Not for Reproduction

Not for Reproduction
Dealer Setup & Adjustment Instructions
These Dealer Setup Instructions cover the following models:
5901350 - IS3200ZKAV3761
5901351 - IS3200ZBV3661
5901352 - IS3200ZKAV3772
5901353 - IS3200ZBV3672
5901412 - IS3200ZBV36 ANSI EXP
5901413 - IS3200ZBV3661 ANSI EXP
5901413 - 3200/72 ANSI EXP
5901458 - IS3200ZBVE3761
5901459 - IS3200ZBVE3772
5901354 - IS3200ZBV3261
5901355 - IS3200ZBV3272
5901359 - IS3200ZBVE37 ANSI-EXP
5901357 - IS3200ZKAV3572
5901358 - IS3200ZBVE3761 ANSI-EXP 5901533 - IS3200ZBVE2861 CAL
5901356 - IS3200ZKAV3561
5901360 - IS3200ZBVE2872 CAL
Table of Contents
ATTENTION SETUP PERSONNEL:
SETUP PROCEDURES ......................................................3
Uncrating ............................................................................3
Connect Battery .................................................................4
Zero-Turn Rider Assembly ...............................................4
Ground Speed Control Lever Adjustment........................4
Seat Position Adjustment.................................................5
Roll Bar Installation...........................................................5
Check Fluid Levels & Tire Pressures ..............................7
Check Engine Oil Level ...................................................7
Check the Hydraulic Oil Level .........................................7
Check Tire Pressures ......................................................7
Check Torque - Mower Blades .........................................8
Install the Mower Deck Pusher Bars (72” ANSI-EXP
Models) ...............................................................................8
Install the Mower Deck (72” ANSI-EXP Models).............9
Install the Discharge Chute (72” ANSI-EXP Models) ...10
Install the Mower Deck Belt (72” ANSI-EXP Models) ...10
Check the Deck Lift Rod Timing ....................................11
Check and Level the Mower Deck .................................12
Determining if the Deck Leveling Needs to Be
Adjusted .........................................................................12
Deck Leveling Adjustment .............................................12
Deck Lift Assist Spring ...................................................13
Check Deck Drive Belt ....................................................14
Check the Mower Belt Idler Tensioner Spring Length ...14
Adjust the Mower Belt Idler Tensioner Spring Length ...14
Lubrication .......................................................................15
Adding Fuel ......................................................................16
Starting the Engine .........................................................16
Perform the Safety Checks ............................................17
Functional Tests ............................................................17
ADJUSTMENT PROCEDURES .......................................18
Neutral Adjustment .........................................................18
Return-to-Neutral Adjustment ........................................19
Parking Brake Adjustment .............................................20
Suspension Adjustment .................................................21
The safety warnings provided in this guide
and in the operator’s manual included with the unit
contain important information that must be obeyed when
assembling, setting-up, operating, servicing, transporting,
or storing the unit.
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These warnings are highlighted by the safety alert
triangle symbol shown above, which signifies that an
important safety message is being provided.
You must read, understand, and follow these
warnings and instructions, and use safe shop
and work practices at all times while working on
or around this unit and all other outdoor power
equipment.
Sections and items denoted by the Setup
symbol provide the information necessary to fully
assemble, test, and prepare the units described above
for delivery to your customers.
A Quick Setup List is provided on page 2 of this
booklet to help you identify and check that the items
have been performed.
Additional information concerning functional
tests, general adjustment procedures, and the location
of normal lubrication points are included in these
instructions.
Although all required lubrication and normal adjustments
on factory-assembled components are done at the
factory, this additional information is provided to assist
you in ensuring that each unit is delivered to the
customer in proper working order.
1
5104463
Rev E
Dealer Setup Instructions
QUICK SETUP LIST:
Page
3
Setup Procedure
Steps to Perform
Uncrating
❏ Remove Crate & Banding.
❏ Open the Hydraulic By-pass Valves.
❏ Release Parking Brake & Push Unit Forward Off Of Skid.
❏ Close the Hydraulic By-pass Valves.
4
Battery Setup
❏ Connect Battery Cables to Battery.
4
Zero-Turn Rider
Assembly
❏ Adjust Ground Speed Control Levers.
6
Roll Bar Installation
❏ Install the Roll Bar.
8
Check Fluid Levels &
Tire Pressures
❏ Check Engine Oil Level.
❏ Adjust Seat.
❏ Check Hydraulic Oil Level.
❏ Check Tire Pressure.
9
Install the 72” Mower
Deck (ANSI-EXP Models
Only)
Check Mower Deck Blade Bolt Torque.
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Check Mower Deck Blade ❑
Bolt Torque
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❑ Install the Mower Deck Pusher Bars.
❑ Install the Mower Deck.
❑ Install the Discharge Chute.
❑ Install the Mower Deck Drive Belt.
12
Check the Mower Deck
❏ Check & Adjust Deck Lift Rod Timing.
❑ Check & Level Mower Deck.
❑ Check Deck Drive Belt.
16
Lubrication &
Fuel Preparation
❏ Lubricate all grease and oil points.
❏ Add fuel.
❏ Start the engine.
18
SAFETY CHECKS
❏ Check for LOOSE HARDWARE.
❏ Check all OPERATOR CONTROLS.
❏ Perform SAFETY INTERLOCK SYSTEM CHECK.
Register Product
❏ To register the product: log onto www.thepowerportal.com, select
the appropriate brand, click “My Resources,” select the “Product
Registration and Rebate” icon and then the “New Product
Registration / Rebate” tab. Fill out and submit the online product
registration form.
2
Dealer Setup Instructions
SETUP PROCEDURES
Uncrating
1. Locate the hydraulic bypass valves (A, Figure 1) on
the transmissions of the unit. There is one hydraulic
bypass valve on each transmission.
2. Open the hydraulic bypass valve. To open the
bypass valves, turn the bypass valve, which is
located on the side of the transmission, clockwise
to the “open” position (marked “bypass” on the
transmission).
3. Push down on the parking brake lever (A, Figure 2)
to release the parking brake.
A
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4. Be sure there are no nails or sharp objects on the
bottom skid to puncture the zero-turn rider’s tires.
Roll the zero-turn rider forward off the bottom skid.
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5. After moving the zero-turn rider, re-engage the
transmissions by turning the bypass valves counterclockwise to the “closed” position (marked “run” on
the transmission.
Figure 1 - Hydraulic System By-Pass
A
Figure 2 - Disengaging the Parking Brake
(lever shown in disengaged position)
3
Dealer Setup Instructions
B
Connect Battery
WARNING
A
BATTERY SAFETY RULES
• Battery acid causes severe burns. Avoid
contact with skin.
• Wear eye protection while handling the battery.
• To avoid an explosion, keep flames and
sparks away from the battery, especially while
charging.
• When installing the battery cables,
CONNECT THE POSITIVE (+) CABLE FIRST and
the negative (-) cable last. If not done in this
order, the positive terminal can be shorted to
the frame by a tool.
Figure 3 - Connect the Battery
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1. Connect the red positive battery cable (A, Figure 3)
to the positive battery post.
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2. Connect the black negative battery cable (B) to the
negative battery post.
A
Zero-Turn Rider
Assembly
C
Ground Speed Control Levers
Installation
B
This procedure is only necessary if the ground speed
control levers are not factory installed on your unit.
There is a LEFT-HAND and a RIGHT-HAND control
lever. When assembled to the control lever base, the
control lever plate should be pointing towards the rear of
the machine as shown in Figure 4.
1. Remove the ground speed control levers and
mounting hardware from the handle bar box.
Figure 4 - Installing and Adjusting the Ground Speed
Control Levers
2. Install the ground speed control levers, (A, Figure 4)
onto the control lever base using the 5/16” hardware
(B) supplied in the box. Prior to tightening the bolts,
align the handles with each other
4
Dealer Setup Instructions
Seat Installation
This procedure is only necessary if the seat is not factory
installed on your unit.
There are two sets of holes in the seat plate that the
seat can be installed in. Use the forward set of holes to
position the operator closer to the front of the machine
and the rear set of holes to position the operator towards
the rear of the machine. Determining what holes to
use is based on the preferred operating position of the
operator.
1. Unpack the seat.
2. Install the seat (A, Figure 5) onto the seat mount
plate (B) and secure with the 5/16 nylock flange nuts
(C).
Ground Speed Control Lever
Adjustment
The ground speed control levers can be adjusted in
three ways. The height of the levers, the alignment of
the control levers, and the placement of the control
levers (how close the ends are to one another) can be
adjusted.
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Figure 5 - Installing the Seat
HEIGHT ADJUSTMENT
1. Remove the mounting hardware (B, Figure 4).
2. Position the ground speed control lever (A) either
up or down from its original position and reinstall the
mounting hardware.
3. Perform the Alignment Adjustment.
ALIGNMENT ADJUSTMENT
1. Loosen the mounting hardware (B, Figure 4).
2. Pivot the ground speed control levers forward or
backwards to align with each other.
3. Once alignment is achieved, retighten the hardware.
PLACEMENT ADJUSTMENT
1. Loosen the jam nut and turn the placement bolt
(C, Figure 4) in or out to adjustment the amount
of distance between the ends of the ground speed
control levers.
Seat Position Adjustment
The seat can be adjusted forwards and backwards.
A
1. Move the seat adjustment lever (A, Figure 5) to the
left, position the seat as desired, and release the
lever to lock the seat into position.
Figure 6 - Seat Position Adjustment
5
Dealer Setup Instructions
C
A
Roll Bar Installation
Loop End
Snap End
Assemble the Retainer Pins
1. Unpack the roll bar and hardware from the box.
D
2. Lock the snap end of the lanyard (A, Figure 7)
through the retainer pin handle (B) and snap
together.
B
3. Install the lanyard anchor (C) onto the lanyard.
Figure 7 - Assemble the Retainer Pins
4. Install the hair pin (D) onto the loop end of the
lanyard as shown in Figure 7.
Install the Roll Bar Top Loop to the Upright
Tubes
A
1. Assemble the top loop (A, Figure 8) to the left
upright tube (B) and right upright tube (C) by loosely
installing the 1/2” bolt (D), through the retainer pin
assembly (E), then through the hole in the top loop
that is closest to rear of the machine, the upright
tube, and then loosely install the 1/2” side lock nut
(F).
D
E
E
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D
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F
C
2. Fold the ROPS to the down position (A, Figure 9)
and lock in place using the retainer pins and hair pin
clips (B).
Install the Roll Bar Assembly on the
Machine
The Roll Bar Assembly is installed in the roll bar pockets
which are part of the main frame of the unit and are
located behind the seat and in front of the engine on
both sides of the unit.
G
B
Figure 8 - Install the Roll Bar Top Loop to the Upright
Tubes
1. Make sure that no fuel lines, cables, or parts of the
wire harness are in the way of the roll bar pockets.
2. From the bottom of the roll bar upright tube measure
up 8” (G, Figure 8) and mark the distance with a
marking tool or a piece of tape. Repeat for other
upright tube.
3. Install the roll bar into the roll bar pockets. The roll
bar is installed so that the safety decals are on the
left side of the machine (as determined from the
operator’s position) facing towards the front of the
machine. When the mark you made is even with the
top of the roll bar pocket, the holes are close to being
lined up. If necessary, use a dead blow hammer and
drift pin to assist in lining up the holes in the roll bar
with the holes in the roll bar pocket.
4. Loosely install the the (4) 1/2” bolts (C, Figure 9),
and 1/2” washers (D), through the frame of the unit,
the roll bar, the outer frame of the unit, and loosely
install the 1/2” side lock nuts (E).
6
Dealer Setup Instructions
5. Tighten the 1/2” hardware that secures the upright
tubes to the frame of the unit to 82 ft. lbs (108 Nm) of
torque.
B
6. Tighten the 1/2” bolt and side lock nuts that secure
the top loop to the upright tubes. Do not over-tighten.
The top loop should pivot snugly with the retainer
pins removed.
A
7. Raise the top loop to the upright position and install
the retainer pins and hair pin clips to secure the roll
bar in the raised position.
Install the Safety Decals (Export Models
Only)
1. Remove the black and yellow CE safety decals (A, &
B, Figure 10) from the publications packet.
2. Remove the three (3) existing English language
decals (C) from the roll bar.
E
D
3. Refer to Figure 10 for decal installation locations.
The long decal, part number 5100536 (A) is installed
below the roll bar pivot on the angled part of the roll
bar. The short decal, part number 5100537 (B), is
installed above the roll bar pivot.
C
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Figure 9 - Install the Roll Bar Assembly on the
Machine
C
B
A
Figure 10 - Install the Safety Decals (Export Models)
7
Dealer Setup Instructions
D E
Check Fluid Levels &
Tire Pressures
A
B
D
Check Engine Oil Level
E
This series of mower has different engine options. Use
Figure 11 to determine if your model is equipped with a
Kawasaki FX or Kawasaki FX DFI Series (A, Figure 11),
Briggs & Stratton Vanguard Big Block Series (895 cc or
993 cc) (B) or a Briggs & Stratton EFI Series (C).
C
D E
1. Use the dipstick (D) to check the engine oil level.
If necessary add engine oil through the engine oil
fill (E). Check the engine manufacturer’s owner’s
manual for oil recommendations.
Check the Hydraulic Oil Level
Do not open the hydraulic reservoirs (B, Figure 12)
unless oil is being added.
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Figure 11 - Checking the Engine Oil Level
Oil Type: 20W-50 conventional detergent motor oil.
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1. Check the oil level when the unit is cold. The oil
should be up to the “FULL COLD” mark on the
transmission oil reservoirs (A). If the oil is below this
level proceed to step 2.
B
2. Before removing the reservoir cap (C), make sure
the area around the reservoir cap and fill neck of
the reservoir is free of dust, dirt and other debris.
Remove the transmission oil caps.
3. Add oil up to the “FULL COLD” mark.
4. Reinstall the reservoir cap.
Check Tire 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 the cut
quality, and extend the tire life.
Tire
Pressure
Front
25 psi (1,72 bar)
Rear
15 psi (1,03 bar)
A
Figure 12 - Checking the Hydraulic Oil Level
Figure 13 - Checking Tire Pressure
8
C
Dealer Setup Instructions
B
Check Torque - Mower
Blades
A
WARNING
Mower blades are sharp. For your personal
safety, do not handle mower blades with bare
hands. Careless or improper handling of blades
may result in serious injury. Blade mounting
bolts must each be installed with a flat washer
then securely tightened. Torque blade mounting
bolts to 70 ft. lbs. (94 N.m.)
TIGHTEN
Figure 14 - Check the Blade Torque
A. Blade Bolt
B. Flat Washer
1. Park the machine on a flat, level surface and engage
the parking brake.
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2. Lock the deck lift pedal in the TRANSPORT position.
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3. Check that blades are installed with the tabs pointing
up toward the deck as shown in Figure 14. Torque
the bolts to 70 ft. lbs. (94 N.m.).
Install the Mower Deck
Pusher Bars (72” ANSI-EXP
Models)
E
F
H
G
J
I
C
D
There is a left-hand (A, Figure 15) and a right-hand
pusher bar (B).
A
1. Measure the pusher bar length from the outside of
the cross tube to the center of the ball joint (C). The
measurement should be 16-9/16” (42.1 cm).
D
2. If the measurement does not equal 16-9/16” (42.1
cm), loosen the jam nut and turn the ball joint until it
the measurement of 16-9/16” (42.1 cm) is achieved.
Tighten the jam nut.
B
Figure 15 - Install the Mower Deck Pusher Bars
3. There are four plastic bushings (D) installed in the
cross tube, two on each end. Make sure that all four
of the plastic bushings are still installed in the cross
tube.
4. Holding the pusher bar in place, insert the mount pin
(E) through the mower decks mounting brackets and
the pusher bar.
5. Secure the mount pin to the mower deck bracket with
the 3/8-16 X 1” bolt (F), 3/8 SAE washers (G), and
3/8 hex nylock flange nut (H) that are provided.
9
Dealer Setup Instructions
6. Secure the other end of the mount pin in place by
installing a 3/8-16 X 1” bolt (I) and .390 X 1.50 X .109
washer (J) into the internal threads of the mount pin.
7. Repeat the process to install the right-hand pusher
bar to the mower deck.
E
A
E
Install the Mower Deck
(72” ANSI-EXP Models)
F
1. Park the zero-turn rider on a flat, level surface.
Engage the parking brake, turn the ignition switch to
OFF, and remove the key.
D
B
Figure 16 - Installing the Mower Deck to the ZTR
(Pusher Bars)
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2. Lock the deck lift pedal in the TRANSPORT position.
Place the deck height adjustment pin in the 4” (10.2
cm) position and lower the deck lift pedal until the
arm contacts the pin. Secure in place if necessary.
C
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3. Center the mower deck underneath the zero-turn
rider’s frame.
4. Fasten the ball joints of the pusher bars (A, Figure
16) to the transmission cradle (B) using the 3/4-16 X
3” bolt (C), 3/4 flat washer (D), 3/4 rod end seal (E),
and the 3/4 hex nylon nut (F).
FRONT
5. Place 2 X 4 blocks underneath each corner of the
mower deck with the 3-1/2” sides being vertical. See
Figure 17.
6. Install the spacer (A, Figure 18) into the eyelit of the
deck linkage (B).
Figure 17 - 2 X 4 Locations
7. Have an assistant use the deck lift pedal to raise
or lower the deck linkages as necessary while you
install the 1/2 bolt (C) and 1/2 washer (D) through the
middle hole (E) of the mower deck connection points
and the spacer and secure with the hex nylock flange
nut (F).
The hardware used to secure the front of the mower
deck to the deck linkages is routed so that the
threads of the bolt face towards the center of the
mower deck.
C
B
B
The hardware used to secure the rear of the mower
deck to the deck linkages is routed so that the
threads of the bolt face towards the outside of the
mower deck.
A
C
D
F
8. Remove the blocking from underneath the mower
deck.
C
C
F
E
D
Figure 18 - Installing the Mower Deck to the ZTR
(Deck Linkages)
10
Dealer Setup Instructions
Install the Discharge
Chute (72” ANSI-EXP Models)
E
D
A
1. Install the discharge chute (A, Figure 19) onto the
mower deck (B) as shown in Figure 19 using the
pivot rod (C).
2. Secure the discharge chute to the mower deck using
two (2) 5/16 washers (D) and nylon nuts (E).
C
The mower deck should never be run without the
discharge chute installed and positioned in the down
position.
E
D
WARNING
B
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Figure 19 - Install the Discharge Chute
Amputation and Thrown Object Hazard
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To avoid injury from rotating blades, stay clear
of deck edge and keep others away. Do not mow
without discharge chute or entire grass catcher
in place.
Install the Mower Deck
Belt (72” ANSI-EXP Models)
72”
F
D
E
1. Lower the mower deck to it’s lowest cutting position
and remove the mower deck guards and the floor
pan of the machine.
2. Install the mower deck drive belt (A, Figure 20) so
that the V-side of the belt rides in the grooves of
the spindle pulleys (B) and the back side of the belt
contacts the faces of the front stationary idler pulley
(C) and the adjustable idler pulley (D).
WARNING
Use extreme caution when rotating the idler
arm with the breaker bar, due to the increased
tension in the spring as the idler arm is being
rotated. Injury may result if the breaker bar is
prematurely released while the spring is under
tension.
B
B
C
B
A
Figure 20 - Installing the Mower Deck Drive Belt (72”
ANSI-EXP Mower Deck
3. Use a 1/2” breaker bar and place the square end
in the eight sided hole located in the idler arm (E).
Carefully rotate the breaker bar clockwise, which
11
Dealer Setup Instructions
relieve the tension on the belt exerted by the idler
arm.
4. Install the belt on the rear stationary idler pulley (F)
and carefully release the tension on the breaker bar.
A
Check the Deck Lift
Rod Timing
1. Park the machine on a flat, level surface. Disengage
the PTO, engage the parking brake, turn off the
engine and remove ignition key. Check that the tires
are properly inflated.
C
B
D
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2. To check the inner lift rod timing (A, Figure 21),
measure and record the distance between the inner
lift pivots (B) and the inner rod pivots (C). Repeat for
other side of unit.
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3. To check the outer lift rod timing (D), measure and
record the distance between the outer lift pivots (E)
and the outer rod pivots (F). Repeat for other side of
unit.
4. If the measurements for the inner rods are equal, and
the measurements for the outer rods are equal, no
further adjustment is required. If the measurements
are NOT equal (greater than 1/8” (3,17 mm)
difference), adjustment is required, continue with
Step 5.
5. Lock the deck lift pedal in the 5” (12,7 cm) position.
See Figure 22. Remove the cutting height
adjustment pin and lower the mower deck.
6. To ensure that the deck is in the lowest position,
push the pedal by hand towards the rear of the unit
and install the height adjustment pin in the 3” (7.6
cm) position to hold in place.
7. Block up the mower deck until all hanger chains are
slack.
8. To adjust the inner lift rod (A, Figure 23): loosen
the jam nut (B) on the front ball joint (C) then remove
the 1/2” hardware (D) fastening the ball joint to the lift
pivot arm. Turn the ball joint clockwise to shorten
the distance between the rod pivots or counterclockwise to lengthen the distance between the rod
pivots. Reinstall the ball joint on the lift pivot arm and
secure with the 1/2” hardware previously removed.
Tighten the jam nut against the lift rod.
9. To adjust the outer lift rod (E, Figure 23): loosen
the jam nut (F) on the front ball joint (G) then remove
the 1/2” hardware (H) fastening the ball joint to the lift
pivot arm. Turn the ball joint clockwise to shorten
the distance between the rod pivots or counter-
E
F
Figure 21 - Measure the Inner & Outer Lift Rods
5”
(12.7 cm)
3”
(10.2 cm)
Figure 22 - Deck Lift Pedal & Pin Position
12
Dealer Setup Instructions
clockwise to lengthen the distance between the
rod pivots. Reinstall the ball joint on the lift pivot
arm and secure with the 1/2” hardware previously
removed. Tighten the jam nut against the lift rod.
10. Remove blocks from under the mower deck.
11. Lift mower deck and reinstall adjustment pin in
desired mowing height.
A
C
B
E
D
Check and Level the
Mower Deck
Before adjusting the deck level, the deck lift rod timing
must be checked, and if necessary, adjusted.
F
G
Determining if the Deck Leveling
Needs to Be Adjusted
H
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WARNING
Figure 23 - Adjust the Inner & Outer Lift Rods
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Avoid Injury! Mower blades are sharp.
Always wear gloves when handling blades or
working near blades.
1. Park the machine on a flat, level surface. Disengage
the PTO, engage the parking brake, turn off the
engine and remove ignition key. Check that the tires
are properly inflated.
A
A
2. Place the deck height adjustment pin in the 4” (10,2
cm) position.
3. See Figure 24. Position the outside mower blades
so they face front-to-back.
A
Figure 24 - Measuring the Blade Height
4. Measure the front tip (A, Figure 24) of the blade
from the cutting edge to the ground.
5. Measure the rear tip (A) of the blade from the cutting
edge to the ground.
• the front measurements should equal 4” (10,2 cm).
• the rear measurements should equal 4-1/4” (10,8
cm).
C
B
If the measurements are greater than 1/8” (3,17 mm)
of what they should be, adjust the deck leveling.
D
Deck Leveling Adjustment
A
1. Place the deck height adjustment pin in the 4” (10,2
cm) position.
2. Loosen the jam nut (A, Figure 25) on the deck
linkages (B).
Figure 25 - Adjusting the Deck Leveling
3. Turn the hex adjusters on the deck linkages (C)
clockwise to raise the mower deck or counter-
13
Dealer Setup Instructions
7. Remove the blocking from under the mower deck.
clockwise to lower the mower deck.
8. Re-check the measurements from the tips of
the mower blades to the ground. The front
measurements should equal 4” (10.2 cm) and the
rear measurements should equal 4-1/4” (10,8 cm).
NOTE: If you are lowering the mower deck measure the
amount of visible threads (D) on the deck linkages. If the
amount of visible threads shown reaches 2” (5.1 cm), do
not lower the mower deck by adjusting the deck linkage
any further.
• if the measurements equal 4” (10.2 cm) in the front
and 4-1/4” (10,8 cm) in the rear, tighten the jam nuts
on the deck linkages. The adjustment procedure is
complete.
4. Re-check the measurements from the tips of
the mower blades to the ground. The front
measurements should equal 4” (10.2 cm) and the
rear measurements should equal 4-1/4” (10.8 cm).
• If the measurements do not equal 4” (10.2 cm)
in the front and 4-1/4” (10,8 cm) in the rear, turn
the hex adjusters on the deck linkages until the
measurements equal 4” (10.2 cm) in the front and
4-1/4” (10,8 cm) in the rear.
• if the measurements equal 4” (10.2 cm) in the front
and 4-1/4” (10.8 cm) in the rear, tighten the jam nuts
on the deck linkages. The adjustment procedure is
complete.
9. Tighten the jam nuts on the deck linkages.
• If the measurements do not equal 4” (10.2 cm) in the
front and 4-1/4” (10.8 cm) in the rear, the hole that
the deck linkage is mounted in on the mower deck
will have to be changed.
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5. Place blocking underneath all four corners of the
mower deck.
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6. Re-position the hardware (A, Figure 26) that secures
the deck linkage to the mower deck.
• If the mower deck was being raised when it was
unable to achieve the 4” (10.2 cm) in the front and
4-1/4” (10.8 cm) in the rear measurement, position
the hardware in the next lower hole (B) in the mower
deck mount (C).
• If the mower deck was being lowered when it was
unable to achieve the 4” (10.2 cm) in the front and
4-1/4” (10.8 cm) in the rear measurement, position
the hardware in the next higher hole in the mower
deck mount.
C
C
C
B
A
Figure 26 - Deck Lift Linkages Mounting Holes
Deck Lift Assist Spring
The deck lift springs (A, Figure 27) are factory set to
provide optimal lifting performance.
Although it is fastened with an adjustable anchor, this is
NOT AN ADJUSTMENT POINT.
A
DO NOT attempt to adjust the spring length or lifting
performance will be compromised.
Figure 27 - Deck Lift Spring Location
A. Deck Lift Spring
14
Dealer Setup Instructions
61”
F
Check Deck Drive Belt
E
E
1. Lower the mower deck to its lowest cutting position.
2. Remove the mower deck guards and floor pan to
gain access to the mower deck belt.
3. Make sure the V-side of the belt (A, Figure 28 &
Figure 29) runs in the pulley grooves of the spindle
pulleys (B), and the PTO clutch pulley. Make sure
that the flat side of the belt contacts the face of the
front stationary idler pulley(s) (C), the adjustable idler
pulley (D), and the rear stationary idler pulley (F).
B
B
A
Figure 28 - Mower Deck Drive Belt Routing - 61”
Mower Deck
72”
Use extreme caution when rotating the idler
arm with the breaker bar, due to the increased
tension in the spring as the idler arm is being
rotated. Injury may result if the breaker bar is
prematurely released while the spring is under
tension.
F
D
E
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4. If the belt is not properly seated, use a 1/2” breaker
bar, and place the square end in the square hole
located in the end of the idler arm (E). Carefully
rotate the breaker bar clockwise, which will relieve
the tension on the belt exerted from the idler arm.
Check the Mower Belt Idler Tensioner
Spring Length
C
B
C
WARNING
5. Re-seat belt and carefully release the tension on the
breaker bar.
D
B
B
C
A
B
Figure 29 - Mower Deck Drive Belt Routing - 72”
Mower Deck
1. Set the mower deck to the 3-1/2” (8.9 cm) position.
2. Use the Mower Belt Idler Tensioner Spring Length
chart to determine the correct spring length for your
unit.
A
Mower Belt Idler Tensioner Spring Length
Deck Size
Measurement
61” Mower Deck
12-1/2” (32 cm)
72” Mower Deck
12” (30 cm)
3. Measure the coil length (A, Figure 30) of the mower
belt idler tensioner spring (B). The measurement
should equal the measurement as indicated in teh
chart. If not, perform the Adjust the Mower Belt Idler
Tensioner Spring Length procedure.
Adjust the Mower Belt Idler Tensioner
Spring Length
D
B
E
C
Figure 30 - Mower Deck Drive Belt Idler Tensioning
Spring
1. Loosen the jam nut (C, Figure 30) on the eyebolt (D).
15
Dealer Setup Instructions
2. Turn the adjustment nut (E) until the measurement as
indicated in the chart is achieved.
3. Re-tighten the jam nut.
4. Re-install the mower deck guards and the floor pan.
Lubrication
Lubricate the unit at the locations shown in Figure 31
through Figure 34 as well as the following lubrication
points.
Grease
front caster wheel axles & yokes
Figure 31 - Lubrication Points - Mower Deck
deck lift pivot blocks
mower deck spindles
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mower deck rear pusher bars
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transmission cradle pivot points
Use grease fittings when present. Disassemble parts to
apply grease to moving parts when grease fittings are
not installed.
Not all greases are compatible. Red grease (p/n
5022285) is recommended. Automotive type, high
temperature, lithium grease may be used when this is
not available.
Oil
control handle pivots & linkages
parking brake shaft pivots
seat plate pivots
deck lift pivot points
Generally, all moving metal parts should be oiled where
contact is made with other parts. Keep oil and grease
off belts and pulleys. Remember to wipe fittings and
surfaces clean both before and after lubrication.
Figure 32 - Lubrication Points - Deck Lift Linkages &
Rear Suspension Cradle
Figure 33 - Control Handle Pivots & Seat Plate Pivots
16
Dealer Setup Instructions
Lubricating the Front Casters:
NOTE: Front casters should be lubricated annually.
1. Remove the 1/4-28 bolt (A, Figure 34) screwed into
the front caster and install a 1/4-28 grease fitting.
2. Grease the front caster.
3. Remove the 1/4-28 grease fitting and reinstall the
1/4-28 bolt.
4. Repeat the process for the other side of the machine.
Adding Fuel
A
Figure 34 - Lubrication Points - Front Caster & Wheel
To add fuel:
1. Remove the fuel cap (A, Figure 35).
B
A
2. Fill the tank to about 1-1/2” (3,81 cm) of the bottom of
the filler neck. This will allow for fuel expansion.
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NOTE: Do not overfill. Refer to your engine manual for
specific fuel recommendations.
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3. Install and hand tighten the fuel cap.
Figure 35 - Adding Fuel
Starting the Engine
MODELS WITH CARBURETED ENGINES
1. While sitting in the operator’s seat, engage the
parking brake and make sure the PTO switch is
disengaged and the ground speed control handles
are locked in the NEUTRAL position. Make sure the
fuel valve (B, Figure 35) is in the “ON” position.
valve (B, Figure 35) is in the “ON” position.
2. Insert the key into the ignition switch and turn it to
START position.
3. The throttle will self-adjust to idle when starting. After
the engine starts allow the engine to warm. Warm up
the engine by running it for at least a minute before
engaging the PTO switch or driving the rider.
2. Set the engine throttle control to FAST throttle
position. Then fully close the choke by pulling the
knob OUT fully.
4. After warming the engine always operate the unit at
FULL throttle when mowing.
3. Insert the key in the ignition switch and turn it to
START.
4. After the engine starts, gradually open the choke
(push knob down fully).
Warm up the engine by running it for at least a minute
before engaging the PTO switch or driving the rider.
MODELS WITH BRIGGS & STRATTON EFI ENGINES
NOTE: To prime a dry fuel system, turn key switch to
ON position for one minute. Allow fuel pump to cycle and
prime system. Turn key switch OFF.
5. After warming the engine, ALWAYS operate the unit
at FULL THROTTLE when mowing.
1. While sitting in the operator’s seat, engage the
parking brake and make sure the PTO switch is
disengaged and the ground speed control levers are
locked in the neutral position.
MODELS WITH KAWASAKI DFI ENGINES
1. While sitting in the operator’s seat, engage the
parking brake and make sure the PTO switch is
disengaged and the ground speed control levers are
locked in the NEUTRAL position. Make sure the fuel
2. Position the throttle control midway between SLOW
and FAST positions.
3. Insert the key into the ignition switch and turn it
to START position. Release switch as soon as
17
Dealer Setup Instructions
engine starts. If starter does not turn engine over,
shut off key switch immediately, and consult engine
operator’s manual. Warm up the engine by running it
for at least a minute before engaging the PTO switch
or driving the rider.
SAFETY INTERLOCK
SYSTEM
4. After warming the engine always operate the unit at
FULL throttle when mowing.
This unit is equipped with safety interlock switches.
These safety systems are present for your safety, do
not attempt to bypass the safety switches, and never
tamper with the safety devices. Check their operation
regularly.
Perform the Safety
Checks
WARNING
Operational SAFETY Checks
Test 1 — Engine should NOT crank if:
• PTO switch is engaged, OR
• Parking brake is not engaged, OR
• Ground speed control levers are not in the
NEUTRAL position.
Disengage the PTO, stop the engine, set the
parking brake, and wait for moving parts to
stop before leaving operator’s position for any
reason.
If the zero-turn rider does not pass the test,
DO NOT operate the zero-turn rider. Under no
circumstance should you attempt to defeat the
purpose of the safety system.
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Functional Tests
Test 2 — Engine SHOULD crank if:
• PTO switch is NOT engaged, AND
• Parking brake is engaged, AND
• Ground speed control levers are locked in the
NEUTRAL position.
Test 3 — Engine should SHUT OFF if:
• Operator rises off seat with PTO engaged, OR
• Operator rises off seat with parking brake
disengaged.
• Operator moves ground speed control levers out of
their neutral positions before disengaging parking
brake.
1. Check the zero-turn rider for loose bolts, screws,
nuts, etc.
2. Start the engine and check all the controls for proper
operation: ground speed control levers, parking
brake, throttle cable, electric PTO clutch, etc.
3. Stop the engine and check for fluid leaks: engine oil,
fuel, and hydraulic oil.
Test 4 — Blade Brake Check
Mower blades and the mower drive belt should come
to a complete stop within seven (7) seconds after the
electric PTO switch is turned off (or the operator rises
off seat). If the mower drive belt does not stop within
seven (7) seconds, see your dealer.
4. If any control fails to operate properly during testing
or seems to be out of adjustment, check and
re-adjust it according to the following Adjustment
Procedures section.
NOTE: Once the engine has stopped, PTO switch must
be turned off, parking brake must be engaged, and
the ground speed control levers must be locked in the
NEUTRAL position after the operator returns to the seat
in order to start the engine.
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.
18
Dealer Setup Instructions
ADJUSTMENT PROCEDURES
If any controls fails to operate properly during testing or
seems to be out of adjustment, check and re-adjust it
according to the following instructions.
Neutral Adjustment
C
B
A
The neutral system for this mower consists of two neutral
linkage rods and a pivot that connects the ground speed
control lever to the transmission. The lower rod that
connects the transmission to the pivot is factory preset
and should not be changed for neutral adjustment
purposes. The adjustment is achieved by changing the
length of the upper rod (A, Figure 36) that connects the
ground speed control lever to the pivot.
Figure 36 - Neutral Adjustment
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Determining if Adjustment is Necessary: If the tractor
“creeps” while the ground speed control levers are
locked in the NEUTRAL, then it may be necessary to
adjust the linkage rods.
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NOTE: Perform this adjustment on a hard, level surface
such as a concrete floor.
1. Disengage the PTO, engage the parking brake and
turn off the engine.
2. There are two nuts (B) on the linkage rod. Loosen
the nuts from the ball joints (C) and turn the linkage
rod to adjust.
• If the machine creeps forward, turn the rod
clockwise (while standing at the rear of the machine,
facing forward);
• If the machine creeps backward, turn the rod
counter-clockwise (while standing at the rear of the
machine, facing forward).
3. Lock the jam nut against the ball joints when neutral
is achieved.
NOTE: This adjustment should not be performed while
the machine is running. It may take several attempts to
achieve neutral, depending on how much the machine
creeps.
19
B
C
Dealer Setup Instructions
Return-to-Neutral
Adjustment
Prior to performing this procedure the Neutral
Adjustment procedure must be completed.
A
C
WARNING
To avoid serious injury, perform adjustments
only with the engine stopped, ignition key
removed, and zero-turn rider parked on level
ground.
1. Lock the ground speed control lever in the neutral
position.
B
Figure 37 - Return-to-Neutral Adjustment
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2. Loosen the set collar (A, Figure 37) on the neutral
return rod (B).
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3. Position the set collar along the neutral return rod
until it contacts and very lightly compresses the
neutral return spring (C). Tighten the set collar.
4. Move the ground speed control levers into the
operating position, pull rearward, and release.
5. Move the ground speed control levers out towards
the neutral position.
• if the ground speed control lever aligns with the
notch in the neutral lock plate, adjustment is
complete.
• if the ground speed control lever stops it’s return
motion past the notch (while standing at the rear of
the machine), reposition the set collar so the neutral
return spring is less compressed.
• if the ground speed control lever stops it’s return
motion before the notch (while standing at the rear
of the machine), re-position the set collar so that the
neutral return spring is more compressed.
6. Repeat the process as necessary until the ground
speed control lever aligns with the notch in the
neutral lock plate.
NOTE: It is important to note that after every adjustment
of the neutral return rod, the lever must be pulled
rearward and released to properly check the return-toneutral position.
20
Dealer Setup Instructions
B
A
A
B
Speed Balancing
Adjustment
If the rider veers to the right or left when the ground
speed control levers are in the maximum forward
position, the top speed of each of these levers can be
balanced by turning the adjustment bolt(s) (A, Figure
38). Only adjust the speed of the wheel that is traveling
faster.
To Reduce the Speed of the Faster Wheel:
1. Loosen the securing nut (B).
2. Turn the top speed adjustment bolt counter-clockwise
to reduce the speed.
Figure 38 - Speed Balancing Adjustment
3. Retighten the securing nut when adjustment is
complete.
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WARNING
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DO NOT adjust the tractor for a faster overall
speed forward or reverse than it was designed
for.
21
Dealer Setup Instructions
3/8”
(.96 cm)
Parking Brake
Adjustment
The parking brake mechanism consists of two parking
brake cables (A, Figure 39) that connect the parking
brake lever shaft to the parking brake control arm on
the transmissions. There is a parking brake spring on
each parking brake cable located below the engine deck
by the transmission. The position of the parking brake
cable in the rear suspension cradle is factory preset and
should not be changed for parking brake adjustment
procedures. The adjustment is achieved by changing
the compressed spring length of the parking brake
springs.
1. Disengage the PTO, engage the parking brake, stop
the engine, and chock the tires.
2-3/4”
(7 cm)
A
C
B
D
Figure 39 - Parking Brake Adjustment
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2. Locate the parking brake springs (B) by the
transmissions.
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3. With the parking brake engaged measure the
compressed spring length. The spring should
measure 2-3/4” (7 cm) when compressed.
4. If the spring length does not equal the measurement,
the spring length will need to be adjusted.
5. Disengage the parking brake.
6. Loosen the set collar (C) and slide it away from the
back of the parking spring bracket (D).
WARNING
Do not adjust the spring to be shorter than
2-1/2” (6.4 cm) when compressed. This may
damage the brake mechanism.
7. Turn the adjustment nut (E) to compress or release
the spring.
8. Engage the parking brake and re-measure the
spring. Continue this process until the compressed
spring length measures 2-3/4” (7 cm).
9. Position the set collar 3/8” (0.96 cm) away from the
parking brake bracket and tighten.
If this does not correct the braking problem, see your
dealer.
22
E
Dealer Setup Instructions
A
Suspension Adjustment
The shock assemblies (A, Figure 40) can be adjusted
in two ways to allow the operator to customize the ride
according to the operator’s weight and/or operating
conditions. You have the option of adjusting the spring
pre-load and/or the upper mounting position.
C
Items to consider be adjusting the suspension:
• Less spring pre-load should be used with light
weight operators, which will provide a softer, more
cushioned ride.
2
B
• More spring pre-load should be used with heavy
weight operator’s, which will provide a stiffer, more
rigid ride.
• There are three positions in which the upper shock
mount can be positioned in. If adjusting the spring
pre-load does not achieve the ride requirement, the
shock should be moved to the next numbered upper
shock mounting position to achieve the desired ride
requirement.
1
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A
• Before adjusting the upper shock mount to a higher
numbered position, you should attempt to achieve the
ride height through the spring pre-load adjustment.
Figure 40 - Suspension Adjustment
• Shock mounting position #3 should always be used
when a rear mounted grass collection system is
installed on the unit.
TO ADJUST THE SPRING PRE-LOAD:
1. Park the machine on a flat, level surface. Disengage
the PTO, stop the engine, and engage the parking
brake.
2. Chock the front wheels to prevent the machine from
rolling. Raise the rear of the machine and secure with
jack stands.
3. Remove the rear drive tires.
WARNING
Spring loaded components can kick back
causing injury. Use two hands when adjusting
the shock springs. This will prevent the wrench
from slipping while pressure is being applied.
4. Using the supplied spanner wrench (p/n 5022853) (B,
Figure 40), insert the tip of the wrench into the notch
in the pre-load adjuster. While holding the wrench
in place with one hand, turn counter-clockwise to
increase the pre-load, turn clockwise to decrease
the pre-load. Make sure both shocks are set to the
same amount of pre-load.
23
3
Dealer Setup Instructions
5. Re-install the rear drive tires. Torque the lug bolts to
85-95 ft.lbs. (115-129 Nm). Remove the jack stands
from under the machine.
NOTE: If a collection system is installed it is
recommended that the rear suspension be adjusted
stiffer due to the added weight of the collection system.
TO ADJUST THE UPPER MOUNTING POSITION
(REAR SHOCKS):
1. Park the machine on a flat, level surface. Disengage
the PTO, stop the engine, and engage the parking
brake.
2. Chock the front wheels to prevent the machine from
rolling. Raise the rear of the machine and secure
with jack stands. The jack stands must be under the
bumper of the machine.
3. Position the jack underneath the rear cross member
of the transmission cradle and slowly raise the rear
suspension to relieve the pressure on the upper
shock mounting bolts.
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4. Remove the upper shock mounting hardware and
pivot the shock to the next higher numbered position
(see Figure 40). Adjust the jack to align the shock
mounts to shocks.
5. Remove the jack from under the transmission cradle.
6. Remove the jack stands from underneath the
machine.
Briggs & Stratton Power Products Group, LLC.
Copyright © 2016 Briggs & Stratton Corporation
Milwaukee, WI, USA. All rights reserved.
FERRIS is a trademark of Briggs & Stratton Corporation
Milwaukee, WI, USA.
Contact Information:
Briggs & Stratton Power Products Group, LLC.
5375 N. Main St.
Munnsville, NY 13409-4003
(800) 933-6175
www.ferrismowers.com
24
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