safety information to make you aware of the hazards and risks associated with this machine and how to avoid them.
Table of Contents Safety Safety Rules & Information ................................2 Identification Numbers .....................................11 Safety Decals .....................................................12 Safety Icons .......................................................13 Safety Interlock System....................................14 Features & Controls ..........................................15 Control Functions..................................................15 Operation .............
Safety Rules & Information Safety Operating Safety Congratulations on purchasing a superior-quality piece of lawn and garden equipment. Our products are designed and manufactured to meet or exceed all industry standards for safety. Do not operate this machine unless you have been trained. Reading and understanding this operator’s manual is a way to train yourself. Power equipment is only as safe as the operator.
Safety Rules & Information Safety Slope Operation Operation on slopes can be dangerous. Using the unit on a slope that is too steep where you do not have adequate wheel traction (and control) can cause sliding, loss of steering, control, and possible rollover. You should not operate on a slope greater than a 3.5 foot rise over a 20 foot length (10 degrees). Always mow across slopes, not up and down (to maintain traction on the wheels) and avoid sudden turns or rapid speed changes.
Safety Safety Rules & Information Roll Bar Use Keep the roll bar in the raised position and fasten the seat belt. There is no roll over protection when the roll bar is down! Do not jump off if the mower tips (it is safer to be secured by the seat belt with the roll bar raised.) Lower the roll bar only when necessary (such as to temporarily clear a low overhanging obstacle) and NEVER remove it. Do NOT use the seat belt when the roll bar is down. Raise the roll bar as soon as clearance permits.
Safety Rules & Information Safety Fuel and Maintenance Always disengage all drives, shutoff the engine, and remove the key before doing any cleaning, refueling, or servicing. Gasoline and its vapors are extremely flammable. Do not smoke while operating or refueling. Do not add fuel while engine is hot or running. Allow engine to cool for at least 3 minutes prior to adding fuel. Do not add fuel indoors, in an enclosed trailer, garage, or any other enclosed area that is not well ventilated.
Safety Rules & Information Safety Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of unit, severe personal injury or death to you, or bystanders, or damage to property or equipment. This mowing deck is capable of amputating hands and feet and throwing objects. The triangle in text signifies important cautions or warnings which must be followed. TRAINING 1.
Safety Rules & Information CAUTION This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss though extended periods of exposure. Wear hearing protection when operating this machine. SLOPE OPERATION Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not drive on it.
Safety Rules & Information SERVICE AND MAINTENANCE Safety To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Safe Handling of Gasoline 1. Extinguish all cigarettes, cigars, pipes, and other sources of ignition. 2. Use only approved gasoline containers. 3. Never remove the gas cap or add fuel with the engine running. Allow the engine to cool before refueling. 4. Never fuel the machine indoors. 5.
Safety Rules & Information ROLL BAR INSTRUCTIONS For models equipped with factory-installed Roll Over Protection System (ROPS). WARNING In order to avoid serious injury or death from roll over, it is important to follow the warnings listed below. OPERATIONAL WARNINGS • Always use the seat belt when the roll bar is in the raised position. • Never use the seat belt when the roll bar is in the down position.
Safety Rules & Information Safety WARNING Failure to properly inspect and maintain the seat belt can cause serious injury or death. INSPECT BUCKLE & LATCH INSPECTION AND MAINTENANCE OF THE ROLL BAR SEAT BELT • The seat belt like the ROLL BAR, needs to be periodically inspected to verify that the integrity has not been compromised through normal machine use, misuse, age degradation, modifications, or a roll over. If the seat belt does not pass all of the following tests, it should be replaced.
Identification Numbers SA M SA PL Safety Identification Numbers All Models E Identification Tag M PL CE Models E When contacting your authorized dealer for replacement parts, service, or information you MUST have these numbers. 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. NOTE: For location of engine identification numbers, refer to the engine owner’s manual. CE IDENTIFICATION TAG MARKINGS A.
Safety Decals Safety SAFETY DECALS This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor 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 effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit.
Safety Icons Warning: Remove Key Before Servicing. Remove the key and consult technical literature before performing repairs or maintenance. Danger: Machine Rollover. Operating on steep slopes can cause sliding and loss of steering, control and rollover. Do not use this machine on slopes greater than 10°. Danger: Machine Rollover. Do not operate on any slopes when wet or slippery. Do not operate near drop-offs or near water. Danger: Dismemberment. This machine can amputate limbs.
Safety Safety Interlock System SAFETY INTERLOCK SYSTEM This unit is equipped with safety interlock switches. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with 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 • Motion control handles are not in the NEUTRAL position, OR • Operator is not on the seat.
Features & Controls Controls Figure 1. CONTROL FUNCTIONS The information below briefly describes the function of the individual controls. Starting, stopping, driving, and mowing 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 section. Ground Speed Levers These levers control the ground speed of the rider.
Features & Controls 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. Glow Plug Indicator (diesel model only) Lamp that indicates that the glow plugs are heating. Hold the ignition key in the “HEAT” position until indicator lamp turns off, then turn the key to start. Controls Throttle Control Moving the throttle control fully forward is FULL throttle position.
Operation GENERAL OPERATING SAFETY Before first time operation: • Be sure to read all information in the Safety and Operation sections before attempting to operate this tractor and mower. • Become familiar with all of the controls and how to stop the unit. • Drive in an open area without mowing to become accustomed to the unit. CHECKS BEFORE STARTING • Check that crankcase is filled to full mark on dipstick. See the engine Operators Manual for instructions and oil recommendations.
Operation PRIMING THE FUEL SYSTEM B Diesel Model Only A Priming the fuel system fills the fuel filters and removes any air bubbles from the fuel system. This must be performed before the first use, after any fuel filter maintenance or if the fuel system is run dry. WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the ignition switch off when changing fuel filter or water separator element. Clean up fuel spills immediately.
Operation WARNING If you do not understand how a specific control functions, or have not yet thoroughly read the FEATURES & CONTROLS section, do so now. Do NOT attempt to operate the tractor without first becoming familiar with the location and function of ALL controls. STARTING THE ENGINE STARTING THE ENGINE (Gas Model) (Diesel Model) 1.
Operation DRIVING THE TRACTOR PUSHING THE RIDER BY HAND 1. Sit in the seat and adjust the seat so that you can comfortably reach all of the controls and see the instrument and gauge panels. DO NOT TOW RIDER Towing the unit will cause hydraulic pump and wheel motor damage. Do not use another vehicle to push or pull this unit. 2. Engage the parking brake. 3. Make sure the PTO switch is disengaged and the ground speed control levers are locked in the neutral position. 4.
Operation ZERO TURN DRIVING PRACTICE The lever controls of the Zero Turn rider are responsive, and learning to gain a smooth and efficient control of the rider’s forward, reverse, and turning movements will take some practice. Spending some time going through the maneuvers shown and becoming familiar with how the unit accelerates, travels, and steers — before you begin mowing —is absolutely essential to getting the most out of the Zero Turn rider.
Operation Practice Turning Around a Corner Practice Turning In Place While traveling forward allow one handle to gradually return back toward neutral. Repeat several times. To turn in place, “Zero Turn,” gradually move one ground speed control lever forward from neutral and one lever back from neutral simultaneously. Repeat several times. NOTE: To prevent pivoting directly on the tire tread, it is best to keep both wheels going at least slightly forward. Operation Executing Turns Figure 6.
Operation ATTACHING A TRAILER A The maximum weight of a towed trailer should be less than 300 lbs (138kg). Secure the trailer with a appropriately sized clevis pin (A, Figure 10) and clip (B). Excessive towed loads can cause loss of traction and loss of control on slopes. Reduce towed weight when operating on slopes. The surface being driven on greatly impacts traction and stability. Wet or slippery surfaces can greatly reduce traction and the ability to stop or turn.
Operation MOWING 1. Engage the parking 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. 7. When finished, slow engine down and shut off the PTO. Operation 8. Stop the engine (see STOPPING THE TRACTOR AND ENGINE).
Operation When and How Often to Mow The time of day and condition of the grass greatly affect the results you’ll get when mowing. For the best results, follow these guidelines: 1. Mow when the grass is between three and five inches high. 2. Mow with sharp blades. Short clippings of grass one inch or shorter decompose more quickly than longer blades. Sharp mower blades cut grass cleanly and efficiently, preventing frayed edges which harm the grass. 3. Mow at time of day when the grass is cool and dry.
Operation Proper Mulching Mulching consists of a mower deck which cuts and recuts clippings into tiny particles and which then blows them down INTO the lawn. These tiny particles decompose rapidly into by-products your lawn can use. UNDER PROPER CONDITIONS, your mulching mower will virtually eliminate noticeable clippings on the lawn surface. NOTE: When mulching under heavy cutting conditions, a rumbling sound may be present and is normal.
Operation STORAGE (Diesel Model) Temporary Storage (30 Days Or Less) Remember, the fuel tank will still contain some fuel, so never store the unit indoors or in any other area where fuel vapor could travel to any ignition source. Fuel vapor is also toxic if inhaled, so never store the unit in any structure used for human or animal habitation.
Operation STORAGE (Gas Model) Temporary Storage (30 Days Or Less) Remember, the fuel tank will still contain some gasoline, so never store the unit indoors or in any other area where fuel vapor could travel to any ignition source. Fuel vapor is also toxic if inhaled, so never store the unit in any structure used for human or animal habitation.
Operation Notes Operation 29
Regular Maintenance MAINTENANCE SCHEDULE & PROCEDURES The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by observing the hour meter.
Operation CHECKING / ADDING FUEL (Diesel) To add fuel: 1. Remove the fuel cap (A, Figure 13). A 2. Fill the tank to the bottom of the fill tube. This will leave room in the tank for fuel expansion. Refer to your engine manual for specific fuel recommendations. 3. Install and hand tighten the fuel cap. 4. Repeat same process for opposite tank. NOTE: The fuel tanks are tied together through a “tee” in the supply lines.
Regular Maintenance CHECKING / ADDING FUEL (Gas) To add fuel: 1. Remove the fuel cap (see A, Figure 13). 2. Fill the tank to 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. 4. Repeat same process for opposite tank. NOTE: The fuel tanks are tied together through a “tee” in the supply lines.
Regular Maintenance CHECK / ADD ENGINE OIL Diesel Model Refer to Figure 15 for dipstick and oil fill locations. Refer to the engine owners manual for specific engine oil check and fill procedures. Also refer to the engine owners manual for specific engine oil and filter change procedures. A B A B CHECK / CHANGE AIR FILTER Refer to the engine owners manual for specific air filter service procedures.
Regular Maintenance CHECK ENGINE COOLANT LEVEL The engine coolant level and quality should be checked before each use, when the engine is cool and off. 1. Remove the radiator pressure cap (A, Figure 18) to check the fluid level. 2. Coolant level should be 1/2” (13mm) below the bottom of the filler tube. If coolant level is low, add coolant until level is 1/2” (13mm) below the bottom of the filler tube. Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water.
Regular Maintenance LUBRICATION Lubricate the unit at the locations shown in Figure 20 through 25. * * Grease: Use grease fittings when present. Disassemble parts to apply grease to moving parts when grease fittings are not installed. Not all greases are compatible. Ferris Red Grease (P/N 5022285) is recommended, automotive-type high-temperature, lithium grease may be used when this is not available. Oil: Figure 22.
Regular Maintenance BATTERY MAINTENANCE NOTE: This unit is equipped with a maintenance-free BCI58 battery) B C Cleaning the Battery and Cables FRO NT 1. Disconnect the cables from the battery, negative cable first (A, Figure 26). 2. Remove the battery retainer strap (C). 3. Remove the battery and clean the tray and surrounding areas with a solution of baking soda and water. A 4. Clean the battery terminals and cable ends with a wire brush until shiny. 5.
Regular Maintenance SERVICING THE MOWER BLADES 1. Blades should be sharp and free of nicks and dents. If not, sharpen blades as described in following steps. 2. To remove blade for sharpening, use a 1” wrench on the flats of the spindle shaft while removing the blade mounting bolt with a 15/16” wrench (Figure 28). 3. Use a file to sharpen blade to fine edge. Remove all nicks and dents in blade edge. If blade is severely damaged, it should be replaced. 4. Balance the blade as shown in Figure 29.
Troubleshooting, Adjustment & Service TROUBLESHOOTING While normal care and regular maintenance will extend the life of your equipment, prolonged or constant use may eventually require that service be performed to allow it to continue operating properly. The troubleshooting guide below lists the most common problems, their causes and remedies. WARNING To avoid serious injury, perform maintenance on the tractor or mower only when the engine is stopped and the parking brake engaged.
Troubleshooting, Adjustment & Service Rider Troubleshooting Continued. PROBLEM CAUSE REMEDY Engine runs, but rider will not drive. 1. 1. Turn dump valve(s) clockwise to close. Torque to 80-120 in.lbs. (9-13.5 N.m.) 2. See Drive Belt Replacement. 3. See problem and cause below. 4. See authorized service dealer 1. Clean as required. 2. Replace belt. 1. See Brake Adjustment. 2. Replace with new brake pads. 1. Check and tighten any loose connections. 2. See Regular Maintenance Section.
Troubleshooting, Adjustment & Service TROUBLESHOOTING COMMON CUTTING PROBLEMS PROBLEM CAUSE REMEDY Streaking. 1. 2. 3. 4. 5. 6. 1. Sharpen your blades. 2. Replace your blades. 3. Always mow at full throttle. 4. Slow down. 5. Clean out the mower. 6. Overlap your cutting rows. 3. 4. 5. Blades are not sharp. Blades are worn down to far. Engine speed is too slow. Ground speed is too fast. Deck is plugged with grass Not overlapping cutting rows enough. Not overlapping enough when turning.
Troubleshooting, Adjustment & Service SEAT ADJUSTMENT See Figure 31. The seat can be adjusted fore and aft. Move the lever forward, position the seat as desired, and release the lever to lock the seat into position. Seat Adjustment Lever GROUND SPEED CONTROL LEVER ADJUSTMENT The control levers can be adjusted in three ways. The alignment of the control levers, the placement of the levers (how close the ends are to one another) and the height of the levers can be adjusted. Figure 31.
Troubleshooting, Adjustment & Service NEUTRAL POSITION AND RETURN SPRING ADJUSTMENT To determine if it is necessary to adjust the neutral position, perform the following steps. 1. Disengage the PTO, engage the parking brake and turn off the engine. 2. Move the ground speed control levers in the operating position, pull levers rearward and release. 3. Move the ground speed control levers towards the neutral position.
Troubleshooting, Adjustment & Service PARKING BRAKE ADJUSTMENT 1. Disengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. B 2. Jack up the rear of the machine and secure with jackstands. Remove both drive tires. A 3. With the parking brake engaged, measure the compressed spring length (see Figure 36). The spring should be 2-1/8” - 2-1/4” (5,4 - 5,7 cm) long when compressed. 4.
Troubleshooting, Adjustment & Service DECK LIFT ROD TIMING ADJUSTMENT 1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72 bar). 2. Install the cutting height adjustment pin in the 33/4” (9,5 cm) position. See Figure 38. 3. To check the lift rod timing, measure and record the distance between the lift pivots and the rod pivots. Repeat for other side of unit. See Figure 39.
Troubleshooting, Adjustment & Service DECK LEVELING ADJUSTMENT NOTE: Before adjusting the deck level, the deck lift rod timing must be checked and/or adjusted. 1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar); front tires to 25 psi (1,72 bar). 2. Install the cutting height adjustment pin in the 4” (10,2 cm) position. See Figure 42. 3.
Troubleshooting, Adjustment & Service SUSPENSION ADJUSTMENT To adjust the spring pre-load: This unit is equipped with adjustable shock assemblies. The shocks can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to customize the ride according to operator’s weight and/or operating conditions. 1. Locate the pe-load adjuster collar on the shock assembly. See Figure 46. 2.
Troubleshooting, Adjustment & Service A B B B C B A Figure 47. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut PTO CLUTCH ADJUSTMENT Check the PTO clutch adjustment after the initial 25 hour break-in period and then after every 100 hours of operation. Also perform the following procedure if the clutch is slipping or will not engage, or if a new clutch has been installed.
Troubleshooting, Adjustment & Service BELT REMOVAL & REPLACEMENT B WARNING If servicing the belts after the engine has been running, use extreme caution when raising the hood or lowering the rear shield. The surface of the hood and rear shield can be hot from the muffler and exhaust manifold. Pump Drive 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.
Troubleshooting, Adjustment & Service PTO Drive 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. Release the hood cam latches and raise the hood until it locks in place. 3. Release the rear guard cam latches and lower or remove the rear guard. 4.
Troubleshooting, Adjustment & Service Figure 51. PTO Belt Routing NOTE: Gray areas indicate the flat side of the belt. Troubleshooting C B B A A A A Figure 52. Spindle Drive Belt Removal A. Idler Arm B. Trim Side Spindle Pulley 50 Figure 53. Spindle Drive Belt Removal A. Spindle Pulley B. Idler Pulley C. Drive Belt www.ferrisindustries.
Troubleshooting, Adjustment & Service BATTERY SERVICE WARNING Keep open flames and sparks away from the battery; the gasses coming from it are highly explosive. Ventilate the battery well during charging. Checking Battery Voltage A voltmeter can be used to determine condition of battery. When engine is off, the voltmeter shows battery voltage, which should be 12 volts. When engine is running, the voltmeter shows voltage of charging circuit which normally is 13 to 14 volts.
Troubleshooting, Adjustment & Service Figure 54. Jump Starting Troubleshooting WARNING Any procedure other than the preceding could result in: (1) personal injury caused by electrolyte squirting out the battery vents, (2) personal injury or property damage due to battery explosion, (3) damage to the charging system of the booster vehicle or of the immobilized vehicle. Do not attempt to jump start a vehicle having a frozen battery because the battery may rupture or explode.
Specifications NOTE: Specifications are correct at time of printing and are subject to change without notice. ENGINE: TRANSMISSIONS: 28 HP* Caterpillar Make Model Horsepower Displacement Electrical System CCA Oil Capacity Caterpillar 3011C 28 @ 3600 rpm 69 Cu. in (1131 cc) 12 Volt, 40 amp. Alternator, Battery: 500 5.2 US qt. (4.9 L) w/ Filter 35 HP* Briggs Make Model Horsepower Displacement Electrical System CCA Oil Capacity Briggs & Stratton 613177 35 @ 3600 rpm 61 Cu. in (993 cc) 12 Volt, 20 amp.
Ferris Industries - a division of Simplicity Manufacturing Inc. Owner's Limited Warranty Information (Effective 04/28/2004) Thank you for purchasing Ferris commercial mowing equipment. Please take a few minutes to read this limited warranty information. It contains all the information you will need to have your Ferris mower repaired in the unlikely event that a breakdown covered by this limited warranty should occur.
OPERATOR’S MANUAL IS4500Z Series Zero-Turn Riding Mower Product Quick Specs: ENGINE: BELTS AND BLADES: 28 HP* Caterpillar Make Model Oil Capacity Caterpillar 3011C 5.2 US qt. (4.9 L) w/ Filter 35 HP* Briggs Make Model Oil Capacity Briggs & Stratton 613177 2.4 US qt. (2.25 L) w/ Filter CHASSIS: Fuel Tanks Rear Wheels Front Wheels Capacity: 15 Gallons (56.8 L) Total Tire Size: 24 x 12.00 -12 Inflation Pressure: 18 psi (1,24 bar) Tire Size: 13 x 6.