operator`s manual - Ferris And Wright Mowers

operator`s manual - Ferris And Wright Mowers
OPERATOR’S
MANUAL
HydroWalk Series
Dual Drive Walk-Behind Mowers
Ferris Industries
5375 North Main Street
Munnsville, NY 13409
800-933-6175
Powerhead
Mower Deck
Model Number
DDSKAV15
DDSKAV15CE
DDSKAV17
DDSKAV17CE
DDSKAV23
DDSKAV23CE
Model Number
DDS48
DDS48R
DDS52
DDS52R
DDSH52
DDS61
DDSH61
5022880
Revision 04
Rev. Date: 06/2006
TP 100-7056-04-WD-F
THIS PAGE INTENTIONALLY BLANK
Table of Contents
Safety Rules & Information ................................2
Identification Tags ...............................................5
Safety Decals .......................................................6
Safety Interlock System......................................7
Features & Controls ............................................8
Troubleshooting, Adjustments & Service
Troubleshooting the Mower ...................................19
Troubleshooting the Mower Deck..........................20
Mowing Height Adjustment ...................................21
Idler Pulley Height Adjustment (48” models) ........21
Deck Leveling Adjustment (DDSH models) ..........22
Mowing Height Adjustment (DDSH models).........23
Mower Belt Replacement......................................24
Mower Belt Replacement (DDSH models) ...........25
Transmission Drive Belt Replacement ..................26
Transmission Neutral & Tracking Adjustments ......27
Neutral Adjustment ............................................27
Tracking Adjustment...........................................27
Transmission Maintenance & Service...................28
Changing Oil & Filters .......................................28
PTO Clutch Adjustment ........................................29
Battery Service .....................................................30
Checking the Battery Voltage ............................30
Charging A Completely Discharged Battery......30
Jump Starting with
Auxiliary (Booster) Battery .............................30
Control Functions....................................................8
Safety Interlock System ..........................................9
Operating the Dual Drive Walk-Behind
General Operating Safety .....................................10
Checks Before Starting .........................................10
Starting the Engine ...............................................11
Stopping the Mower ..............................................11
Driving the Mower .................................................11
Mowing..................................................................12
Pushing the Mower by Hand.................................12
Storage..................................................................13
Starting After Long Term Storage .........................13
Regular Maintenance
Maintenance Schedule .........................................14
Checking Tire Pressures.......................................14
Checking/Adding Fuel...........................................15
Fuel Filter ..............................................................15
Oil & Filter Change ...............................................15
Check / Change Air FIlter .....................................15
Check Hydraulic Oil Level .....................................15
Lubrication ............................................................16
Battery Maintenance .............................................17
Checking Battery Fluid ......................................17
Cleaning the Battery and Cables.......................17
Servicing the Mower Blades .................................18
Replacement Parts & Accessories ..................32
Lawn Care & Mowing Information ...............LC-1
International Symbols...................................LC-8
Technical Manuals.........................................LC-8
NOTE: In this manual, “left” and “right” are referred to as
seen from the operating position.
WARNING
WARNING
You must read, understand and comply with all safety
and operating instructions in this manual before
attempting to set-up and operate your machine.
Engine exhaust from this product contains
chemicals known, in certain quantities, to cause
cancer, birth defects, or other reproductive harm.
Failure to comply with all safety and operating
instructions can result in loss of machine control,
serious personal injury to you and / or bystanders,
and risk of equipment and property damage. The
triangle in the text signifies important cautions or
warnings which must be followed.
1
Safety Rules & Information
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
OPERATION
1. Read, understand, and follow all instructions in the
manual and on the unit before starting. If the operator(s) or mechanic(s) can not read English it is the
owner’s responsibility to explain this material to them.
2. Become familiar with the safe operation of the equipment, operator controls, and safety signs.
3. All operators and mechanics should be trained. The
owner is responsible for training the users.
4. Only allow responsible adults, who are familiar with
the instructions, to operate the unit.
5. Never let children or untrained people operate or
service the equipment. Local regulations may
restrict the age of the operator.
6. The owner/user can prevent and is responsible for
accidents or injuries occurring to themselves, other
people or property.
7. Data indicates that operators, age 60 years and
above, are involved in a large percentage of riding
mower-related injuries. These operators should evaluate their ability to operate the riding mower safely
enough to protect themselves and others from serious injury.
1. Never run an engine in an enclosed area.
2. Mow only in the daylight or with good artificial light,
keeping away from holes and hidden hazards.
3. Be sure all drives are in neutral and parking brake is
engaged before starting engine. Only start engine
from the operator’s position. Use seat belts if provided.
4. Be sure of your footing while using pedestrian controlled equipment, especially when backing up. Walk,
don’t run. Reduced footing could cause slipping.
5. Slow down and use extra care on hillsides. Be sure
to travel in the recommended direction on hillsides.
Turf conditions can affect the machines stability. Use
caution when operating near drop-offs.
6. Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while traveling in reverse.
7. Be aware of the mower discharge direction and do
not point it at anyone. Do not operate the mower
without either the entire grass catcher or the deflector in place.
8. Slow down and use caution when making turns and
when changing directions on slopes.
9. Never raise deck with the blades running.
10. Never leave a running unit unattended. Always disengage the PTO, set parking brake, stop engine, and
remove keys before dismounting. Keep hands and
feet away from the cutting units.
11. Turn off the PTO switch to disengage the blades
when not mowing.
12. Never operate with guards not securely in place. Be
sure all interlocks are attached, adjusted properly
and functioning properly.
13. Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
14. Do not change the engine governor setting or overspeed the engine.
15. Stop on level ground, lower implements, disengage
drives, engage parking brake, shut off engine before
leaving the operator’s position for any reason including emptying the grass catchers or unclogging the
chute.
16. Stop equipment and inspect blades after striking
objects or abnormal vibration occurs. Make necessary repairs before resuming operations.
17. Keep hands and feet away from the cutting units.
18. Look behind and down before backing up to be sure
of a clear path.
19. Never carry passengers and keep pets and
bystanders away.
20. Do not operate the unit while under the influence of
alcohol or drugs.
21. Slow down and use caution when making turns and
crossing roads and sidewalks. Stop blades if not
mowing.
22. Use care when loading or unloading the machine
into a trailer or truck.
PREPARATION
1. Evaluate the terrain to determine what accessories
and attachments are needed to properly and safely
perform the job. Use only accessories and attachments approved by the manufacturer.
2. Wear appropriate clothing including safety shoes,
safety glasses and ear protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
3. Inspect the area where the equipment is to be used
and remove all objects such as rocks, toys and wire,
which can be thrown by the machine.
4. Use extra care when handling gasoline and other
fuels. They are flammable and vapors are explosive.
a) Use only an approved container.
b) Never remove fuel cap or add fuel with the engine
running. Allow engine to cool before refueling. Do
not smoke.
c) Never refuel or drain the machine indoors.
5. Check that operator’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
TP 600-7124-04-UV-F
2
Safety Rules & Information
23. Use care when approaching blind corners, shrubs,
trees or other objects that may obscure vision.
24. To reduce fire hazard, keep unit free of grass, leaves
& excess oil. Do not stop or park over dry leaves,
grass or combustible materials.
25. The engine in this unit is not factory equipped with a
spark arrester. It is a violation of California Public
Resource Code Section 4442 to use or operate the
engine on or near any forest-covered, brush-covered,
or grass-covered land unless the exhaust system is
equipped with a spark arrester meeting any applicable local or state laws. Other states or federal area
may have similar laws.
26. OSHA regulations may require the use of hearing
protection when exposed to sound levels greater
than 85 dBA for an 8 hour time period.
Do Not
1. Avoid starting, stopping, or turning on a slope. If
tires lose traction (i.e. machine stops forward motion
on a slope), disengage the blade(s) (PTO) and drive
slow off the slope.
2. Do not turn on slopes unless necessary, and then,
turn slowly and gradually uphill, if possible. Never
mow down slopes.
3. Do not mow near drop-offs, ditches, or embankments. The operator could lose footing or balance or
mower could suddenly turn over if a wheel is over
the edge of a cliff or ditch, or if an edge caves in.
4. Do not mow on wet grass. Reduced footing or traction could cause sliding.
5. Do not try to stabilize the unit by putting your foot on
the ground. (ride-on units)
6. Do not mow excessively steep slopes.
7. Do not use grass catcher on steep slopes.
8. Do not mow slopes if you cannot back up them.
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.
TOWED EQUIPMENT (RIDE-ON UNITS)
1. Tow only with a machine that has a hitch designed
for towing. Do not attach towed equipment except at
the hitch point.
2. Follow the manufacturer’s recommendations for
weight limit for towed equipment and towing on
slopes. See attaching a trailer under OPERATION.
3. Never allow children or others in or on towed equipment.
4. On slopes, the weight of the towed equipment may
cause loss of traction and loss of control.
5. Travel slowly and allow extra distance to stop.
6. Do not shift to neutral and coast down hill.
SLOPE OPERATION
Slopes are a major factor related to loss-of-control and tipover 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.
WARNING
CHILDREN
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the
unit and the mowing activity. Never assume that children
will remain where you last saw them.
1. Keep children out of the mowing area and under the
watchful care of another responsible adult.
2. Be alert and turn unit off if children enter the area.
3. Before and during reverse operation, look behind and
down for small children.
4. Never carry children, even with the blade(s) off. They
may fall off and be seriously injured or interfere with
safe unit operation. Children who have been given
rides in the past may suddenly appear in the mowing
area for another ride and be run over or backed over
by the machine.
5. Never allow children to operate the unit.
6. Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
Never operate on slopes greater than 17.6 percent
(10°) which is a rise of 3-1/2 feet (106 cm)
vertically in 20 feet (607 cm) horizontally.
Select slow ground speed before driving onto
slope. Use extra caution when operating on
slopes with rear-mounted grass catchers.
Mow across the face of slopes, not up and down,
use caution when changing directions and DO
NOT START OR STOP ON SLOPE.
Do
1. Mow across slopes, not up and down.
2. Remove obstacles such as rocks, tree limbs, etc.
3. Watch for holes, ruts, or bumps. Uneven terrain
could overturn the unit. Tall grass can hide obstacles.
4. Use slow speed. Choose a slow speed so that you
will not have to stop or change speed while on the
slope.
5. Use extra care with grass catchers or other attachments. These can change the stability of the unit.
6. Keep all movement on the slopes slow and gradual.
Do not make sudden changes in speed or direction.
7. See your authorized dealer for recommendations of
available weights to improve stability.
EMISSIONS
1. Engine exhaust from this product contains chemicals
known, in certain quantities, to cause cancer, birth
defects, or other reproductive harm.
2. Look for the relevant Emissions Durability Period and
Air Index information on the engine emissions label.
3
Safety Rules & Information
SERVICE AND MAINTENANCE
10. Let engine cool before storing and do not store near
flame.
11. Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
12. Park machine on level ground. Never allow untrained
personnel to service machine.
13. Use jack stands to support components when
required.
14. Carefully release pressure from components with
stored energy.
15. Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first
and negative last.
16. Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace blades. Never straighten or weld
them.
17. Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
18. Charge batteries in an open well ventilated area,
away from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear protective clothes and use insulated tools.
19. Grass catcher components are subject to wear, damage, and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently
check components and replace with manufacturer’s
recommended parts, when necessary.
20. Check brake operation frequently. Adjust and service
as required.
21. Use only factory authorized replacement parts when
making repairs.
22. Always comply with factory specifications on all settings and adjustments.
23. Only authorized service locations should be utilized
for major service and repair requirements.
24. Never attempt to make major repairs on this unit
unless you have been properly trained. Improper
service procedures can result in hazardous operation, equipment damage and voiding of manufacturer’s warranty.
25. Units with hydraulic pumps, hoses, or motors:
WARNING: Hydraulic fluid escaping under pressure
may have sufficient force to penetrate skin and cause
serious injury. If foreign fluid is injected into the skin
it must be surgically removed within a few hours by a
doctor familiar with this form of injury or gangrene
may result. Keep body and hands away from pin
holes or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, and not hands, to
search for leaks. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines
are in good condition before applying pressure to the
system. If leaks occur, have the unit serviced immediately by your authorized dealer.
26. WARNING: Stored energy device. Improper release
of springs can result in serious personal injury.
Springs should be removed by an authorized technician.
27. Models equipped with an engine radiator: WARNING:
Stored energy device. To prevent serious bodily
injury from hot coolant or steam blow-out, never
attempt to remove the radiator cap while the engine
is running. Stop the engine and wait until it is cool.
Even then, use extreme care when removing the
cap.
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. Never store the machine or fuel container where
there is an open flame, spark, or pilot light such as
near a water heater or other appliance.
6. Never fill containers inside a vehicle or on a truck
bed with a plastic bed liner. Always place containers
on the ground away from your vehicle before filling.
7. Remove gas-powered equipment from the truck or
trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser nozzle.
8. Keep nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
9. If fuel is spilled on clothing, change clothing immediately.
10. Never over-fill the fuel tank. Replace gas cap and
tighten securely.
11. Use extra care in handling gasoline and other fuels.
They are flammable and vapors are explosive.
12. If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of spillage
and avoid creating any source of ignition until fuel
vapors have dissipated.
13. Replace all fuel tank caps and fuel container caps
securely.
Maintenance and Storage
1. Always observe safe refueling and fuel handling
practices when refueling the unit after transportation
or storage.
2. Always follow the engine manual instructions for storage preparations before storing the unit for both
short and long term periods.
3. Always follow the engine manual instructions for
proper start-up procedures when returning the unit to
service.
4. Never store the machine or fuel container inside
where there is an open flame, such as in a water
heater. Allow unit to cool before storing.
5. Shut off fuel while storing or transporting. Do not
store fuel near flames or drain indoors.
6. Keep all hardware, especially blade attachment bolts,
tight and keep all parts in good working condition.
Replace all worn or damaged decals.
7. Never tamper with safety devices. Check their proper operation regularly.
8. Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
9. Clean grass and debris from cutting units, drives,
mufflers, and engine to prevent fires. Clean up oil or
fuel spillage.
4
Safety Rules & Information
ROLL BAR INSTRUCTIONS
• BEFORE FIRST TIME USE - Inspect the ROLL BAR
structure and mounting hardware for:
For models equipped with factory-installed Roll Over
Protection System (ROPS).
1) Check to make sure the machine GVW (Gross
Vehicle Weight), including attachments, restrained
payload, fuel and operator, is not in excess of the
maximum weight specified on the ROLL BAR
label.
WARNING
In order to avoid serious injury or death from roll
over, it is important to follow the warnings listed
below.
2) Make sure there isn’t any missing, damaged, or
loose mounting hardware.
3) Make sure the ROLL BAR has been correctly and
completely installed.
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.
• Remember there is no roll over protection when the
roll bar is in the down position so it is very important
to always keep the roll bar in the raised position
whenever possible.
• Lower the roll bar to the down position only when it is
absolutely necessary.
• Check for overhead clearances before driving under
any objects. Do not allow roll bar to contact low
overhanging obstacles such as tree branches and
guide wires.
• Never remove the roll bar from the vehicle.
• Do not exceed the machine weight rating of the roll
bar.
• Read and follow all of the instructions shown below
regarding the inspection and maintenance of the roll
bar structure and the seat belt.
• EVERY 100 HOURS - Inspect the ROLL BAR structure and mounting hardware for:
1) Any cracks in the structure (structural members
and/or welds).
2) Significant corrosion on any part of the ROLL
BAR structure or hardware.
3) Missing, damaged, or loose mounting hardware
4) Mounting hardware that is of a grade lesser than
specified.
5) Machine GVW (Gross Vehicle Weight), including
attachments, restrained payload, fuel and operator, in excess of the maximum weight specified on
the ROLL BAR label.
6) Any modifications that have been made, such as
unauthorized welds and holes.
WARNING
7) Any permanent deformation or twisting of the
ROLL BAR structure.
Failure to properly inspect and maintain the ROLL
BAR protective structure can cause serious injury
or death.
8) That the ROLL BAR label is still in place and is
readable.
INSPECTION OF THE ROLL BAR PROTECTIVE
STRUCTURE
A ROLL BAR, like any other safety device, needs to be
periodically inspected to verify that the integrity of the
device has not been compromised through normal
machine use, misuse, age degradation, modifications, or a
roll over.
9) That the ROLL BAR on-product warning labels
are still on the ROLL BAR and are readable.
• If there is any doubt as to the condition of the ROLL
BAR, remove the machine from service and contact
your dealer for assistance.
To maintain operator roll over protection and roll bar effectiveness:
• If a ROLL BAR becomes damaged for any reason,
such as a collision, roll over or impact, the ROLL
BAR must be replaced. Small undetectable cracks
can reduce the effectiveness of the ROLL BAR.
Never weld, straighten, or repair the ROLL BAR.
• Never alter the ROLL BAR by welding anything to it
or by drilling additional holes.
5
Safety Rules & Information
INSPECT BUCKLE
& LATCH
WARNING
Failure to properly inspect and maintain the seat
belt can cause serious injury or death.
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.
INSPECT WEBBING
• BEFORE EACH USE – Conduct the following
inspections/maintenance of the seat belt and retraction mechanism:
1) Check for dirt or debris in the retraction mechanism. If dirt or debris is found, it should be
removed.
2) Check to make sure the retraction mechanism
retracts easily and completely.
3) Check for damage to any part of the seat belt
such as nicks, cuts, loose stitching, or fraying.
4) Check that the buckle and latch operate properly
and that the latch plate is not excessively worn,
deformed, or the buckle is damaged or cracked.
The seat belt should latch and release easily.
6
Identification Numbers
Identification Numbers
SA
M
P LE
Powerhead
Identification Tag
SA
Model No.: XXXXXXXXXX
kW:
XXX
Engine RPM: XXXX
LpA:
XX dB(A)
Vibration @ Wheels: XXX
Vibration @ Seat: XXX
M
Ferris Industries, Inc.
Munnsville, NY USA 13409
North American
Models
Mower Deck
Identification Tag
200X
PL XXX
E
CE Models
PRODUCT
XXX
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.
DATA
Unit SERIAL Number
Mower Deck Model Number
Mower Deck SERIAL Number
Dealer Name
Date Purchased
ENGINE REFERENCE DATA
NOTE: For location of engine identification numbers,
refer to the engine owner’s manual.
Engine Make
Engine Model
Engine Type/Spec.
Engine Code/Serial Number
CE IDENTIFICATION TAG MARKINGS
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
REFERENCE
Unit Model Number
A
B
Manufacturer’s Identification Number
Power Rating in Kilowatts
Maximum Engine Speed in Rotations per Minute
Sound Pressure at Operator’s Position in Decibels **
Vibration at the Wheels *
Vibration at the Seat *
Manufacturer’s Address
Year of Manufacture
CE Compliance Logo
Sound Power in Decibels ***
Mass of Unit in Kilograms
I
H
J
C
Model No.: XXXXXXXXXX
kW:
XXX
Engine RPM: XXXX
LpA:
XX dB(A)
Vibration @ Wheels: XXX
Vibration @ Seat:
XXX
D
E
F
Ferris Industries, Inc.
Munnsville, NY USA 13409
200X
XXX
XXX
G
CE Models:
Place copy of
Identification Tag here.
This unit complies with European Harmonized Lawn Mower
Standard EN 836, European Machinery Directive 98/37/EC,
and European EMC Directive 89/336/EC
* Tested according to EN 836:1997/A2:2001, EN 1032:
1996, EN 1033:1995
** Tested according to EN836:1997/A2:2001
*** Tested according to 2000/14/EC
5
K
Safety Decals
GENERAL
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.
The safety decals below are on your rider and mower.
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.
These labels are easily applied and will act as a constant visual reminder to you, and others who may use
the equipment, to follow the safety instructions necessary for safe, effective operation.
If any of these decals are lost or damaged, replace them
at once. See your local dealer for replacements.
All DANGER, WARNING, CAUTION and instructional
messages on your rider and mower should be carefully
read and obeyed. Personal bodily injury can result when
these instructions are not followed. The information is for
your safety and it is important!
Warning Decal
Part No. 22189
Dash Panel Decal
Part No. 22325
Danger Decal
Part No. 1704276
Warning Decal
Part No. 20037
Warning Decal
Part No. 21159
Danger Decal
Part No. 1704277
Danger Decal
Part No. 21411
6
Warning Decal
Part No. 21818
Danger Decal
Part No. 49658
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 handle is not in the NEUTRAL position
Test 2 — Engine SHOULD crank if:
• PTO switch is NOT engaged, AND
• Parking brake is engaged, AND
• Motion control handle is in the NEUTRAL position
Test 3 — Engine should SHUT OFF if:
• Operator releases the operator presence handles
with PTO engaged, OR
• Operator releases the operator presence handles
with parking brake disengaged.
Test 4 — Blade Brake Check
Mower blades and mower drive belt should come to a
complete stop within seven seconds after electric PTO
switch is turned off (or operator releases the operator
presence handles). If mower drive belt does not stop
within seven 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 handle must be returned to the NEUTRAL position in order to start the engine.
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.
7
Features & Controls
Please take a moment and familiarize yourself with the name, location, and function of
these controls so that you will better understand the safety and operating instructions
provided in this manual.
CONTROL FUNCTIONS
The information below briefly describes the function of 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.
Ignition Switch
Forward Speed Control Lever
Reverse Speed Control Levers
These levers control the ground speed of the mower.
The forward lever control the forward ground speed of
both drive wheels.
The left reverse lever controls the steering and reverse
ground speed of the left drive wheel and the right
reverse lever controls the steering and reverse ground
speed of the right drive wheel.
NOTE: The further a lever is moved away from the neutral position the faster the drive wheel will turn.
The ignition switch starts and stops the engine, it has
three positions:
OFF
Stops the engine and shuts off the
electrical system.
RUN
Allows the engine to run and powers the
electrical system.
START Cranks the engine for starting.
NOTE: Never leave the ignition switch in the RUN position with the engine stopped–this drains the battery.
See the Operation section for steering instructions.
8
Features & Controls
Parking Brake Handle
The parking brake is applied by pushing DOWN on the
parking brake handle until it stops. To release the parking brake, pull UP on the handle until it locks over center.
PTO (Power Take Off) Switch
The PTO switch engages and disengages the mower.
Pull UP on the switch to engage, and push DOWN to
disengage.
Engine Kill/Operator Presence Handles
These handles are a major factor in the safety interlock
system of the mower. Both handles are tied together so
depressing one handle depresses both. The operator
must depress the handles in order to deactivate the
engine kill system. Handles must be depressed to disengage the parking brake and engage the PTO switch.
Throttle Control
The throttle controls engine speed. Move the throttle forward to increase engine speed and back to decrease
engine speed. Always operate at FULL throttle.
Choke
Close the choke for cold starting. Open the choke once
the engine starts. A warm engine may not require choking. Pull the knob UP to close the choke. Push to knob
DOWN to open the choke.
Neutral Return Pedal
The neutral return pedal provides a hands-free return to
neutral. This is used in conjunction with the Reverse
Speed Control Levers (B) to properly stop the machine.
See the Operating the Dual Drive Walk-Behind Mower
section for steering instructions.
Fuel Tank Cap
To remove the cap, turn counterclockwise.
Fuel Shut Off Valve (not shown)
The fuel shut off valve is located under the fuel tank.
Turning the handle until it is VERTICAL will allow fuel to
be supplied to the engine. Turning the handle until it is
HORIZONTAL shuts off the fuel supply to the engine.
9
Operation
GENERAL OPERATING SAFETY
CHECKS BEFORE STARTING
Before first time operation:
• Be sure to read all information in the Safety and
Operation sections before attempting to operate this
tractor and mower.
• Check that crankcase is filled to full mark on dipstick.
See the engine Operator’s Manual for instructions
and oil recommendations.
• Make sure all nuts, bolts, screws and pins are in
place and tight.
• Become familiar with all of the controls and how to
stop the unit.
• Fill the fuel tank with fresh fuel. Refer to engine
manual for fuel recommendations.
• Drive in an open area without mowing to become
accustomed to the unit.
WARNING
A
B
Before leaving the operator’s position for any
reason, engage the parking brake, disengage the
PTO, stop the engine and remove the key.
To reduce fire hazard, keep the engine, tractor and
mower free of grass, leaves and excess grease.
Do not stop or park tractor over dry leaves, grass
or combustible materials.
Gasoline is highly flammable and must be
handled with care. Never fill the tank when the
engine is still hot from recent operation. Do not
allow open flame, smoking or matches in the area.
Avoid over-filling and wipe up any spills.
Figure 2.
A.
B.
10
Pre-start Checks
Crankcase Oil Fill
Fuel Tank Filler Neck
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.
DRIVING THE MOWER
The hydrostatic transmission has an infinite number of
speeds between full speed forward and reverse, with the
faster speeds being achieved by moving the speed control lever and steering control levers farthest in the direction of travel.
TO MOVE FORWARD
1. Disengage the parking brake.
2. Gently move the speed control lever forward until
desired speed is achieved.
STARTING THE ENGINE
TO MOVE BACKWARD
1. Engage the parking brake and make sure the PTO
switch is disengaged and the motion control lever is
in the NEUTRAL position.
2. Set the engine throttle control to FAST throttle position. Then fully close the choke by pulling the knob
OUT fully.
1. Disengage the parking brake.
2. Gently squeeze both steering control levers evenly,
until desired speed is achieved.
TO SLOW OR STOP MACHINE
1. Gently squeeze both steering control levers evenly to
slow the machine.
NOTE: A warm engine may not require choking.
2. Continuing to squeeze the steering control levers will
stop the machine.
3A.Insert the key into the ignition switch and turn it to
the RUN position (15hp & 17hp models). Firmly and
sharply pull the recoil until the engine starts.
3. Once the machine is stopped, firmly depress the
neutral return pedal to place the transmissions in
neutral.
3B.Insert the key into the ignition switch and turn it to
the START position (23hp model).
4. After the engine starts, gradually open the choke
(push knob down fully).
TO TURN MACHINE
Warm up the engine by running it for at least a minute
before engaging the PTO switch or driving the mower.
To make a left-hand turn:
5. After warming the engine, ALWAYS operate the
unit at FULL THROTTLE when mowing.
In the event of an emergency the engine can be
stopped by simply turning the ignition switch to
STOP. Use this method only in emergency situations.
For normal engine shut down follow the procedure given
in STOPPING THE MOWER
STOPPING THE MOWER
1. Gently squeeze both steering control levers evenly to
stop the machine.
3. Once the machine is stopped, firmly depress the
neutral return pedal to place the transmissions in
neutral.
2. Disengage the PTO by pushing down on the PTO
switch.
3. Engage the parking brake by pushing the handle forward until it stops.
Gently squeeze the left-hand steering control lever. A
sharp or gentle turn is determined by the amount of
force applied to the steering control lever.
To make a right-hand turn:
Gently squeeze the right-hand steering control lever. A
sharp or gentle turn is determined by the amount of
force applied to the steering control lever.
NOTE: ALWAYS REDUCE SPEED IN A TURN
For normal use, the throttle should be kept fully open
and the ground speed of the machine determined by the
speed control lever. When transporting the machine or
when loading or unloading from a truck or trailer, partial
throttle should be used to slow the reaction time of the
controls and reduce noise.
Practice maneuvering the machine at a slow engine
speed on level ground with the blade engagement switch
in the "OFF" position until you are familiar with the controls.
4. Move the throttle control to mid-throttle position and
turn the ignition key to OFF Remove the key.
11
Operation
MOWING
PUSHING THE MOWER BY HAND
Before mowing, set the cutting height as described in
the Troubleshooting, Adjustments & Service section.
1. Engage the parking brake. Make sure the PTO
switch is disengaged and the motion control lever is
in the NEUTRAL position.
DO NOT TOW MACHINE
Towing the machine will cause hydraulic
transaxle damage. Do not use another vehicle to push or pull this unit.
1. Disengage the PTO, engage the parking brake, turn
the ignition OFF, and remove the key.
2. Start the engine (see STARTING THE ENGINE).
3. Set the throttle to FULL.
2. To disengage the transmissions (free-wheel position),
lift the hydraulic release levers (A, Figure 3) located
in front of the transmission fan screen. Lock into
position shown in Figure 3.
4. Engage the PTO by pulling up on the PTO switch (E,
Figure 1).
5. Begin mowing. See Lawn Care section for tips on
mowing patterns, lawn care, and trouble shooting
information.
3. Disengage the parking brake.
The mower can now be pushed by hand.
6. When finished, shut off the PTO.
4. After moving the mower, re-engage the transmissions (drive position) by unlocking the levers and
returning them to the down position. If the levers are
not completely down, a partial by-pass may potentially damage the transmissions.
7. Stop the engine (see STOPPING THE TRACTOR
AND ENGINE).
A
Figure 3.
A.
12
Hydraulic System By-Pass
Hydraulic Release Lever (right-hand side shown)
Operation
STORAGE
WARNING
Temporary Storage (30 Days Or Less)
Never store the unit, with gasoline in engine or
fuel tank, in a heated shelter or in enclosed,
poorly ventilated enclosures. Gasoline fumes may
reach an open flame, spark or pilot light (such as
a furnace, water heater, clothes dryer, etc.) and
cause an explosion.
Handle gasoline carefully. It is highly flammable
and careless use could result in serious fire
damage to your person or property.
Drain fuel into an approved container outdoors
away from open flame or sparks.
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.
Here is a checklist of things to do when storing your unit
temporarily or in between uses:
• Keep the unit in an area away from where children
may come into contact with it. If there’s any chance
of unauthorized use, remove the spark plug (s) and
put in a safe place. Be sure the spark plug opening is
protected from foreign objects with a suitable cover.
• If the unit can’t be stored on a reasonable level surface, chock the wheels.
• Clean all grass and dirt from the mower.
Long Term Storage (Longer Than 30 Days)
Before you store your unit for the off-season, read the
Maintenance and Storage instructions in the Safety
Rules section, then perform the following steps:
1. Drain crankcase oil while engine is hot and refill with
a grade of oil that will be required when unit is used
again.
2. Prepare the mower deck for storage as follows:
a. Remove mower deck from the unit.
b. Clean underside of mower deck.
c. Coat all bare metal surfaces with paint or light coat
of oil to prevent rusting.
3. Clean external surfaces and engine.
4. Prepare engine for storage. See engine owner’s
manual.
10. Drain fuel system completely or add a gasoline stabilizer to the fuel system. If you have chosen to use a
fuel stabilizer and have not drained the fuel system,
follow all safety instructions and storage precautions
in this manual to prevent the possibility of fire from
the ignition of gasoline fumes. Remember, gasoline
fumes can travel to distant sources of ignition and
ignite, causing risk of explosion and fire.
NOTE: Gasoline, if permitted to stand unused for
extended periods (30 days or more), may develop
gummy deposits which can adversely affect the engine
carburetor and cause engine malfunction. To avoid this
condition, add a gasoline stabilizer to the fuel tank and
run the engine a few minutes, or drain all fuel from the
unit before placing it in storage.
STARTING AFTER LONG TERM
STORAGE
Before starting the unit after it has been stored for a long
period of time, perform the following steps.
1. Remove any blocks from under the unit.
5. Clean any dirt or grass from cylinder head cooling
fins, engine housing and air cleaner element.
2. Install the battery if it was removed.
6. Cover air cleaner and exhaust outlet tightly with plastic or other waterproof material to keep out moisture,
dirt and insects.
4. Fill the fuel tank with fresh gasoline. See engine
manual for recommendations.
3. Unplug the exhaust outlet and air cleaner.
5. See engine owner’s manual and follow all instructions for preparing engine after storage.
7. Completely grease and oil unit as outlined in the
Normal Care section.
6. Check crankcase oil level and add proper oil if
necessary. If any condensation has developed during
storage, drain crankcase oil and refill.
8. Clean up unit and apply paint or rust preventative to
any areas where paint is chipped or damaged.
9. Be sure the battery is filled to the proper level with
water and is fully charged. Battery life will be
increased if it is removed, put in a cool, dry place
and fully charged about once a month. If battery is
left in unit, disconnect the negative cable.
7. Inflate tires to proper pressure. Check fluid levels.
8. Start the engine and let it run slowly. DO NOT run at
high speed immediately after starting. Be sure to run
engine only outdoors or in well ventilated area.
13
Regular Maintenance
MAINTENANCE SCHEDULE & PROCEDURES
The following schedule should be followed for normal care of your mower. You will need to keep a record of your
operating time.
See
Page
SAFETY ITEMS
Check Safety Interlock System
●
9
Check Mower Blade Stopping Time
29
See
Page
NORMAL CARE ITEMS
Check Rider/Mower for loose hardware
—
Check Engine Oil Level
15*
Check Engine Air Filter
15*
Check / Adjust PTO Clutch
29
Change Engine Oil & Filter **
15*
Change Transmission Oil & Filters
28
Lubricate Mower & Mower Deck
16
Check Mower Deck Belt Tension***
Before
Before
First Use Each Use
Every
Every
Every
5 Hours 25 Hours 100 Hours
●
●
Before
Before
First Use Each Use
●
●
●
Every
Every
Every
5 Hours 25 Hours 100 Hours
●
●
●
●
●
****●
*****●
****● Every 50 Hours
●
****●
●
14
●
****●
Check Hydraulic Fluid
15
●
****●
Check Fuel Filter
15
●
Clean Battery & Cables
17
●
Clean & Sharpen Mower Blades
18
●
Inspect Spark Plug
15*
●
See the engine manufacturer's owner's manual.
**
Change original engine oil after first 5 hours of operation.
***
Check belt tension after first 5 hours of operation.
****
More often in hot (over 85° F: 30° C) weather or dusty operating conditions.
*****
Service after the first 25 hours, then after every 100 hours.
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.
Tire
Pressure
25 psi (172 kPa)
Rear
15 psi (103 kPa)
****●
****● Every 500 Hours
24/25
Front
Spring
& Fall
●
Check Tire Pressure
*
Spring
& Fall
Figure 4.
14
Checking Tire Pressure
Regular Maintenance
CHECKING / ADDING FUEL
WARNING
To add fuel:
1. Remove the fuel cap (see A, Figure 2).
Gasoline is highly flammable and must be
handled with care. Never fill the tank when the
engine is still hot from recent operation. Do not
allow open flame, smoking or matches in the area.
Avoid over-filling and wipe up any spills.
Do not remove fuel filter when engine is hot, as
spilled gasoline may ignite. DO NOT spread hose
clamps further than necessary. Ensure clamps
grip hoses firmly over filter after installation.
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.
FUEL FILTER
The fuel filter (D, Figure 2) is located in the fuel line
between fuel shut off valve and carburetor, near the fuel
pump. If filter is dirty or clogged, replace as follows:
1. Shut off the fuel tank selection valve.
Do not use gasoline containing METHANOL,
gasohol containing more than 10% ethanol,
gasoline additives, premium gasoline, or white
gas because engine/fuel system damage
could result.
2. Disconnect the negative battery cable.
3. Place a container below the filter to catch spilled fuel.
4. Using a pliers, open and slide hose clamps from fuel
filter.
A
5. Remove hoses from filter.
6. Install new filter in proper flow direction in fuel line.
7. Secure with hose clamps.
8. Reconnect the negative battery cable when finished.
B
OIL & FILTER CHANGE
Refer to engine owners manual.
CHECK / CHANGE AIR FILTER
Refer to engine owners manual.
C
REPLACE SPARK PLUG
Refer to engine owners manual.
CHECK HYDRAULIC OIL LEVEL
1. Observe the oil reservoirs (B, Figure 2). The oil level
should be at the “FULL” line (C, figure 2).
2. Before removing the reservoir caps, make sure the
area around the reservoir cap is free of dust, dirt, or
other debris.
D
Figure 5.
A.
B.
C.
D.
3. If necessary, unscrew the reservoir cap and add SAE
straight 20 or 30 weight motor oil. DO NOT use
multi-grade oils. Fill until oil level reaches “FULL”
line.
4. Reinstall oil reservoir caps.
15
Fuel Tank, Oil Reservoir & Fuel Filter
Fuel Cap
Oil Reservoirs
“FULL” Line
Fuel Filter
Regular Maintenance
LUBRICATION
Lubricate the machine at the lubrication points shown in
Figures 6 - 11.
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 22285) is strongly recommended. Automotive-type
high-temperature, lithium grease may be used when this
is not available.
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 6.
Figure 8.
Blade Spindles
Figure 9.
Caster Tire Pivots & Axles
Motion Control Pivot & Rod Pivot
Figure 10. Steering Lever Pivots & Operator
Presence Pivots
Figure 7.
Lower Motion Control Pivots & Neutral
Return Pedal Pivot
Figure 11. Parking Brake Lever Pivot & Link Pivot
16
Regular Maintenance
BATTERY MAINTENANCE
Checking the Battery Fluid
NOTE: It is not necessary to check the battery fluid
level if machine is equipped with a maintenance-free
battery.
A
1. Remove the battery box cover to access the battery.
2. Remove the battery filler cap(s) (A, Figure 12). Fluid
must be even with the split ring full mark. If not, add
distilled water.
3. Reinstall the filler cap(s).
Cleaning the Battery and Cables
B
1. Disconnect the cables from the battery, negative
cable first (C, Figure 12).
C
2. Clean the battery terminals and cable ends with a
wire brush until shiny.
3. Reinstall the battery and reattach the battery cables,
positive cable first (see B, Figure 12)
Figure 12. Battery Compartment
A.
B.
C.
4. Coat the cable ends and battery terminals with petroleum jelly or non-conducting grease.
WARNING
Be careful when handling the battery. Avoid
spilling electrolyte. Keep flames and sparks away
from the battery.
When removing or installing battery cables,
disconnect the negative cable FIRST and reconnect
it LAST. If not done in this order, the positive
terminal can be shorted to the frame by a tool.
17
Vent Cap(s)
Positive (+) Cable & Terminal
Negative (-) Cable & Terminal
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. Remove the deck guard.
3. Raise the mower deck and secure with jackstands.
4. To remove blade for sharpening, use two (2) 15/16”
wrenches to remove the nut from the top of the blade
bolt. (Figure 13).
5. Use a file or hand-held grinder, sharpen blade to fine
edge. Remove all nicks and dents in blade edge. If
blade is severely damaged, it should be replaced.
LOOSEN
6. Balance the blade as shown in Figure 14. Center the
blade’s hole on a nail lubricated with a drop of oil. A
balanced blade will remain level.
Figure 13. Removing the Blade
7. Reinstall each blade with the tabs pointing up toward
deck as shown in Figure 15. The blade spacers,
blade, washer and bolt must be reinstalled in the
exact same order in which they were removed.
Torque bolts to 70-90 ft.lbs. (94-120 N.m.).
WARNING
Nail
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.For your personal
safety, blade mounting bolts must each be
installed with a flat washer then securely
tightened. Torque blade mounting bolts to
70-90 ft.lbs. (94-120 N.m.)
Figure 14. Balancing the Blade
B
A
TIGHTEN
Figure 15. Installing the Blade
A.
B.
18
Bolt
Flat Washer
Troubleshooting
Adjustments & Service
TROUBLESHOOTING
WARNING
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.
To avoid serious injury, perform maintenance on
the mower only when the engine is stopped and
the parking brake engaged.
The troubleshooting guide below lists the most common
problems, their causes and remedies.
Always remove the ignition key, disconnect the
spark plug wire and fasten it away from the plug
before beginning the maintenance, to prevent
accidental starting of the engine.
See the information on the following pages for instructions on how to perform most of these minor adjustments and service repairs yourself. If you prefer, all of
these procedures can be performed for you by your local
authorized dealer.
TROUBLESHOOTING THE MOWER
PROBLEM
CAUSE
REMEDY
Engine will not turnover or start.
1.
2.
1. Engage parking brake.
2. Place in OFF position.
3.
4.
5.
6.
7.
8.
Engine starts hard or runs poorly.
Parking brake not engaged.
PTO (electric clutch) switch
in ON position.
Out of fuel.
Engine flooded.
Fuse blown.
Battery terminals require
cleaning.
Battery discharged or dead.
Wiring loose or broken.
9. Solenoid or starter motor faulty.
10. Safety interlock switch
faulty.
11. Spark plug(s) faulty, fouled
or incorrectly gapped.
12. Water in fuel.
13. Gas is old or stale.
1. Fuel mixture too rich.
2.
Engine knocks.
Excessive oil consumption.
Engine exhaust is black.
Spark plug faulty, fouled, or
incorrectly gapped.
1. Low oil level.
2. Using wrong grade oil.
1. Engine running too hot.
2. Using wrong weight oil.
3. Too much oil in crankcase.
1. Dirty air filter.
2. Engine choke control
is in closed position.
19
3. If engine is hot, allow it to cool, then refill
the fuel tank.
4. Move throttle control out of CHOKE position.
5. Replace fuse.
6. Clean the battery terminals
7. Recharge or replace.
8. Visually check wiring & replace broken or
frayed wires. Tighten loose connections.
9. Repair or replace. See authorized service dealer
10. Replace as needed. See authorized
service dealer.
11. Clean and gap or replace.
See engine manual.
12. Drain fuel & refill with fresh fuel.
13. Drain fuel & replace with fresh fuel.
1. Clean air filter. Check choke adjustment
(throttle control).
2. Clean and gap or replace.
(See engine manual.)
1. Check/add oil as required.
2. See engine manual.
1. Clean engine fins, blower screen and
air cleaner.
2. See engine manual.
3. Drain excess oil.
1. Replace air filter. See engine manual.
2. Open choke control.
Troubleshooting, Adjustment & Service
Rider Troubleshooting Continued.
PROBLEM
CAUSE
REMEDY
Engine runs, but mower will
not drive.
1.
1. Move into drive position.
Brake will not hold.
2.
3.
4.
1.
2.
1.
Mower steers hard or
handles poorly.
1.
2.
Transmission drive belt slips.
Transmission release lever(s)
in “neutral” position.
Belt is broken.
Drive belt slips.
Brake is not fully released.
Pulleys or belt greasy or oily.
Belt stretched or worn.
Internal brake disc on
transaxle worn.
Steering linkage is loose.
Improper tire inflation.
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 authorized service dealer
1. Check and tighten any loose connections.
2. See Regular Maintenance Section.
TROUBLESHOOTING THE MOWER DECK
PROBLEM
CAUSE
REMEDY
Mower cut is uneven.
1.
2.
1. See Mower Adjustment.
2. See Regular Maintenance Section.
4.
1. Set throttle to full.
2. Decrease Ground Speed.
3. Sharpen or replace blades.
See Mower Blade Service.
4. Clean or replace belt as necessary.
Mower cut is rough looking.
Mower not leveled properly.
Drive tires not inflated
equally or properly.
1. Engine speed too slow.
2. Ground speed too fast.
3. Blades are dull.
5.
Engine stalls easily with
mower engaged.
1.
2.
3.
4.
Excessive mower vibration.
1.
2.
3.
Excessive belt wear or breakage.
Mower drive belt slips
or fails to drive.
4.
1.
2.
1.
1.
2.
Mower drive belt slipping
because it is oily or worn.
Blades not properly fastened
to arbors.
Engine speed too slow.
Ground speed too fast.
Cutting height set too low.
Discharge chute jamming
with cut grass.
Blade mounting screws
are loose.
Mower blades, arbors,
or pulleys are bent.
Mower blades are out
of balance.
Belt installed incorrectly.
Bent or rough pulleys.
Using incorrect belt.
Belt tension improperly adjusted.
Idler pulley spring broken or not
properly adjusted.
Mower drive belt broken.
20
5. See Servicing the Mower Blades.
1. Set to full throttle.
2. Decrease Ground Speed.
3. Cut tall grass at maximum cutting
height during first pass.
4. Cut grass with discharge pointing toward
previously cut area.
1. Tighten to 70-90 ft.lbs. (94-120 N.m.).
2. Check and replace as necessary.
3. Remove, sharpen, and balance blades.
See Maintenance Section.
4. Reinstall Correctly.
1. Repair or replace.
2. Replace with correct belt.
1. Adjust belt tension. See Belt Replacement
1. Repair or adjust as needed.
2. Replace drive belt.
Troubleshooting, Adjustment & Service
MOWING HEIGHT ADJUSTMENT
Height Of Cut
The mowing height is determined by three factors: the
mount position of the mower deck, the number of blade
spacers above the spindle and the number of caster
spacers above the caster arm.
1-3/4”
2”
2-1/4”
2-1/2”
2-3/4”
3”
3-1/4”
3-1/2”
3-3/4”
4”
Refer to the Height Of Cut chart to the right for the correct settings to obtain the desired height of cut.
Remember, the “Blade Spacers” and “Caster Spacers”
columns refer to the number ABOVE the spindle and
caster arm. See Figure 16.
Mount
Blade
Caster
Position
Spacers
Spacers
(C, Fig. 16) (B, Fig. 16) (A, Fig. 16)
U
1
3
U
2
3
U
3
3
U
3
2
L
4
2
L
2
1
L
3
1
L
3
0
L
4
0
L
5
0
C
A
B
B
A
Figure 16. Mowing Height Adjustment Points
A.
B.
C.
Caster Spacers
Blade Spacers
Deck Mount Position (shown in “L”)
IDLER PULLEY HEIGHT
ADJUSTMENT
DDS48 & DDS48R ONLY
If a mowing height of 2-1/2” or lower is desired, the deck
drive belt ider pulley height needs to be adjusted.
1. Remove the deck drive belt. See MOWER BELT
REPLACEMENT AND ADJUSTMENT section on
page 24.
2. Move the idler pulley spacers from the top of the pulley to the bottom of the pulley. See Figure 17.
3. Reinstall the deck drive belt. See MOWER BELT
REPLACEMENT AND ADJUSTMENT section on
page 24.
Figure 17. Adjust Idler Pulley Spacer Position
21
Troubleshooting, Adjustment & Service
DECK LEVELING ADJUSTMENT
(DDSH Models only)
1. Make sure there is one spacer above and below the
frame on the front caster shafts and place hairpin
clips in the 2” cutting height position (see Figure 18).
B
2. Rotate the blade on the RIGHT-HAND side (discharge side) until the tip faces the front of the
machine.
A
Figure 18. Caster Spacers & Hairpin Clip
A.
B.
Caster Spacer
Hairpin Clip
3. Loosen the jam nuts (A, Figure 19) located on the
front deck hanger shafts (B). Turn the right side shaft
until a cutting height of 2” is obtained at the very tip
of the blade towards the front of the machine.
B
A
Figure 19. Front Hanger Shaft Adjustment
A.
B.
Jam Nut
Front Hanger Shaft
4. Now place a straight edge on top of the cutter deck
approximately 1” to the outside of the front deck
mount on the right side and measure to the floor
(see Figure 20). Record your measurement.
5. Repeat the measuring procedure listed in Step 4 for
the left-hand side of the mower deck.
Straight Edge
6. Compare the measurements taken in Step 4 & 5. If
they differ by more than 1/16”, the front deck hanger
shaft on the LEFT side (non-discharge side) must be
adjusted.
Measure Here
7. Adjust the two front hanger shafts as needed until
the tip of the blade is 2” from the floor and the measurements taken from the top of the deck to the floor
are within 1/16" of each other.
Figure 20. Mowing Height Measurement
8. Once the level of the deck has been adjusted, there
should be no slack in the front hanger shafts. If one
shaft moves, a shim (P/N 20928) is required.
22
Troubleshooting, Adjustment & Service
Shimming the Hanger Shafts
Once it has been determined that a shim (P/N 20928) is
required, you first must determine which rear hanger
shaft requires the shim.
B
A
The shim (A, Figure 21) must be placed in between the
spacer (B) and the retaining collar (C) on the OPPOSITE side from which the front shaft has movement or
slack (see Figure 22).
Once the shim has been assembled in the proper location, repeat Step 2 - 8 in the DECK LEVELING
ADJUSTMENT section. This adjustment may need to
be repeated more than once until the proper number of
shims has been installed to obtain the proper cutting
height, equal measurements from side to side and no
movement of the front hanger shafts.
C
Figure 21. Shim Assembly Position
A.
B.
C.
Shim
Spacer
Retaining Collar
Figure 22. Proper Shim Location
MOWING HEIGHT ADJUSTMENT
CUTTING HEIGHT
(DDSH Models only)
C
CASTER SPACER PLACEMENT
Refer to the Height Selection decal (A, Figure 23) located on the deck hanger frame and adjust the positions of
the caster spacers and hairpins to obtain the desired
mowing height. Perform adjustment to all four shafts.
2-1/4
2
1-3/4
2-3/4
2-1/2
2-1/4
3-1/4
3
2-3/4
3-3/4
3-1/2
3-1/4
4-1/4
4
3-3/4
4-3/4
4-1/2
4-1/4
46028
A
B
Figure 23. Mowing Height Adjustment
A.
B.
C.
23
Height Selection Decal
Caster Spacer
Hairpin Clip
Troubleshooting, Adjustment & Service
MOWER BELT REPLACEMENT AND
ADJUSTMENT
To avoid damaging belts, DO NOT
PRY BELTS OVER PULLEYS.
PTO Clutch to Deck Belt
A
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.
D
C
E
Check
Tension Here
2. Remove the mower deck guard.
3. Remove the rear engine deck guard.
4. Loosen the wing nut (C, Figure 24) to release the
belt tension on the deck drive belt (B).
5. Slide the drive belt over the edge of the spindle pulley and then slide the belt around the idler pulley.
Drop the belt from the PTO clutch pulley groove.
B
F
6. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves.
Figure 24. PTO Clutch to Deck Belt
A.
B.
C.
7. Install the drive belt on the PTO pulley, the idler pulley and center spindle pulley. Tighten the wing nut
(C, Figure 24) until a 10 lb. (44.5 newton) force is
required to deflect the belt 1/2” (1,27cm) between the
idler pulley and center spindle pulley. Jam hex nut
(D) against anchor. See Figure 23.
8. Run the mower under no-load condition for about 5
minutes to break-in the new belt and re-check belt
tension. Adjust if necessary.
Stationary Idler Pulley
Deck Drive Belt
Wing Nut
D. Hex Nut
E. Adjustable Idler Pulley
F. Center Spindle Pulley
C
B
Spindle Belt
A
1. Remove PTO clutch to Deck belt. See instructions
above.
2. Loosen the nylon nut (C, Figure 25) to release the
belt tension on the spindle drive belt (B).
3. Slide the drive belt over the edge of one of the spindle pulleys and then slide the belt around the idler
pulley and remaining spindle pulleys.
A
D
A
4. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves (for single v-section belts).
Figure 25. Spindle Drive Belt
A.
B.
C.
D.
5. Install the spindle drive belt on the spindle pulleys
and the idler pulley. Tighten the nylon nut (C, Figure
25) until a 10 lb. (44.5 newton) force is required to
deflect the belt 1/2” (1,27cm) between the idler pulley
and right-hand spindle pulley. See Figure 25.
6. Run the mower under no-load condition for about 5
minutes to break-in the new belt and re-check belt
tension. Adjust if necessary.
Check
Tension Here
24
Spindle Pulley
Spindle Drive Belt
Nylon Lock Nut
Idler Pulley
Troubleshooting, Adjustment & Service
MOWER BELT REPLACEMENT AND
ADJUSTMENT
(DDSH Models only)
To avoid damaging belts, DO NOT
PRY BELTS OVER PULLEYS.
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.
B
A
2. Remove the mower deck guard.
3. Remove the rear engine deck guard.
Figure 26. 52” Mower PTO Belt
A.
B.
4. Loosen the spring compression nut (B, Figure 26 &
27) to release the belt tension.
Belt Tension Spring
Spring Compression Nut
5. Slide the drive belt over the edge of the idler pulley
and then slide the belt under the idler pulley. Drop
the belt from the PTO clutch pulley groove.
B
6. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves (Figure 28).
A
7. Install the drive belt on the PTO pulley, the spindle
pulleys and idler pulleys. Tighten the spring compression nut (B, Figure 26 & 27) until the belt tension
spring (A, Figure 26 & 27) is 3/4” (1,90cm) long.
8. Run the mower under no-load condition for about 5
minutes to break-in the new belt and re-check spring
length. Adjust if necessary.
Figure 27. 61” Mower PTO Belt
A.
B.
Belt Tension Spring
Spring Compression Nut
C
D
A
A
B
D
A
D
Figure 28. Mower PTO Belt Routing
A.
B.
25
Spindle Pulley
PTO Drive Belt
C. Spring-loaded Idler Pulley
D. Stationary Idler Pulley
Troubleshooting, Adjustment & Service
TRANSMISSION DRIVE BELT
REPLACEMENT
B
C
A
D
To avoid damaging belts, DO NOT
PRY BELTS OVER PULLEYS.
FRONT
E
I
1. Remove the deck drive belt. See MOWER BELT
REPLACEMENT AND ADJUSTMENT sections.
2. Remove the grass screen that covers the transmission cooling fans.
F
3. Remove the clutch anchor bolts (A, Figure 29) that
fasten the clutch anchor pad to the anchor.
4. Unplug the PTO clutch from the wire harness.
G
5. Remove the spring anchor nut (E) and remove the
belt tension spring (D).
G
H
Figure 29. Transmission Drive Belt
WARNING
A.
B.
C.
D.
E.
STORED ENERGY DEVICE: Improper release of
the belt tension spring can result in personal
injury.
Use extreme caution when removing this spring.
6. Drop the belt (H) from the crankshaft pulley and
around the PTO clutch.
7. From the front of the machine, pull the belt towards
the front while sliding it up and over the transmission
cooling fans.
8. Remove the old belt and replace with a new one.
Make sure the V-side of the belt runs in the pulley
grooves.
9. Install belt over the transmission cooling fans and on
the transmission input pulleys (G), around the idler
pulleys (F & I) and on the crankshaft pulley.
10. Reinstall the belt tension spring (D) onto the anchor
bolt and reinstall the nylon nut (E).
11. Plug the PTO clutch into the wire harness.
12. Reinstall the clutch anchor pad and hardware (B &
A). Tighten securely.
13. Reinstall grass screen and fasten securely.
14. Reinstall the deck drive belt. See MOWER BELT
REPLACEMENT AND ADJUSTMENT sections.
26
Anchor Hardware
Clutch Anchor Pad
PTO Clutch & Drive Pulley
Belt Tension Spring
Spring Anchor Nut
F.
G.
H.
I.
Spring-loaded Idler Pulley
Transmission Input Pulley
Belt
Stationary Idler Pulley
Troubleshooting, Adjustment & Service
TRANSMISSION NEUTRAL &
TRACKING ADJUSTMENTS
Neutral Adjustment
1. Park the machine on a smooth, level surface such as
a concrete floor, away from bystanders and preferably facing a wall. Disengage the PTO, engage the
parking brake, turn off the engine, and remove the
ignition key.
2. Chock the front caster wheels. Raise the drive
wheels off the ground and secure the machine with
jack stands.
3. Start the engine and adjust throttle control to SLOW
(lowest setting). See the STARTING THE ENGINE
section for proper starting instructions.
B
A
Figure 30. Neutral & Tracking Adjustment Points
A.
B.
4. Disengage the parking brake.
Left-Hand Adjustment
Right-Hand Adjustment
5. Using a 1/2” deep socket, SLOWLY turn the adjustment nut COUNTER-CLOCKWISE until the drive tire
begins to rotate forward.
6. SLOWLY turn the adjustment nut CLOCKWISE until
the drive tire begins to rotate backwards.
7. Set the adjustment half way in between where the
forward and backwards rotations began.
8. Adjust the throttle control to FULL (highest setting).
Cycle the speed control lever and neutral return
pedal several times to insure and accurate adjustment has been made.
Tracking Adjustment
Before making a tracking adjustment, be sure to check
the following:
• Drive tires are inflated to 15 psi (103 kPa).
• Caster tires are inflated to 25 psi (172 kPa), are
greased and turn freely.
• All controls are free from damage and operate freely.
• Machine is at full operating temperature.
• Make sure the machine is in neutral when the foot
pedal is depressed. If not, adjust neutral as
described above.
If Machine Veers to the LEFT:
If Machine Veers to the RIGHT:
1. Turn the LEFT adjustment nut 1/8 - 1/4 turn
COUNTER-CLOCKWISE.
1. Turn the RIGHT adjustment nut 1/8 - 1/4 turn
COUNTER-CLOCKWISE.
2. Turn the RIGHT adjustment nut 1/8 - 1/4 turn
CLOCKWISE.
2. Turn the LEFT adjustment nut 1/8 - 1/4 turn
CLOCKWISE.
3. Drive machine on a flat, level surface to test and
repeat steps 1 & 2 as necessary.
3. Drive machine on a flat, level surface to test and
repeat steps 1 & 2 as necessary.
27
Troubleshooting, Adjustment & Service
TRANSMISSION MAINTENANCE
AND SERVICE
B
The hydrostatic transmissions are sealed units that
require no maintenance other than the following.
• Keep the grass screen and transmission cooling fins
clear or grass, leaves and debris.
• Keep oil level in the reservoirs (A, Figure 31) at the
“FULL” line (B). Extra oil in the reservoir will not benefit the machine.
C
• If it is necessary to add oil to the reservoirs, use SAE
straight 20 or 30 weight motor oil. DO NOT use a
multi-grade oils. Make sure the area around the oil
reservoirs is free from dust, dirt and debris before
opening the reservoirs.
Figure 31. Oil Reservoirs
• Make sure the oil reservoirs caps are tight.
A.
B.
• Keep water, dirt and debris from entering the oil
reservoirs. A small amount of a contaminant could
damage the transmissions.
Oil Reservoirs
“FULL” Line
Make sure transmissions and immediate surrounding areas are free from
dirt and debris before changing the
oil and filters. Cleanliness while performing this operation is extremely
important.
Changing Oil & Filters
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.
Figure 32. Transmission Oil Filter Location
2. Place a drain pan under each transmission and
remove the filters to drain the oil. See Figure 32.
(left-hand side shown)
3. Once oil has drained from transmissions, replace
with new filters (P/N 5021068X1), placing a light film
on the seal of the filter before installing. Hand-tighten filter only.
4. Fill oil reservoirs 3/4 full with SAE straight 20 or 30
weight motor oil.
To Bleed Air From Transmissions
4. Run engine for 5 minutes. Watch the oil level in the
reservoirs. Add oil to the “FULL” line (B, Figure 31)
as necessary.
1. Locate the machine in a secure area, away from
bystanders and preferably facing a wall. Raise the
drive tires off the ground and secure with jackstands.
5. With engine running, cycle controls forward and
reverse untile positive responce to the drive is
achieved. Do not attempt to move the unit until bleeding is complete or serious damage may occur.
2. Continue to fill reservoirs to the full line until the oil
level stops going down.
3. Start the engine and adjust throttle control to just
above idle. See the STARTING THE ENGINE section for proper starting instructions.
6. Watch oil levels for the next few days and add oil to
the reservoirs as necessary.
28
Troubleshooting, Adjustment & Service
A
B
B
B
C
Figure 34. Adjust PTO Clutch
B
A.
B.
C.
A
Window
Adjustment Nut
.016”-.018” (0,40-0,45mm) Feeler Gauge
Figure 33. PTO Clutch Adjustment
A.
B.
Adjustment Window (Qty. 3, one shown)
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.
1. Remove key from ignition switch and disconnect
spark plug wires to prevent the possibility of accidental starting while the PTO is being adjusted.
2. See Figure 33. Note the position of the 3 adjustment
windows (A) in the side of the brake plate and the
nylock adjustment nuts (B).
3. Insert a .016”-.018” (0,40-0,45mm) feeler gauge (C)
through each window, positioning the gauge between
the rotor face and the armature face as shown in
Figure 34.
WARNING
To avoid serious injury, perform adjustments only
with engine stopped, key removed and machine
on level ground.
Blade Brake Check
Mower blades and mower drive belts should come to a
complete stop within seven seconds after electric PTO
switch is turned off.
1. Remove deck guard(s) for checking blade brake stop
time ONLY. NEVER OPERATE the machine without
guard(s) in place.
1. With parking brake engaged and PTO disengage,
start the engine engine.
4. Alternately tighten the adjustment nuts (B, Figure 33)
until the rotor face and armature face just contacts
the gauge.
2. Observe the mower drive belt. Engage the PTO and
wait several seconds. Disengage the PTO and check
the amount of time it takes for the mower drive belt
to stop.
5. Check the windows for an equal amount of tension
when the gauge is inserted and removed, and make
any necessary adjustments by tightening or loosening the adjustment nuts.
3. If the mower drive belt does not stop within seven
seconds, perform the PTO Clutch Adjustment. If the
belt still does not stop within seven seconds, see
your dealer.
NOTE: The actual air gap between the rotor and armature may vary even after performing the adjustment procedure. This is due to dimensional variations on component parts, and is an acceptable condition.
6. Check the mower blade stopping time. The mower
blades and mower drive belt should come to a complete stop within seven seconds after the electric
PTO switch is turned off.
29
Troubleshooting, Adjustment & Service
BATTERY SERVICE
Jump Starting With Auxiliary (Booster)
Battery
WARNING
Jump starting is not recommended. However, if it must
be done, follow these directions. Both booster and discharged batteries should be treated carefully when using
jumper cables. Follow the steps below EXACTLY, being
careful not to cause sparks. Refer to Figure 35.
1. Both batteries must be of the same voltage.
Keep open flames and sparks away from the
battery; the gasses coming from it are highly
explosive. Ventilate the battery well during
charging.
2. Position the vehicle with the booster battery adjacent
to the vehicle with the discharged battery so that
booster cables can be connected easily to the batteries in both vehicles. Make certain vehicles do not
touch each other.
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.
3. Wear safety glasses and shield eyes and face from
batteries at all times. Be sure vent caps are tight.
Place damp cloth over vent caps on both batteries.
A dead battery or one too weak to start the engine may
not mean the battery needs to be replaced. For example, it may mean that the alternator is not charging the
battery properly. If there is any doubt about the cause of
the problem, see your dealer. If you need to replace the
battery, follow the steps under Cleaning the Battery &
Cables in the Regular Maintenance Section.
4. Connect positive (+) cable to positive post of discharged battery (wired to starter or solenoid).
5. Connect the other end of same cable to same post
marked positive (+) on booster battery.
6. Connect the second cable negative (-) to other post
of booster battery.
Charging a Completely Discharged Battery
1. Be aware of all the safety precautions you should
observe during the charging operation. If you are
unfamiliar with the use of a battery charger and
hydrometer, have the battery serviced by your dealer.
7. Make final connection on engine block of stalled
vehicle away from battery. Do not lean over batteries.
8. Start the engine of the vehicle with the booster battery. Wait a few minutes, then attempt to start the
engine of the vehicle with the discharged battery.
2. Add distilled water sufficient to cover the plate (fill to
the proper level near the end of the charge). If the
battery is extremely cold, allow it to warm before
adding water because the water level will rise as it
warms. Also, an extremely cold battery will not
accept a normal charge until it becomes warm.
9. If the vehicle does not start after cranking for thirty
seconds, STOP PROCEDURE. More than thirty seconds seldom starts the engine unless some mechanical adjustment is made.
3. Always unplug or turn the charger off before attaching or removing the clamp connections.
10. After starting, allow the engine to return to idle
speed. Remove the cable connection at the engine
or frame. Then remove the other end of the same
cable from the booster battery.
4. Carefully attach the clamps to the battery in proper
polarity (usually red to [+] positive and black to [-]
negative).
11. Remove the other cable by disconnecting at the discharged battery first and then disconnect the opposite end from the booster battery.
5. While charging, periodically measure the temperature of the electrolyte. If the temperature exceeds
125° F (51.6° C), or if violent gassing or spewing of
electrolyte occurs, the charging rate must be reduced
or temporarily halted to prevent battery damage.
12. Discard the damp cloths that were placed over the
battery vent caps.
6. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and
the electrolyte temperature is at least 60° F). The
best method of making certain a battery is fully
charged, but not over charged, is to measure the
specific gravity of a cell once per hour. The battery
is fully charged when the cells are gassing freely at
low charging rate and less than 0.003 change in specific gravity occurs over a three hour period.
30
Troubleshooting, Adjustment & Service
THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES
To
Starter
Switch
To
Starter
Switch
Jumper Cable
Starting
Vehicle
Battery
Discharged
Vehicle
Battery
Jumper Cable
To Ground
Engine
Block
MAKE CERTAIN VEHICLES DO NOT TOUCH
Figure 35. Jump Starting
WARNING
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. If a frozen battery is suspected, examine
all fill vents on the battery. If ice can be seen or if
the electrolyte fluid cannot be seen, do not
attempt to start with jumper cables as long as the
battery remains frozen.
For your personal safety, use extreme care when
jump starting. Never expose battery to open flame
or electric spark – battery action generates
hydrogen gas which is flammable and explosive.
Do not allow battery acid to contact skin, eyes,
fabrics, or painted surfaces. Batteries contain a
sulfuric acid solution which can cause serious
personal injury or property damage.
When removing or installing battery cables,
disconnect the negative cable FIRST and
reconnect it LAST. If not done in this order, the
positive terminal can be shorted to the frame by a
tool.
To avoid engine damage, do not disconnect
battery while engine is running. Be sure terminal
connections are tight before starting.
31
Specifications
NOTE: Specifications are correct at time of printing and are subject to change without notice.
* Actual sustained equipment horsepower will likely be lower due to operating limitations and environmental factors.
ENGINE:
CHASSIS:
15 HP* Kawasaki Manual Start
Fuel Tanks
Rear Wheels
Make
Model
Horsepower
Displacement
Electrical System
Oil Capacity
Kawasaki
FH451V
15 @ 3600 rpm
26.30 Cu. in (431 cc)
12 Volt Clutch Coil, 13 amp
3.8 pt. (1.8L) w/ Filter
17 HP* Kawasaki Manual Start
Make
Model
Horsepower
Displacement
Electrical System
Oil Capacity
Kawasaki
FH500V
17 @ 3600 rpm
30.15 Cu. in (494 cc)
12 Volt Clutch Coil, 13 amp
3.8 pt. (1.8L) w/ Filter
23 HP* Kawasaki Electric Start
Make
Model
Horsepower
Displacement
Electrical System
Oil Capacity
Kawasaki
FH680V
23 @ 3600 rpm
41.19 Cu. in (675 cc)
12 Volt, 13 amp. Alternator, Battery: 340 CCA
4.0 pt. (1.9L) w/ Filter
Front Wheels
Capacity: 5 Gallons (18.9 L)
Tire Size: 17 x 7.50 -12
Inflation Pressure: 15 psi (1,03 bar)
Tire Size: 9 x 3.5 - 6
Inflation Pressure: 25 psi (1,72 bar)
TRANSMISSION:
Eaton 771-101 & 771-102
Type
Hydraulic Fluid
Speeds
@ 3400 rpm
Continuous Torque
Output
Maximum Weight
on Axle
Unitized Drive Transaxles
Mobil DTE26 Hydraulic Oil OR SAE 20W-20
Motor Oil OR SAE 30 Motor Oil
Forward: 0-6 MPH (0-9.65 km/h)
Reverse: 0-2 MPH (0-3.22 km/h)
162 ft. lbs. (219 N.m.)
900 lbs. (408 Kg)
DIMENSIONS:
Overall Length
48” Model
52” Model
61” Model
Overall Width
48” Model
52” Model
61” Model
Height
Weight (apx..)
48” Model
52” Model
61” Model
32
72” (183 cm)
72” (183 cm)
76” (193 cm)
57” (145
61” (155
70” (118
42” (107
cm)
cm)
cm)
cm)
665 lbs. (302 kg)
700 lbs. (318 kg)
730 lbs. (331 kg)
Lawn Care
& Mowing Information
GENERAL INFORMATION
•
•
•
•
•
•
•
Proper mowing is an important part of maintaining your
lawn in the best possible condition. A healthy and well
maintained lawn is better able to resist drought, weeds,
and other stresses. But too much maintenance is as
detrimental to your lawn as neglect. Proper care for your
lawn involves more than just “cutting the grass.” To have
a healthy lawn, you need to know:
Types of Grass, Climate and Conditions
How and When to Water, Fertilize & Aerate
How High to Mow the Grass
When and How Often to Mow
What Mowing Patterns to Use
Proper Mowing Methods
How to Solve Common Mowing Problems
TYPES OF GRASS, CLIMATE AND
CONDITIONS
A variety of grasses are commonly grown in household
lawns, but two main groups known as cool-season
grasses (varieties of bluegrass, ryegrass, and fescue),
and warm-season grasses (typically bermuda, buffalo
grass, and zoysia varieties) are the most common.
The cool-season grasses are better suited to cooler climates, and do not endure hot and dry weather as well as
warm-season grasses, but conversely, the warm-season
grasses do not grow as well in cooler climates. Most residential lawns are typically seeded with a mixture of these
grasses. (A local nursery or lawn center may help you to
identify what kind of grass your lawn contains from a
sample.)
Knowing your climate and conditions is also important to
proper lawn care. Drier climates or conditions will require
additional watering, while wetter climates may require
more frequent mowing.
HOW AND WHEN TO WATER,
FERTILIZE & AERATE
The best method of watering a lawn is to imitate a slow,
soaking rain, applying about 1 inch of water. A method
of verifying the amount that you have watered, is to place
several empty tin cans (low shallow cans work best) in
various spots around the lawn, and check the depth of
water in the can during the watering process.
HOW TO FERTILIZE YOUR LAWN
Every lawn’s watering needs are unique and are dependent upon the type of grass and soil, the amount of local
rainfall, and other conditions. Most lawns are watered
too often, but with too little water. However too much
water can allow development of diseases with your lawn.
It is best to water the lawn only when necessary, and
then to water it slowly, evenly, and deeply—imitating
a slow, soaking rain.
WHEN TO WATER YOUR LAWN
When the lawn begins to wilt, the grass’s color dulls, or
footprints stay compressed for more than a few seconds,
the lawn is beginning to dry out, and needs additional
moisture. The best time to water is early morning to allow
the water to soak deeply into the lawn and reduce the
amount that evaporates in the hot afternoon sun.
TP 600-7000-01-UV-FD
HOW TO WATER YOUR LAWN
Fertilizing with a slow-release fertilizer provides missing
nutrients which help create slow, even growth. While
opinions vary on the need for fertilizing, when and how
much to fertilize will be more a factor of the condition of
the lawn and soil than any routine. Remember that overfertilizing can cause harm, and that most fertilizing
should be applied in the spring so that it will release into
the lawn through the summer. For more information,
check with a local nursery or lawn care specialist, and
read and follow the fertilizer manufacturer’s instructions.
AERATING YOUR LAWN
Consider aerating your lawn in spring. Using an aerator
to remove cores of soil from the lawn increases the
speed of clipping decomposition and encourages deeper
root growth by opening up the soil and permitting greater
movement of water, fertilizer and air.
LC-1
Lawn Care & Mowing Information
HOW HIGH TO
MOW THE GRASS
Cut less than
1/3
Often cutting height is a
matter of personal preference. Typically, you should
mow the grass when it is is
between three and five
inches high. The proper
cutting height range for a
specific lawn will depend
upon several factors,
including the type of grass,
the amount of rainfall, the
prevailing temperature, and
the lawn’s overall condition.
Optimal
cutting point
at less than
1/3 from top
of grass blade
Cutting down to this
area contributes to
thatch problems
Cutting the grass too short
causes weak, thin grass
plants, which are easily
damaged by dry periods
and pests. Cutting too short
is often more damaging
than allowing the grass to be slightly higher.
Letting grass grow a bit longer—especially when it is hot and
dry—reduces heat build-up, preserves needed moisture and
protects the grass from heat damage and other problems.
However, allowing grass to grow too high can cause thin turf
and additional problems.
1/3
Cutting off too much at one time shocks the plant’s growth
system and weakens the grass plants. A good rule of
thumb is the 1/3 rule: to cut no more than one third of
the grass height, and never more than 1 inch at a time.
The amount of grass you are able to cut in one pass is also
effected by the type of mowing system you are using (for
example, broadcasting with side discharge decks can
process a much larger volume of grass than mulching does).
NOTE: We cover some specific mowing instructions for
mulching and broadcasting later in this Lawn Care section.
Cut Here On
First Pass
Cut
Here On
Second
Pass
1 inch
Proper Cutting Height
Tall Grass Requires Incremental Cutting
For extremely tall grass, set the cutting height at maximum for the first pass, and then reset it to the desired
height and mow a second or third time.
Don’t cover the grass surface with a heavy layer of
clippings. Consider using a grass collection system
and starting a compost pile.
LC-2
Lawn Care & Mowing Information
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:
l Mow when the grass is between three and five inches
high.
l 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.
l Mow at time of day when the grass is cool and dry.
Late afternoon or early evening often provide these
ideal mowing conditions.
l Avoid mowing after rain or even heavy dew, and
never mulch when the grass is wet (moist grass does
not mulch well, and clumps beneath the mower
deck).
WHAT MOWING PATTERNS TO USE
Where possible, make one or two passes around the
outside of the area discharging the grass INTO the lawn
to keep the cut grass off fences and walks.
Always start mowing on a smooth, level area.
The size and type of area to be mowed will determine
the best mowing pattern to use. Obstructions such as
trees, fences and buildings, and conditions such as
slopes and grades must also be considered.
l Cut long straight strips overlapping slightly.
l Where possible, change patterns occasionally to
eliminate matting, graining or a corrugated appearance.
l For a truly professional cut, mow across the lawn in
one direction, then recut the lawn by mowing perpendicular to the previous cut.
Note: Always operate the engine at full throttle when
mowing.
The remainder of the mowing should be done in the
opposite direction so that the clippings are dispersed
OUT onto the area of lawn previously cut.
If you hear the engine slowing down, you are mowing too
fast—using a slower ground speed will improve the cutting efficiency of the blades and prevents many common
cutting problems. Use an appropriate ground speed for
the thickness and height of the grass you are cutting (3rd
gear or slower for manual gear models). If you hear the
engine slowing down you are mowing too fast, use a
slower ground speed.
LC-3
Lawn Care & Mowing Information
MOWING METHODS
Proper Broadcast Mowing
Broadcasting, or side-discharging, disperses fine clippings evenly over the entire lawn. Many golf courses use
this method. Your mower has a deep dish deck to allow
freer circulation of clippings so they are broadcast evenly
over the lawn.
ENGINE SPEED & GROUND SPEED FOR BROADCASTING
Always operate the engine at full throttle when mowing.
If you hear the engine slowing down, you are mowing too
fast—using a slower ground speed will improve the cutting efficiency of the blades and prevents many common
cutting problems.
slowing down you are mowing too fast, use a slower
ground speed.
ALWAYS use an appropriate ground speed for the thickness and height of the grass you are cutting (3rd gear or
slower for manual gear models). If you hear the engine
Mow when the grass is 3-5 inches long. Do not cut the
grass shorter than 2 to 2-1/2 inches. Do not cut off more
that 1 inch of grass in a single pass.
HOW MUCH GRASS TO CUT OFF WHEN BROADCASTING
Proper Mulching
HOW MUCH GRASS TO MULCH
Mulching consists of a mower
Mulching
Action
deck which cuts and recuts clipThe best mulching action typicalpings into tiny particles and
ly results from cutting only the
which then blows them down
top 1/2 inch to 3/4 inch of grass
INTO the lawn. These tiny partiblade. This provides short clipcles decompose rapidly into bypings which decompose properly
products your lawn can use.
(much more quickly than longer
UNDER PROPER CONDIclippings). The ideal cutting
TIONS, your mulching mower will virtually eliminate
height will vary with climate, time of year, and quality of
noticeable clippings on the lawn surface.
your lawn. We recommend that you experiment with both
the cutting height and ground speed until you achieve
NOTE: When mulching under heavy cutting conditions, a
the best cut. Start with a high cutting height and using
rumbling sound may be present and is normal.
progressively lower settings until you find a cutting height
MULCHING REQUIRES EXCELLENT MOWING
that is matched to your mowing conditions and preferCONDITIONS
ences.
Mulching mowers cannot function properly if the grass is
wet, or if the grass is simply to high to cut. Even more
than normal mowing, mulching requires that the grass be
dry and the the appropriate amount is cut.
Do not use the mower as a mulching mower during the
first two or three mowings in the spring. The long grass
blades, quick growth, and often wetter conditions are
more suitable for broadcasting (side-discharging) or
grass bagging operation.
ENGINE SPEED & GROUND SPEED FOR BROADCASTING
Use full engine throttle matched with a slow ground
speed so that clippings will be finely cut. Ground speed
while mulching should be HALF of the speed that would
be used when broadcasting (side discharging) under
similar conditions. Since mulching requires more horsepower than broadcasting, using a slower ground speed is
vitally important for proper mulching operation.
LC-4
Lawn Care & Mowing Information
TIPS On Dealing With Clippings
Clippings are beneficial to your lawn. A common misconception about clippings is that they automatically
lead to thatch—this is untrue. Short clippings produced
by broadcasting and clippings produced by mulching
methods actually contribute to a healthy lawn
because they:
COMPOSTING
The best way to recycle excess clippings and leave your
lawn looking immaculate is to collect them with an efficient collection system and deposit them in a compost
pile. A compost pile is a collection of grass, leaves, and
other organic wastes which—when properly tended—
decompose into an odorless, topsoil material. This
material, in turn, acts as an inexpensive fertilizer for your
lawn and garden.
How to start a healthy compost pile:
1 Build a bin using bricks, fencing, cement blocks, etc. or purchase a prefabricated bin from a garden store. The bin
should also have venting on each side and from the bottom
to the top.
2 Fill the bin with alternating layers of yard waste. Follow this
recipe:
First layer: 3-4 inches of chopped brush or other coarse
material.
Second layer: 6-8 inches of mixed leaves, grass clippings,
sawdust, etc. Materials should be "sponge damp."
Third layer: 1 inch of soil to add micro-organisms that help
break down organic matter.
Fourth layer: 1-2 inches of manure to provide the nitrogen
needed by micro-organisms.
Keep adding layers until the bin is almost full. Top off with
a 4-6 inch layer of straw and scoop out a "basin" to catch
rain water.
3 Four or five days later the pile will reach temperatures of
140-160 degrees. At this time you'll notice it settling, a
good sign your compost is working properly.
4 After 5-6 weeks, fork materials into a new pile, turning the
outside of the old heap into the center of the new one. Add
water if necessary. The compost should be ready to use
within three to four months when dark brown, crumbly, and
earthy-smelling.
LC-5
•
•
•
•
Reduce the evaporation of water from your lawn.
Provide a cushioning layer to reduce lawn wear.
Moderate soil temperature.
Clippings act as a safe, non-polluting and inexpensive fertilizer that nourishes your lawn. Fresh cut
grass blades are 85% water, and are a rich source
of nitrogen which is essential to lush growth. And
one garbage bag of clippings contains about 1/4 lb.
of usable organic nitrogen.
Lawn Care & Mowing Information
SOLUTIONS FOR COMMON MOWING PROBLEMS
Streaking
Streaking
Streaking is when thin strips of uncut grass are left
behind the mower. Streaking is usually caused by
operator error or poor blade maintenance.
CAUSE
SOLUTION
Blades are not sharp
Blades are worn down too 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
Sharpen your blades
Replace your blades
Always mow at full throttle
Slow down
Clean out the mower
Overlap your cutting rows
When turning your effective cutting width
decreases–overlap more when turning
Stepped Cutting
Stepped Cutting
Stepped cutting is sharp ridges or uneven levels left in
the lawn surface. Stepped cutting is usually caused by
mower deck damage or misadjustment, or damage to
mower blades.
CAUSE
SOLUTION
Deck is not leveled correctly
Tires are not properly inflated
Blades are damaged
Deck shell is damaged
Mower spindle is bent or loose
Blades are installed incorrectly
Level the deck correctly
Check and inflate the tires
Replace the blades
Repair or replace the deck
Repair or replace the spindle
Reinstall the blades correctly
LC-6
Lawn Care & Mowing Information
Uneven Cutting
Uneven Cutting
Uneven cutting is waviness or smooth troughs in the
lawn surface. Uneven cutting is usually caused by
mower deck damage or misadjustment.
CAUSE
SOLUTION
Deck is not leveled correctly
Blades are dull or worn
Blades are damaged
Deck is clogged with grass clippings
Deck shell is damaged
Mower spindle is bent or loose
Blades are installed incorrectly
Level the deck correctly
Sharpen or replace the blades
Replace the blades
Clean out the deck
Repair or replace the deck
Repair or replace the spindle
Reinstall the blades correctly
Scalping
Scalping
Scalping is when the mower deck comes close to or hits
the ground. Scalping can be caused by the mower deck
misadjustment, unevenness in the lawn, or by mower
deck bouncing because the ground speed is too fast.
CAUSE
SOLUTION
Lawn is uneven or bumpy
Mower deck cutting height is set too low
Ground speed is too fast
Deck is not leveled correctly
Tire pressure is low or uneven
Roll or level the lawn
Raise the cutting height
Slow down
Correctly level the deck
Check and inflate the tires
Stingers
Stingers
Stingers are sparse patches of uncut grass left behind
the mower. Stingers are usually caused by operator
error or poor blade maintenance.
CAUSE
SOLUTION
Blades are not sharp or are nicked
Blades are worn down too far
Engine speed is too slow
Ground speed is too fast
Deck is plugged with grass
Sharpen your blades
Replace your blades
Always mow at full throttle
Slow down
Clean out the mower
LC-7
Common International Symbols
PTO Clutch
Choke
Fast (Throttle)
Parking Brake
Slow (Throttle)
Brake
Throttle
Mower Cutting
Height Adjustment
Fuel
Headlights
Technical Manuals
Additional Technical Literature Available
Operators Manuals
Additional copies of this manual are available, (and as part of
our product support commitment, we maintain a stock of
printed operators manuals going back many years!)
Parts Manuals
Fully illustrated parts manuals are also available —
these manuals show all of the product’s components in
exploded views (“3D” illustrations which show the relationship of
the parts and how they go together), as well as giving the replacement part numbers and quantities used. Important assembly notes and
special torque values are included in these manuals.
For the applicable manuals currently available for
your model, contact your local dealer. Have the
information listed in the box at the right available
when making your request.
Model:
Serial No.:
Your Name:
Address:
City, State, Zip:
Visa/Mastercard No.:
Card Expiration Date:
LC-8
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.
Owner's Responsibilities - As a condition to our obligations under this limited warranty, you shall have read the operator's manual and you shall have
completed and submitted to Ferris, within 20 days from the date of purchase, the Ferris Product Registration. You must properly service and maintain
your Ferris product as described in the operator's manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.
The Ferris equipment, including any defective part covered by this limited warranty, must be returned to an authorized Ferris dealer within the warranty
period for warranty service. This limited warranty extends only to equipment operated under normal conditions and in accordance with Ferris' instructions.
Warranty Start Date - The limited warranty coverage begins on the day you buy your new Ferris commercial mowing equipment. An authorized Ferris
dealer will assist you in filling out a Ferris Product Registration with specific information for the model you purchase and your personal information,
which must be returned to Ferris.
Limited Warranty - The limited warranty, set forth below, is a written guarantee by Ferris, during the warranty period, to repair or replace parts which
have a substantial defect in materials or workmanship. The warranty is "limited" because it is for a specified period of time, applies to the original purchaser only, and is subject to other restrictions.
FERRIS LIMITED WARRANTY
Ferris Industries (Ferris) warrants, in accordance with the provisions below, to the original purchaser only, for the periods described below that the
commercial mower shall be free from substantial defects in material or workmanship under normal use and service. If you wish to file a claim under
this limited warranty, you must provide prompt notice of your claim to an authorized Ferris dealer during the warranty period. Ferris' obligation under
this limited warranty is, at Ferris' option, to repair or replace any part or parts of the mower, which, in the judgment of Ferris, are found to be defective
and covered by this limited warranty. An authorized Ferris dealer will repair or replace the defective part or parts, at the dealer's place of business, at
no charge for the labor or parts. This limited warranty applies only to mowers sold in the United States and Canada and is subject to the following limitations.
Covered Parts
All Mowers
Warranty Period
2-years (24 months) from date of retail purchase by the original
purchaser for parts & labor (90 days for rental mowers)
(Except as noted below*)
*Belts, Tires, Brake Pads
And Hoses, Battery, Blades
90 days from date of retail purchase by the original purchaser
*Attachments
1 year from date of retail purchase by the original purchaser
*Engine
If the engine manufacturer provides any warranty on the mower's engine, Ferris will assign that warranty to the
original purchaser of the mower if such assignment is reasonably practicable. Please refer to the engine manufacturer's warranty statement, if any, that is included in the owner's packet. We are not authorized to handle
warranty adjustments or repairs on engines. Ferris offers NO WARRANTY on mower engines. Ferris does not
guarantee or represent that any engine manufacturer will comply with the terms of its warranty.
Items and Conditions Not Covered
This warranty does not cover, and Ferris makes NO WARRANTY regarding, the following:
• Mowers or their parts if a complete and accurate Ferris Product Registration has not been received by Ferris.
• Loss or damage to person or property other than that expressly covered by the terms of this limited warranty.
• Pickup and delivery charges and risk of loss or damage in transit to and from any authorized Ferris dealer.
• Any damage or deterioration due to normal use, wear and tear, or environmental or natural elements, or exposure.
• Cost of regular maintenance service or parts, such as but not limited to, filters, fuel, lubricants, tune-up parts, and adjustments.
• Claims arising due to failure to follow Ferris' written instructions, or improper storage or maintenance.
• Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the mowing equipment,
or other than as recommended in the operator's manual or other written operational instructions provided by Ferris.
• Use of non-Ferris approved parts or accessories.
• Any overtime or other extraordinary repair charges or charges relating to repairs or replacements.
• Rental of like or similar replacement equipment during the period of any warranty, repair or replacement work.
• Loss of revenue, time or use of the mowing equipment.
• Travel, telephone or other communication charges.
• Damage from continued use of defective mowing equipment.
• Freight charges on replacement parts.
• Any mowing equipment or part which, in the judgment of Ferris, has been altered or tampered with in any way or has been subjected to misuse,
abuse, abnormal usage, unauthorized repair, neglect or accident, damage in transit, or has had the serial numbers altered, effaced or removed.
• Any equipment, part or item not mentioned under "Covered Parts," above.
General Conditions
Ferris is continually striving to improve its products, and therefore reserves the right to make improvements or changes without incurring any obligation
to make changes or additions to products sold previously. Any oral or written description of Ferris products is for the sole purpose of identifying the
products and shall not be construed as an express warranty. No warranty claim shall give rise to a right for the purchaser to cancel or rescind any
sale. No person is authorized to make any warranty or assume for Ferris any liability not strictly in accordance with this limited warranty. Any assistance Ferris provides to or procures for the purchaser outside the terms, limitations or exclusions of this limited warranty will not constitute a waiver of
the terms, limitations or exclusions of this limited warranty, nor will such assistance extend or revive the limited warranty. Ferris will not reimburse the
purchaser for any expenses incurred by the purchaser in repairing, correcting or replacing any defective products except for those incurred with Ferris'
prior written permission and in accordance with this limited warranty.
Ferris' sole and exclusive liability with respect to this limited warranty, and the purchaser's exclusive remedy, shall be repair or replacement as set forth
herein. All warranty work must be performed by an authorized Ferris dealer using only Ferris approved replacement parts. FERRIS SHALL HAVE NO
LIABILITY FOR ANY OTHER COST, LOSS OR DAMAGE, INCLUDING BUT NOT LIMITED TO, ANY INCIDENTAL, COMPENSATORY, INDIRECT,
PUNITIVE, SPECIAL OR CONSEQUENTIAL LOSS OR DAMAGE. FERRIS' AGGREGATE LIABILITY WITH RESPECT TO A DEFECTIVE PRODUCT OR PART SHALL BE LIMITED TO AN AMOUNT EQUAL TO THE MONIES PAID BY THE PURCHASER FOR THAT DEFECTIVE PRODUCT
OR PART. THIS LIMITED WARRANTY, AND FERRIS' OBLIGATIONS HEREUNDER, ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. FERRIS SHALL NOT BE LIABLE TO THE PURCHASER, OR TO ANYONE CLAIMING
UNDER THE PURCHASER, FOR ANY OTHER OBLIGATIONS OR LIABILITIES, INCLUDING, BUT NOT LIMITED TO, OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR WARRANTY, NEGLIGENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY,
WITH RESPECT TO FERRIS PRODUCTS OR FERRIS' ACTS OR OMISSIONS OR OTHERWISE.
It is the express wish of the parties that this agreement and any related documents be drafted in English. Il est la volonté expresse des parties que
cette convention et tous les documents s'y rattachent soient rédigés en anglais.
OPERATOR’S
MANUAL
HydroWalk Series
Dual Drive Walk-Behind Mowers
Ferris Industries
5375 North Main Street
Munnsville, NY 13409
800-933-6175
www.ferrisindustries.com
© Copyright 2006 Ferris Industries
All Rights Reserved. Printed in USA.
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