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IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Dealer Setup
& Adjustment Instructions
Ferris IS2500Z Diesel - Zero-Turn Riding Mower -
Yanmar Diesel Engine - 48”, 52” & 61” Mower Deck
This Dealer Setup Instruction covers the following products:
Model No.
Description
DOMESTIC MODELS
5900798 IS2500ZY20D52
5900799 IS2500ZY2461
5900500 IS2500ZY2452
EXPORT MODELS
5900780 IS2500ZY20D48RDCE
5900781 IS2500ZY20D52RDCE
5900782 IS2500ZY20D48SDCE
5900783 IS2500ZY20D52SDCE
5900931 IS2500ZY24D61CE
5900932 IS2500ZY20D61RDCE
5900943 IS2500ZY20D52 ANSI-EXP
5900949 IS2500ZY24D61ANSI-EXP
5900993 IS2500ZY24D52CE
5900994 IS2500ZY24D52RDCE
TABLE OF CONTENTS:
SETUP PROCEDURES
Quick Setup List ................................................................2
Uncrating ............................................................................3
Battery Installation ............................................................4
Tractor Assembly ..............................................................5
Motion Control Handle Assembly ....................................5
Seat Assembly .................................................................5
Roll Bar Assembly .............................................................6
Check Fluid levels .............................................................8
Check Engine Oil Level ...................................................8
Check Engine Coolant Level ...........................................8
Check Hydraulic Oil Level ...............................................9
Check Tire Pressure ..........................................................9
Mower Assembly ...............................................................9
for
Deck Lift Spring ...............................................................12
Check Deck Drive Belt ....................................................12
Lubrication .......................................................................15
Adding Fuel ......................................................................16
Priming The Fuel System ...............................................16
The safety warnings provided in this guide and
Starting The Engine ........................................................17
in the operator’s manual included with the unit
Perform Safety Checks ...................................................17
contain important information that must be obeyed
Functional Tests ............................................................17
when assembling, setting-up, operating, servicing,
You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all
Safety Interlock System .................................................17
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.
ADJUSTMENT PROCEDURES
Reproduction
Neutral Adjustment .........................................................20
Return-To-Neutral Adjustment .......................................20
times while working on or around this unit and all other outdoor power equipment.
Suspension Adjustment .................................................21
Sections and items denoted by the
Setup
symbol
Parking Brake Adjustment .............................................22
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.
5101977
Rev: J
1
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Setup Procedures
Quick Setup List
Page Setup Procedure
3
Uncrating
4
Battery Installation
5
Tractor Assembly
6
Roll Bar Assembly
8
Check Fluid Levels
9
Check Mower Assembly
15
Lubrication &
Fuel Preparation
17
SAFETY CHECKS
Steps to Perform
❏
Remove Crate & Banding.
❏
Loosen Hydraulic Release Valves.
❏
Release Parking Brake and Roll Tractor forward off skid.
❏
Tighten Hydraulic Release Valves.
❏
Connect
❏
Assemble the Motion Control Handles.
❏
Assemble the Seat.
❏
Assemble the Retainer Pins.
❏
Assemble the Top Loop.
❏
Install the Roll Bar.
❏
❏
❏ for
❏
Check Engine Coolant level.
❏
Check Tire Pressure
❏
❏
Not
❏
Check Deck Drive Belt.
❏
Lubricate all grease & oil points.
❏
Add
❏
Prime the Fuel System
Reproduction
❏
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.
2
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Uncrating
1. Using a reciprocating utility saw or equivalent, cut the crate away from the bottom skid. Remove the crate.
Remove the shrink-wrap plastic.
2. Cut the nylon banding from the front of the frame and the rear bumper.
IMPORTANT NOTE
When cutting crate from bottom skid, use caution around tractor tires and mower rollers.
Figure 1. Hydraulic System By-Pass
A. Hydraulic Release Valve
(left-hand pump shown)
3. Lift the seat plate to gain access to the hydraulic pumps.
A
4. Locate the hydraulic release valves (A, Figure 1) on the bottom side of the hydraulic pumps.
5. Open the hydraulic release valves. To open the release valves, turn the release valve, COUNTER-
CLOCKWISE 2 full turns MAX.
6. Push down on the parking brake lever (A, Figure 2) to release the parking brake.
7. Be sure there are no nails or sharp objects on the tractor forward off the bottom skid.
Not position) by turning the release valves clockwise and tighten to 80-120 in/lbs (9-13.5 N.m.).
for
Figure 2. Disengaging the Parking Brake
(lever shown in disengaged position)
A. Parking Brake Lever
A
Reproduction
3
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
F
Battery Installation
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 battery, especially while charging.
• When installing battery cables,
CONNECT THE POSITIVE (+) CABLE FIRST and negative (-) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool.
E
3TNM68 Engine Models
S/N: 2014887976 & Below
C
D
Connect Battery
Removing the Floor Pan to Access the Battery:
1.
(CE Models Only):
Loosen and remove the floor pan retaining bolt (D, Figure 3).
2.
(All Models: S/N 2014696070 & Below):
Tilt the left side of the floor pan (C, Figure 3) up so that the locking pins clear the holes in the frame. Slide the floor pan to the left until it stops.
(All Models: 2014696071 & Above):
retention pins (F).
Not
3. Raise the floor pan straight up and remove from the machine.
A
for
Figure 3. Battery Compartment
A. Positive (+) Cable & Terminal
B
B. Negative (-) Cable & Terminal
C. Floor Pan
D. Floor Pan Retaining Bolt
E. Hair Pins with Lanyards
F. Floor Pan Retention Pins
Connect the Battery Cables to the Battery:
1. Connect the positive (red) battery cable (A) to the positive battery post.
negative battery post.
Reproduction
3. Coat the cable ends and battery terminals with petroleum jelly or non-conducting grease.
Reinstalling the Floor Pan:
1.
(All Models: S/N 2014696070 & Below):
Insert the floor pan so that the right locking pins go into the holes in the right side of the frame. Push the floor pan to the right until it stops and then lower the floor pan into place.
(All Models: 2014696071 & Above):
Insert the floor pan onto the machine and install the two hair pins with lanyards (E) into the floor pan retention pins (F)
2.
(CE Models Only):
Reinstall and tighten the floor pan retaining bolt (D).
3TNM68 Engine Models:
S/N: 2014887977 & Above
3TNM72 Engine Models:
All
A
4
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Tractor
Assembly
A
Motion Control Handle Assembly
1. Remove the handles and mounting hardware from the handle bar box.
NOTE: There is a LEFT-HAND and a RIGHT-HAND control handle. When assembled to the base, the handle base should be pointing towards the rear as shown in Figure 4.
2. Install the ground speed control handles (A, Figure
4) onto the control lever base using the 5/16-18 x
3/4” bolts, 5/16” lock washers and 5/16” flat washers
(B, C, & D). Prior to tightening the bolts, align the handles with each other.
B
Figure 4. Control Handle Installation
A. Control Handle
B. 5/16-18 x 3/4” Bolt(s), 5/16” Lock Washer(s) &
5/16” Flat Washer(s)
Seat Assembly
1. Unpack the seat.
2. Install the seat onto the seat mount plate and secure with the 5/16-18 nylock flange nuts (A, Figure 5).
Not for
A
A
A. 5/16-18 Nylock Flange Nuts
5
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Roll Bar Assembly
Assemble Retainer Pins
1. Unpack the roll bar and hardware from the box.
2. Assemble the foam ring (A, Figure 6) onto the retainer pin (B).
3. Loop the snap end of the lanyard (C) through the retainer pin handle and snap together.
4. Install the lanyard anchor (D) onto the lanyard.
5. Install the clevis pin (E) onto the loop end of the lanyard as shown in Figure 6.
Snap End
B
C
A
D
Figure 6. Assemble the Retainer Pins
A. Foam Ring
B. Retainer Pin
C. Lanyard
D. Lanyard Anchor
E. Clevis Pin
Assemble the Top Loop
1. Install the plastic cap (B, Figure 7) into the end of the top loop tube (A). Repeat for other end of tube.
2. Make sure the rubber stop (C) is properly seated against the inside of the pivot mount. See Figure 8.
for
A
Not
Figure 7. Assemble the Top Loop
A. Top Loop Tube
B. Plastic Cap
C. Rubber Stop
Install the Roll Bar
C
1. See Figure 8. Remove and save the (2) 1/2-13 X
3-1/2” bolt (D, Figure 8), 1/2” SAE washer, and 1/2-
Reproduction the threads of the 1/2-13 X 3-1/” bolts.
2. Install the upright tube (A) (refer to Figure 9 for correct oreintation) on the outside of the bumper (B) as shown in Figure 8 and loosely reinstall the 1/2” hardware previously removed.
3. Repeat steps 1 and 2 for the other side of the machine.
IMPORTANT: Make sure the upright tubes are angled towards the front of the unit. See Figure 9.
Figure 8. Install the Upright Tubes
A. Upright Tube
B. Bumper
C. Frame
D. 1/2” x 3-1/2” Bolt GD.5
E. 1/2” Flat Washer
F. 1/2” Nylock Flange Nut (not shown)
B
E
A
C
D
Loop End
E
B
6
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
4. Install the top loop (A, Figure 10) onto the upright tubes (B). From the outside, install the 1/2” x 3” bolt (C) through the retainer pin assembly (D), then through the top lop and upright tube and shown in
FIgure 10. Loosely install the 1/2” side lock nut (E).
Repeat for other side.
5. Tighten the hardware securing the upright tubes to the frame and bumper (see Figure 8). Torque the hardware to 75 ft. lbs. (102 Nm).
6. Tighten the 1/2” x 3” bolts and hex side lock nuts
(C & E) securing the top loop (A) to the upright tubes
(B). Do not over-tighten. The top loop should pivot snugly with the retainer pins removed.
7. Raise the top loop (A) until the rubber stops (F) contact the upright tubes.
8. Push or pull the top of the roll bar forward against the rubber stops and install the retainer pins and hair pin clips to secure the roll bar in the raised position.
Figure 9. Upright Tube Orientation
A
F
C
D
Not for
C D
E
B
B
E
D C
B
Figure 10. Install Top Loop
A. Top Loop
B. Upright Tube
C. 1/2” x 3” Bolt GD.5
D. Retainer Pin Assembly
E. 1/2” Side Lock Nut
F. Rubber Stop
Reproduction
B
Install The Safety Decals (Export Models)
A
1. Remove the black and yellow CE safety decals(A &
B, Figure 11) from the publication packet.
2. Install safety decal part no. 5100536 (A) over existing decal located below pivot point of the roll bar (C) of RH upright tube. Install safety decal part no.
5100537 (B) over existing decal located above the pivot point of the roll bar (C) of RH upright tube.
Repeat procedure for LH upright tube.
C
7
Figure 11. Install CE Safety Decals (LH Side Shown)
A. Part No. 5100536
B. Part No. 5100537
C. Pivot Point of the Roll Bar
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
B
Check
Fluid Levels
Check Engine Oil Level
1. Park machine on a flat, level surface.
2. Use the dipstick (A, Figure 12) to check the engine oil level. If necessary add engine oil through the engine oil fill (B). Check engine manufacturer’s owner’s manual for oil recommendations.
Check Engine Coolant Level
A
WARNING
Figure 12. Engine Oil Fill
A. Dipstick
B. Engine Oil Fill
If engine is warm, DO NOT remove radiator cap.
Escaping steam can cause burns.
Never remove the radiator cap or radiator
D reservoir cap while the engine is hot or running. Severe thermal burns or injury can occur by escaping steam or hot coolant.
• Do NOT touch hot radiator or open reservoir when engine is running.
• Stop and allow engine to cool before removing the radiator cap or the reservoir cap and before changing or adding coolant.
before each use, when the engine is cool and off.
The cooling system is a closed type. Never open
Not for
A
C
B
the radiator cap unless you are flushing the system.
Opening the radiator cap may induce air into the cooling system and may cause overheating.
(See Figure 13).
Reproduction
2. Check the coolant level only at the overflow reservoir
(A, Figure 13). The coolant level should be at the
Figure 13. Checking the Engine Coolant Level
A. Overflow Reservoir
LOW (COLD) mark.
B. LOW (Cold) Mark
FULL
LOW
C. FULL (Hot) Mark
D. Cap
3. If the coolant level is insufficient, remove the cap
(E) from the reservoir and add coolant to the LOW
(COLD) mark. See engine owners manual for specific engine coolant specifications.
4. Reinstall the cap.
NOTE: Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water. See engine owners manual for engine coolant specifications.
8
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Check Hydraulic Oil Level
1. Before removing the reservoir cap, make sure the area around the reservoir cap and fill neck of the reservoir is free of dust, dirt, or other debris.
2. Unscrew the reservoir cap (B, Figure 14).
3. Look down the filler neck of the hydraulic oil reservoir
(A, Figure 14) and observe the oil level. When cold, the oil level should be approximately 4” (10 cm) below top of the filler neck.
4. If necessary, add either Mobil 1™, 15W-50 synthetic oil or Castrol Syntec™ 5W-50 oil. DO NOT use conventional oils.
5. Reinstall the reservoir cap.
Figure 14. Checking Hydraulic Oil Level
A. Hydraulic Oil Reservoir
B. Reservoir Cap
B
A
Check Tire Pressures
Tire 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 cut quality, and extend tire life.
Check Mower
Not for
Figure 15. Checking Tire Pressure
Tire Pressure psi bar
Front 25 1,72
Rear 18 1,24
B
Assembly
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 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 machine on a flat, level surface and engage the parking brake.
2. Lock the deck lift pedal in the 5” (12,7 cm) position.
3. Check that blades are installed with the tabs pointing up toward deck as shown in Figure 16. Torque bolts to 70 ft.lbs. (94 N.m.).
A
TIGHTE N
Figure 16. Check Blade Torque
A. Blade Bolt
B. Flat Washer
C
9
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Adjust Deck Lift Rod
Timing
Inner Rod
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).
Measure 2nd
Measure 1st
2. To check the inner lift rod timing, measure and record the distance between the inner lift pivots and the inner rod pivots. Repeat for other side of unit. See
Figure 17.
Measure 2nd
Measure 1st
3. To check the outer lift rod timing, measure and record the distance between the outer lift pivots and the outer rod pivots. Repeat for other side of unit.
See Figure 17.
Outer Rod
Figure 17. Measure the Inner & Outer Lift Rods
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” (3,17mm) difference), adjustment is required, continue with
Step 5.
5. Lock the deck lift pedal in the 5” (12,7cm) position.
Remove the cutting height adjustment pin (Figure 18) and lower the mower deck.
6. To ensure that the deck is in the lowest position, position to hold in place.
Not
7. Block up the mower deck until all hanger chains are for
Figure 18. Deck Lift Pedal & Pin Position
slack.
3”
(10,2 cm)
8. Refer to Figure 19. To adjust the inner lift rod, loosen the jam nut on the front ball joint then remove Reproduction
Reinstall the ball joint on the lift pivot arm and secure
Inner Rod
Adjust Here with the 1/2” hardware previously removed. Tighten the jam nut against the lift rod.
9. Refer to Figure 19. To adjust the outer lift rod, loosen the jam nut on the front ball joint then remove the 1/2” hardware fastening the ball joint the the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise 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.
Adjust Here
Outer Rod
Figure 19. Adjust the Inner & Outer Lift Rods
11. Lift mower deck and reinstall adjustment pin in desired mowing height.
10
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Check & Level the
Mower Deck
NOTE: Before adjusting the deck level, the deck lift rod timing must be checked and adjusted if necessary.
Coarse Adjustment
1. Park machine on a flat, level surface 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.
3. Place 2 x 4 blocks under each corner of the mower deck with the 3-1/2” sides being vertical.
Flat Nosed Decks:
Place a 1/4” (0,64 cm) thick spacer on top of the rear 2 x 4 blocks. See Figure
20.
Figure 20. 2 x 4 Locations
52” Models
4.
52” Models:
Loosen the nuts and allow the front of the deck to rest on the 2 x 4’s. Slide the chains in the slots until the chains are tight and tighten the nuts. See Figure 21.
61” Models:
Adjust the front eyebolts until the chains are tight and the deck is still resting on the 2 x 4’s. Tighten jam nuts. See Figure 21.
5.
Flat-Nosed Decks:
Loosen the nuts and allow the rear of the deck to rest on the 2 x 4’s and 1/4” spacers.
iCD Slope-Nosed Decks:
Loosen the nuts and and tighten the nuts. See Figure 21.
Not
6. Remove all 2 x 4 blocks and spacers from under the mower deck.
for
61” Models
A
7.
For your safety, DO NOT handle mower blades with bare hands.
Position the outside mower blades so that they face front-to-back (Figure 22).
Reproduction ground. Repeat this process for the other side of the machine.
Figure 21. Hanger Chain Adjustment
A. Adjustment Points
A
Flat-Nosed Decks:
The front measurements should be 4” (10,2 cm), the back measurements should be
4-1/4” (10,8 cm).
A iCD Slope-Nosed Decks:
The measurements should be 4” (10,2 cm).
If the measurements are greater than 1/8” (3,17 mm) of what they should be adjust the deck height until they are correct.
A
A
A
A
Figure 22. Checking The Blade Height Measurement
11
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Fine Adjustment Procedure (52” Models
Only)
1. Loosen the jam nut (A, Figure 23) and turn the fine adjustment bolt (B) to adjust the deck height until the front measurement equals 4” (10,2 cm) and the back measurement equals 4-1/4” (11,43 cm).
• Turn the bolt CLOCKWISE to raise the deck.
• Turn the bolt COUNTER-CLOCKWISE to lower the deck.
2. Position the outside mower blades so that they face front-to-back.
3. Re-measure from the front tip of the blade from the cutting edge to the ground. Measure from the rear tip of the blade from the cutting edge to the ground.
Repeat the process for the other side of the machine.
4. Once the front measurement equals 4” (10,2 cm) and the back measurement equals 4-1/4” (11,43 cm), re-tighten the jam nut.
B
A
Figure 23. Fine Adjustment of the Deck Cutting
Height
A. Jam Nut
B. Fine Adjustment Bolt
Deck Lift Spring
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.
Figure 24. Deck Lift Spring Location
A. Deck Lift Spring
Reproduction
12
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Check Deck Drive Belt
1. Make sure the V-side of the belt runs in the pulley grooves (Figure 25).
2. If 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 (A, Figures 26). Carefully rotate the breaker bar COUNTER-CLOCKWISE, which will relieve the tension on the belt exerted from the idler arm.
3. Re-seat belt and carefully release the tension on the breaker bar.
To avoid damaging belts, DO NOT
PRY BELTS OVER PULLEYS.
WARNING
Use extreme caution when rotating the idler arm with the breaker bar, due to the increased tension in the spring as the idler arm is being rotated.
Injury may result if the breaker bar is prematurely released while the spring is under tension.
52” Deck
D
B
C
61” Deck
D
B
C
A
Figure 25. Mower PTO Belt
Routing
A. Spindle Pulley
52” Deck
A
A
for
A
D
Not
D. Stationary Idler Pulley
D
61” Deck
A
D
A
A
B
Figure 26. Mower PTO Belt
A. Idler Arm
A
B. Stationary Idler Pulley
13
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Check the Mower Belt Tensioner Spring
Length
1. Park the machine 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. Lower the mower deck to its lowest cutting position.
3. Use the Mower Belt Idler Spring Length chart to determine the correct spring length (E, Figure 27).
4. Measure the coil length (E) of the mower belt tensioner spring (A). The measurement should equal the measurement as indicated in the chart . If the measurement does not equal the measurement as indicated in the chart, adjust the anchor eyebolt.
E
D
B
A
C
Adjusting the Mower Belt Idler Spring
Length
Figure 27. Mower Belt Idler Spring Length
A. Mower Belt Tensioner Spring
1. Loosen the jam nut (C) on the anchor eyebolt (B).
B. Anchor Eyebolt
Deck Size
Mower Belt Idler Spring Length
52” Mower Deck
61” Mower Deck
inch
6-3/8
6-3/4
C. Jam Nut
2. Turn the adjustment nut (D) the measurement as indicated in the chart is achieved.
3. Retighten the jam nut.
cm
16,2
Not
D. Adjustment Nut
E. Measurement
for
Reproduction
14
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Lubrication
Lubricate the unit at the locations shown in Figure 28 through 34 as well as the following lubrication points.
Grease:
• front caster wheel axles & yokes
• deck lift pivot blocks
• mower deck spindles
• mower deck idler arm
• pump & PTO drive idler arms
• drive shaft universal joint
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 hightemperature, lithium grease may be used when this is not available.
Figure 30. Control Handle Pivots & Seat Plate Pivots
Oil:
• control handle pivots
• seat plate pivots
• deck lift pivots
• discharge chute hinge
Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease
Not for
Figure 31. Deck Lift Linkage Pivots
Reproduction
Figure 32. PTO Drive Idler Arm
Figure 28. Deck Lubrication
Figure 29. Pump Drive Idler Arm
15
Figure 33. Suspension Pivots
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
LUBRICATING THE FRONT CASTERS
NOTE: Front casters should be lubricated annually.
1. Remove the 1/4-28 bolt (A, Figure 34) screwed into the caster and install a 1/4-28 grease fitting.
2. Grease the front caster
3. Remove the 1/4-28 grease fitting and reinstall the
1/4-28 bolt
4. Repeat the process for the other side of the machine.
Figure 34. Front Caster & Wheel
A. 1/4-28 Bolt
A
Adding Fuel
To add fuel:
1. Remove the fuel cap (A, Figure 35).
2. Fill the tank to the bottom of the fill tube. This will leave room in the tank 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.
Priming The Fuel
for
Not
Figure 35. Fill Fuel Tank
A. Fuel Cap
System
To prime the fuel system:
1. Make sure that there is fuel in the fuel tanks and that
Reproduction fuel to the system.
C
B
A
Figure 36. Fuel Shut Off Valve
A. Fuel Shut Off Valve Location
B. Open Position
C. Closed Position
A
16
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Starting The Engine
1. While sitting in the operators 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. Set the throttle to middle position (set throttle to FULL when starting in cold weather)
3.
S/N: 2015276814 & Below:
Turn the key to the
HEAT position.
SAFETY INTERLOCK
SYSTEM
CE Models (S/N: 2014390038 & Below)
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
S/N: 2015276815 & Above:
Turn the key to the
HEAT/RUN position.
Hold the key to turn the glow plug indicator light on and activate the glow plugs.
brake, and wait for moving parts to stop before leaving operator’s position for any reason.
If the tractor does not pass the test, do not operate tractor. Under no circumstance should you attempt to defeat the purpose of the safety system.
Functional Tests
Test 1 — Engine should NOT crank if:
WARNING
• PTO switch is engaged, OR
• Parking brake is not engaged, OR
4. Wait until the glow plug indicator light turns off, then turn the key to START. If the engine does not start immediately, move the throttle control to FULL.
• Motion control handles are not in the NEUTRAL position.
NOTE: Do not crank the engine continuously for more than 30 seconds. Allow the starter motor to cool for two minutes before cranking the engine again.
5. After the engine starts, move the engine throttle control to SLOW. Warm up the engine by running it for at least a minute.
6. Move the throttle to FULL before engaging the PTO switch or driving the machine.
Perform
Safety Checks
Not
Test 2 — Engine SHOULD crank if:
for position.
Test 3 — Engine should SHUT OFF if:
• Operator rises off seat under any condition.
• Operator moves motion control handles out of their neutral positions before disengaging parking brake.
Test 4 — Blade Brake Check
Mower blades and mower drive belt should come to a complete stop within seven (7) seconds after electric
PTO switch is turned off (or operator rises off seat).
If mower drive belt does not stop within seven (7) seconds, see your dealer.
NOTE: Once the engine has stopped, PTO switch must be turned off, parking brake must be engaged, and the motion control handles must be locked in the NEUTRAL position after the operator returns to the seat in order to start the engine.
1. Check the tractor for loose bolts, screws, nuts, etc.
2. Start the engine and check all 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: oil, engine coolant, fuel and hydraulic oil.
WARNING
If 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.
4. If any control fails to operate properly during testing or seems to be out of adjustment, check and readjust it according to the following Adjustments section.
17
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
SAFETY INTERLOCK
SYSTEM
WARNING
If 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.
ANSI-Export Models (S/N: All);
CE Models (S/N: 2014390039 & Above)
Adjustment Procedures
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.
Seat Adjustment
The seat can be adjusted forward and back.
Operational SAFETY Checks
S/N: 2014582798 & Below:
Test 1 — Engine should NOT crank if:
• PTO switch is engaged, OR
Move the seat adjustment lever (A, Figure 37) towards forward, position the seat as desired, and release the lever to lock the seat into position.
• Parking brake is not engaged, OR
S/N: 2014582799 & Above:
• Motion control handles are not in the NEUTRAL position.
Test 2 — Engine SHOULD crank if:
• PTO switch is NOT engaged, AND
• Parking brake is engaged, AND
• Motion control handles are locked in the NEUTRAL position.
Test 3 — Engine should SHUT OFF if:
• Operator rises off seat with PTO engaged, OR
Not
• Operator rises off seat with parking brake disengaged.
Move the seat adjustment lever towards the left, position the seat as desired, and release the lever to lock the for
& Below
A
• Operator moves motion control handles out of their neutral positions before disengaging parking brake.
Test 4 — Blade Brake Check
Reproduction
PTO switch is turned off (or operator rises off seat).
If mower drive belt does not stop within seven (7)
S/N: 2014582799
A
seconds, see your dealer.
NOTE: Once the engine has stopped, PTO switch must be turned off, parking brake must be engaged, and the motion control handles must be locked in the NEUTRAL position after the operator returns to the seat in order to start the engine.
Figure 37. Seat Adjustment
A. Seat Adjustment Lever
18
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
C
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.
To Adjust the Handle Alignment
Loosen the mount bolts (A, Figure 38) and pivot the levers (C) to align with each other.
B
A
To Adjust the Handle Placement
Loosen the jam nuts and adjust the placement bolt (B) in or out to properly adjust the lever end spacing.
To Adjust the Handle Height
Figure 38. Control Lever Adjustment
A. Alignment Hardware
B. Placement Hardware
C. Ground Speed Control Lever
Remove the mounting hardware and reposition the handle either up or down from its original position. You will need to readjust the handle alignment as described above.
Speed Balancing
Adjustment
If the rider veers to the right or left when the ground speed control levers are in the maximum forward
Not faster.
for
A
TO REDUCE THE SPEED OF THE FASTER WHEEL
1. Loosen the securing nut.
2. Turn the top speed adjustment bolt COUNTER-
CLOCKWISE to reduce the speed.
complete.
Reproduction
Figure 39. Top Speed Adjustment
A. Top Speed Adjustment Bolt
B. Control Lever Base
WARNING
DO NOT adjust the tractor for a faster overall speed forward or reverse than it was designed for.
B
19
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Neutral Adjustment &
Return-To-Neutral
NEUTRAL ADJUSTMENT
If the tractor “creeps” while the ground speed control levers are locked in NEUTRAL, then it may be necessary to adjust the linkage rod.
NOTE: Perform this adjustment on a hard, level surface such as a concrete floor.
C
A
B
1. Disengage the PTO, engage the parking brake and turn off the engine.
2. There are three nuts (B, Figure 40) on the linkage rod. The first two are to be used together to turn the rod and the third (towards the front of the machine) is used to lock the rod in place. Loosen the jam nut that locks against the ball joint (C, Figure 40) and turn the linkage rod (A) to adjust. If the machine creeps forward, turn the rod CLOCKWISE (while standing at the rear of the machine, facing forward),
Figure 40. Neutral Adjustment
(RH side shown)
A. Adjustment Linkage Rod
B. Nuts
C. Ball Joint
if the machine creeps backward, turn the rod
COUNTER-CLOCKWISE.
3. Lock the jam nut (B) against the ball joint when neutral is achieved.
NOTE: This adjustment should not be performed while the machine is running. It may take several attempts to achieve neutral, depending upon how much the machine creeps.
RETURN-TO-NEUTRAL ADJUSTMENT
Not
To determine if it is necessary to adjust the neutral return, perform the following steps.
for
B
A
Figure 41. Return to Neutral Adjustment
1. Disengage the PTO, engage the parking brake and
A. Return Spring
turn off the engine.
2. Move the ground speed control levers into the
Reproduction the notches in the neutral lock plate, it is necessary
B. Set Collar
to adjust the return spring (A, Figure 41).
TO ADJUST:
1. Loosen the set collar (B) locked against the return spring (A).
2. Lock the ground speed control levers in neutral.
3. Tighten set collar against the return spring.
4. Pull lever rearward and release to check that the lever stops aligned with notch in the neutral lock plate.
It is important to note that after every adjustment of the neutral return spring, the lever must be returned to locked position to properly check the neutral position.
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
To adjust the upper mounting position (Rear
Suspension):
Suspension Adjustment
The shock assembly can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to maintain the ride height.
1. Park machine on a flat, level surface. Disengage the
PTO, stop the engine and engage the parking brake.
Use less pre-load for light weight operators. Use more pre-load for heavy weight operators.
2. Raise the rear of the machine and secure with jackstands. The jackstands must under the bumper.
Chock the front wheels to prevent the machine from rolling.
To adjust the spring pre-load:
1. Park machine on a flat, level surface. Disengage the
PTO, stop the engine and engage the parking brake.
3. Position the jack under the cross member that ties the suspension arms together and slowly raise the rear suspension to relieve the pressure on the upper shock mounting bolts.
2. See Figure 42. Using the supplied spanner wrench
NOTE: This will require small adjustments to the jack’s
(p/n 5022853), insert the tip of the wrench into
position. The shock should move freely on the mounting
the notch in the pre-load adjuster. While holding
bolt when the pressure is relieved.
the wrench with both hands, turn CLOCKWISE to
4. Remove the upper shock mounting hardware and decrease the pre-load, turn COUNTER-CLOCKWISE pivot the shock to the position #2 (see Figure 42. to increase the pre-load. Make sure that for each
Use two hands when adjusting the shock springs.
This will prevent the wrench from slipping while pressure is being applied.
Not
FRONT
Adjust the jack to align the shock mounts to the shock (Figure 42) that the left-hand and right-hand are set to the same amount of pre-load.
NOTE: Spanner wrench is located under the seat. Rear tires must be removed to adjust the rear suspension
WARNING
shocks.
5. Reinstall the upper shock mounting hardware and tighten securely.
for
SPANNER
REAR
WRENCH
Reproduction
Figure 42. Suspension Adjustment
21
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Parking Brake
Adjustment
1. Disengage the PTO, engage the parking brake, stop the engine and remove the ignition key.
2. This unit has two brake springs (A, Figure 43). The brake springs are located under the front of the fuel tanks. Locate the brake springs. See Figure 43.
4. With the parking brake engaged, measure the compressed spring length. The spring should be
1-1/8” (2,9 cm) when compressed.
(0,3 cm)
(,25 cm)
C
A
(7 cm)
(2,9 cm)
CAUTION
Do not adjust the spring to be shorter than
1-1/8” (2,9 cm) when compressed. This may
Figure 43. Parking Brake Adjustment damage the brake mechanism.
A. Brake Spring
B. Adjustment Nut
5. If the spring is not within this range, release the
C. Set Collar
parking brake and turn the adjustment nut (B) to
D. Parking Brake Bracket
compress or release the spring.
6. Engage the parking brake and remeasure the spring.
7. Position the set collar (C) 1/4” (0,25 cm) away from the parking brake bracket (D) and tighten.
Not for
B
D
Reproduction
22
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
NOTES
Not for
Reproduction
23
IS2500Z - Yanmar Diesel Engine - 48”, 52”, & 61” Mower Deck
Not for
Reproduction
Briggs & Stratton Power Products Group, LLC.
Copyright © 2012 Briggs & Stratton Corporation
Milwaukee, WI, USA. All Rights Reserved.
FERRIS is a trademark of Briggs & Stratton Corporation,
Milwaukee, WI, USA.
Briggs & Stratton Power Products Group, LLC.
5375 North Main Street
Munnsville, NY 13409
(800) 933-6175 www.ferrisindustries.com
24
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Table of contents
- 2 Quick Setup List
- 3 Uncrating
- 4 Battery Installation
- 5 Tractor Assembly
- 5 Motion Control Handle Assembly
- 5 Seat Assembly
- 6 Roll Bar Assembly
- 8 Check Fluid levels
- 8 Check Engine Oil Level
- 8 Check Engine Coolant Level
- 9 Check Hydraulic Oil Level
- 9 Check Tire Pressure
- 9 Mower Assembly
- 12 Deck Lift Spring
- 12 Check Deck Drive Belt
- 15 Lubrication
- 16 Adding Fuel
- 16 Priming The Fuel System
- 17 Starting The Engine
- 17 Perform Safety Checks
- 17 Functional Tests
- 17 Safety Interlock System
- 20 Neutral Adjustment
- 20 Return-To-Neutral Adjustment
- 21 Suspension Adjustment
- 22 Parking Brake Adjustment