Ferris Industries Lawn Mower IS4000Z KAV27 User Manual

OPERATOR’S  
MANUAL  
IS4000Z Series  
Zero-Turn Riding Mower  
Tractor:  
Models  
IS4000Z/D31  
Mower Deck:  
Description  
IS4000Z w/ 31 HP B&S,D Engine  
Models  
Description  
4000/72 72” Mower Deck  
4000/61 61” Mower Deck  
IS4000Z/KAV27 IS4000Z w/ 27 HP Kawasaki Engine  
22470  
Ferris Industries  
Rev. No. 04  
Rev. Date: 9/2003  
TP 100-7002-04-4Z-F  
5375 North Main Street  
Munnsville, NY 13409  
800-933-6175  
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Table of Contents  
Troubleshooting, Adjustments & Service.......22  
Troubleshooting the Rider.....................................22  
Troubleshooting the Mower...................................23  
Seat Adjustment....................................................24  
Ground Speed Control Lever Adjustment.............24  
Speed Balancing Adjustment................................24  
Parking Brake Adjustment ....................................25  
Suspension Height Adjustment.............................26  
Mowing Height Adjustment ...................................26  
Mower Deck Leveling Adjustment.........................27  
Deck Lift Spring Adjustment .................................27  
PTO Clutch Adjustment ........................................28  
Blade Brake Check ...............................................28  
Neutral Adjustment ...............................................29  
Belt Removal & Replacement...............................30  
Mower Deck Drive Belt.................................30  
Clutch Drive Belt ..........................................31  
Pump Drive Belt ...........................................32  
Gearbox Maintenance...........................................33  
Check Gearbox Oil Level .............................33  
Change Gearbox Oil ....................................33  
Battery Service .....................................................34  
Checking the Battery Voltage.......................34  
Charging A Completely  
Identification Numbers .......................................2  
Safety Rules & Information ................................3  
Features & Controls............................................6  
Control Functions....................................................6  
Safety Interlock System ..........................................7  
Operating the Zero Turn Rider ...........................8  
General ...................................................................8  
Checks Before Starting...........................................8  
Starting the Engine .................................................9  
Stopping the Rider..................................................9  
Mowing....................................................................9  
Pushing the Rider by Hand.....................................9  
Zero Turn Driving Practice ....................................10  
Storage..................................................................12  
Starting After Long Term Storage .........................12  
Regular Maintenance ........................................14  
Maintenance Schedule .........................................14  
Checking Tire Pressures.......................................14  
Checking/Adding Fuel...........................................15  
Fuel Filter..............................................................15  
Oil & Filter Change ...............................................15  
Check / Change Air Filter......................................15  
Replace Spark Plug..............................................15  
Check Hydraulic Oil Level.....................................15  
Check Antifreeze Level .........................................16  
Change Antifreeze ................................................16  
Clean Radiator Screens........................................16  
Check Warning Lights and Buzzer........................16  
Lubrication ............................................................17  
Battery Maintenance.............................................19  
Checking Battery Fluid.................................19  
Discharged Battery.................................34  
Jump Starting with  
Auxiliary (Booster) Battery......................34  
Lawn Care & Mowing Information.............LC—1  
NOTE: In this manual, “left” and “right” are referred to as  
seen from the operating position.  
Cleaning the Battery and Cables.................19  
Servicing the Mower Blades .................................20  
WARNING  
Engine exhaust from this product contains  
chemicals known, in certain quantities, to cause  
cancer, birth defects, or other reproductive harm.  
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.  
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.  
© Copyright 2003 Ferris Industries  
All Rights Reserved. Printed in USA.  
TP 100-7002-04-4Z-F  
1
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Identification  
Numbers  
IDENTIFICATION TAG LOCATIONS  
When contacting your  
Authorized Dealer for  
replacement parts, service,  
or information YOU MUST  
HAVE THESE NUMBERS.  
Tractor  
identification tag  
XXXXXXX  
XXXXXXX  
IDENTIFICATION NUMBERS  
Record your model name/number, unit and mower deck,  
manufacturer numbers and engine serial number in the  
space provided for easy reference.  
PRODUCT REFERENCE DATA  
Model Description Name/Number  
Unit MFG Number  
Unit SERIAL Number  
The Tractor I.D. tag is located on the inside of the  
main frame rail, behind the deck height plate.  
Mower Deck MFG Number  
Mower Deck SERIAL Number  
The Mower Deck I.D. tag is located under the right-  
hand guard, near the front of the deck.  
Date Purchased  
Dealer Name  
For location of Engine Serial Number, refer to the  
Engine Owner’s Manual.  
ENGINE REFERENCE DATA  
Be sure to fill out and return the Warranty Registration  
Card supplied with your unit.  
Engine Make/Model  
Engine ID/Serial Number  
2
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Safety Rules  
& Information  
Read these safety rules and follow them closely. Failure to obey these rules could result in loss of con-  
trol of the unit, severe personal injury or death to you, or bystanders, or damage to property or equip-  
ment. This mowing deck is capable of amputating hands and feet and throwing objects. The trian-  
gle  
in text signifies important cautions or warnings which must be followed.  
OPERATION  
TRAINING  
• Never run an engine in an enclosed area.  
• Read, understand, and follow all instructions in the  
manual and on the unit before starting. If the opera-  
tor(s) or mechanic(s) can not read English it is the  
owner’s responsibility to explain this material to them.  
• Mow only in the daylight or with good artificial light.  
• 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 provid-  
ed.  
• Become familiar with the safe operation of the equip-  
ment, operator controls, and safety signs.  
• All operators and mechanics should be trained. The  
owner is responsible for training the users.  
• Do not mow in reverse unless absolutely necessary.  
Always look down and behind before and while trav-  
elling in reverse.  
• Only allow responsible adults, who are familiar with  
the instructions, to operate the unit.  
• 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 deflec-  
tor in place.  
• Never let children or untrained people operate or  
service the equipment. Local regulations may  
restrict the age of the operator.  
• Slow down and use caution when making turns and  
when changing directions on slopes.  
• The owner/user can prevent and is responsible for  
accidents or injuries occurring to themselves, other  
people or property.  
• Never raise deck with the blades running.  
• Data indicates that operators, age 60 years and  
above, are involved in a large percentage of riding  
mower-related injuries. These operators should eval-  
uate their ability to operate the riding mower safely  
enough to protect themselves and others from seri-  
ous injury.  
• Never leave a running unit unattended. Always disen-  
gage the PTO, set parking brake, stop engine, and  
remove keys before dismounting. Keep hands and  
feet away from the cutting units.  
Turn off the PTO switch to disengage the blades  
when not mowing.  
PREPARATION  
• Never operate with guards not securely in place. Be  
sure all interlocks are attached, adjusted properly  
and functioning properly.  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and safely  
perform the job. Use only accessories and attach-  
ments approved by the manufacturer.  
• Never operate with the discharge deflector raised,  
removed or altered, unless using a grass catcher.  
• Wear appropriate clothing including safety shoes,  
safety glasses and ear protection. Long hair, loose  
clothing or jewelry may get tangled in moving parts.  
• Do not change the engine governor setting or over-  
speed the engine.  
• Stop on level ground, lower implements, disengage  
drives, engage parking brake, shut off engine before  
leaving the operator’s position for any reason includ-  
ing emptying the grass catchers or unclogging the  
chute.  
• 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.  
• Use extra care when handling gasoline and other  
fuels. They are flammable and vapors are explosive.  
• Stop equipment and inspect blades after striking  
objects or abnormal vibration occurs. Make neces-  
sary repairs before resuming operations.  
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.  
• Do not operate the unit while under the influence of  
alcohol or drugs.  
• Slow down and use caution when making turns and  
crossing roads and sidewalks. Stop blades if not  
mowing.  
c) Never refuel the unit indoors.  
• Check that operator’s presence controls, safety  
switches and shields are attached and functioning  
properly. Do not operate unless they are functioning  
properly.  
• Use extra care when loading or unloading the unit  
into a trailer or truck.  
• Use care when approaching blind corners, shrubs,  
trees or other objects that may obscure vision.  
3
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Safety Rules & Information  
SLOPE OPERATION  
CHILDREN  
Slopes are a major factor related to loss-of-control and  
tip-over accidents, which can result in severe injury or  
death. All slopes require extra caution. If you cannot  
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 chil-  
back up the slope or if you feel uneasy on it, do not drive dren will remain where you last saw them.  
on it.  
• Keep children out of the mowing area and under the  
watchful care of another responsible adult.  
WARNING  
• Be alert and turn unit off if children enter the area.  
Never operate on slopes greater than 30 percent  
(16.7°) which is a rise of three feet vertically in 10  
feet horizontally. In the forward direction, this  
machine will climb a slope too steep to mow  
safely.  
• Before and during reverse operation, look behind and  
down for small children.  
• Never carry children. They may fall off and be seri-  
ously injured or interfere with safe unit operation.  
• Never allow children to operate the unit.  
• Select slow ground speed before driving onto slope.  
In addition to front and rear weights, use extra cau-  
tion when operating on slopes with rear-mounted  
grass catcher.  
• Use extra care when approaching blind corners,  
shrubs, trees, or other objects that may obscure  
vision.  
• Watch for any changes in the terrain such as ditches,  
holes, rocks, dips and rises, which change the oper-  
ating angle of the machine.  
TRANSPORTING AND STORAGE  
• Always observe safe refueling and fuel handling  
practices when refueling the unit after transportation  
or storage.  
• Carefully follow the “Do’s” and “Dont’s” listed below.  
• Always follow the engine manual instructions for  
storage preparations before storing the unit for both  
short and long term periods.  
Do  
• See your authorized dealer for recommendations of  
available weights to improve stability.  
• Always follow the engine manual instructions for  
proper start-up procedures when returning the unit to  
service.  
• Remove obstacles such as rocks, tree limbs, etc.  
• Watch for holes, ruts, or bumps. Uneven terrain could  
overturn the unit. Tall grass can hide obstacles.  
• Never store the unit or fuel container inside where  
there is an open flame or pilot light, such as in a  
water heater. Allow unit to cool before storing.  
• Use slow speed. Choose a slow speed so that you  
will not have to stop or change speed while on the  
slope.  
• Use extra care with grass catchers or other attach-  
ments. These can change the stability of the unit.  
SERVICE AND MAINTENANCE  
• Use extra care when handling gasoline and other  
fuels. They are flammable and vapors are explosive.  
• Keep all movement on the slopes slow and gradual.  
Do not make sudden changes in speed or direction.  
a) Use only an approved container.  
Do Not  
b) Never remove fuel cap or add fuel with the engine  
running. Allow engine to cool before refueling. Do  
not smoke.  
• Do not start or stop on a slope. If tires lose traction,  
disengage the blade(s) and proceed slowly straight  
down the slope.  
• Do not turn on slopes unless necessary, and then,  
turn slowly and gradually downhill, if possible.  
c) Never refuel the unit indoors.  
• Never run a unit in an enclosed area.  
• Do not mow near drop-offs, ditches, or embank-  
ments. The mower could suddenly turn over if a  
wheel is over the edge of a cliff or ditch, or if an edge  
caves in.  
• Keep nuts and bolts, especially blade attachment  
bolts, tight and keep equipment in good condition.  
• Never tamper with safety devices. Check their proper  
operation regularly.  
• Do not mow on wet grass. Reduced traction could  
cause sliding.  
• Keep unit free of grass, leaves, or other debris build-  
up. Clean up oil or fuel spillage.  
• Do not try to stabilize the unit by putting your foot on  
the ground.  
• Stop and inspect the equipment if you strike an  
object. Repair, if necessary, before restarting.  
• Do not use grass catcher on steep slopes.  
• Never make adjustments or repairs with the engine  
running unless specified otherwise in the engine  
manufacturer’s manual.  
4
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Safety Rules & Information  
WARNING  
Hydraulic fluid escaping under pressure may  
have sufficient force to penetrate skin and cause  
serious injury.  
• Grass catcher components are subject to wear, dam-  
age, and deterioration, which could expose moving  
parts or allow objects to be thrown. Frequently check  
components and replace with manufacturer’s recom-  
mended parts, when necessary.  
• Mower blades are sharp and can cut. Wrap the  
blade(s) or wear gloves, and use extra caution when  
servicing them.  
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.  
• Check brake operation frequently. Adjust and service  
as required.  
• Use only factory authorized replacement parts when  
making repairs.  
• Always comply with factory specifications on all  
settings and adjustments.  
• Only authorized service locations should be utilized  
for major service and repair requirements.  
• Never attempt to make major repairs on this unit  
unless you have been properly trained. Improper  
service procedures can result in hazardous opera-  
tion, equipment damage and voiding of manufactur-  
er’s warranty.  
WARNING  
STORED ENERGY DEVICE  
Improper release of the deck lift assist spring can  
result in serious personal injury. Spring should  
be removed by an authorized dealer only.  
SAFETY DECALS  
This unit has been designed and manufactured to pro-  
vide you with the safety and reliability you would expect  
from an industry leader in outdoor power equipment  
manufacturing.  
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!  
Reading this manual and the safety instructions will pro-  
vide 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  
while you are operating your unit.  
If any of these decals are lost or damaged, replace them  
at once. See your local dealer for replacements.  
These labels are easily applied and will act as a con-  
stant visual reminder to you, and others who may use  
the equipment, to follow the safety instructions neces-  
sary for safe, effective operation.  
Decal - Danger  
Decal - Danger  
Part No. 1704277  
Part No. 1704276  
WARNING  
BEWARE OF  
Decal - Warning/Danger  
Part No. 46387  
POWER DRIVEN PARTS  
Decal - Warning  
Part No. 20337  
5
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Features & Controls  
of the Zero Turn Rider  
Please take a moment and familiarize yourself with  
the name, location, and function of the following.  
This will enable you to understand the safety and oper-  
ating instructions provided in this manual.  
A
B
A
C
E
H
I
J
K
L
D
M
F
N
G
O
Figure 1. CONTROL FUNCTIONS  
The information below briefly describes the function of the individual controls. Starting, stopping, driving, and mow-  
ing 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.  
A. Ground Speed Control Levers  
C. Ignition Switch  
These levers control the ground speed of the rider. The  
left lever controls the left rear drive wheel and the right  
lever controls the right rear drive wheel.  
The ignition switch starts and stops the engine, it has  
three positions:  
OFF  
Stops the engine and shuts off the  
electrical system.  
Moving a lever forward increases the FORWARD speed  
of the associated wheel, and pulling back on a lever  
increases the REVERSE speed.  
RUN  
Allows the engine to run and powers the  
electrical system.  
Note: The further a lever is moved away from the neutral  
position the faster the drive wheel will turn.  
START Cranks the engine for starting.  
NOTE: Never leave the ignition switch in the RUN posi-  
tion with the engine stopped–this drains the battery.  
See the Operating the Zero Turn Rider section, page 8,  
for steering instructions.  
D. Parking Brake Handle  
B. Seat Adjustment Lever  
The parking brake is applied by pulling UP on the park-  
ing brake handle until it locks over-center. To release the  
parking brake, push the handle DOWN.  
The seat can be adjusted forward and back. Move the  
lever forward, position the seat as desired, and release  
the lever to lock the seat in position.  
6
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Features & Controls  
E. PTO (Power Take Off) Switch  
SAFETY  
INTERLOCK SYSTEM  
The PTO switch engages and disengages the mower.  
Pull UP on the switch to engage the mower, and push  
DOWN to disengage the mower.  
This unit is equipped with safety interlock switches and  
other safety devices. These safety systems are present  
for your well being, do not attempt to bypass safety  
switches, and never tamper with safety devices. Check  
their operation regularly.  
F & G. Deck Lift Pedal & Cutting Height  
Adjustment Pin  
These control the cutting height of the mower deck.  
Depress the pedal until it locks into the TRANSPORT  
position. Place the adjustment pin in the desired cutting  
height and release the lift pedal.  
Operational SAFETY Checks  
Your unit is equipped with a seat switch safety system.  
Check the seat switch operation every fall and spring  
with the following tests.  
H & I. Throttle / Choke Control  
Pulling the round choke control knob (I) out fully chokes  
the engine for cold starts. (A warm engine may not  
require choking.) Moving the throttle control (H) fully for-  
ward is FULL throttle position. Always operate the unit  
at FULL throttle when mowing.  
Test 1 — Engine should NOT crank if:  
• PTO switch is engaged, OR  
• Parking brake is not engaged, OR  
• Motion control handles are not in the NEUTRAL  
position, OR  
J. Hour Meter  
Measures the time of the PTO being engaged.  
• Operator is not on the seat.  
Test 2 — Engine SHOULD crank if:  
K. Voltmeter  
Measures the battery voltage.  
• PTO switch is NOT engaged, AND  
• Parking brake is engaged, AND  
L. Water Temperature Gauge (IS4000Z/D31 only)  
Measures the engine coolant temperature.  
• Motion control handles are locked in the NEUTRAL  
position, AND  
M. Indicator Lights & Warning Buzzer  
• Operator is on the seat.  
The indicator lights will illuminate and buzzer will sound  
when the ignition switch is in the “ON” position before  
cranking the engine. After the engine is running, the  
indicator lights will illuminate and the buzzer will sound  
when there is either low oil pressure or high coolant  
temperature.  
Test 3 — Engine should SHUT OFF if:  
• Operator rises off seat with PTO engaged, OR  
• Operator rises off seat with parking brake disen-  
gaged, OR  
• Operator moves the control levers out of the neutral  
position with the parking brake engaged.  
N. Fuel Tank Selection/Shut Off Valve  
Test 4 — Blade Brake Check  
Turning the handle to the desired position determines  
which tank will be supplying fuel. With the handle point-  
ing towards the left, it will draw fuel from the left-hand  
tank. With the handle pointed towards the right, it will  
draw fuel from the right-hand fuel tank. With the handle  
pointing towards the operator, it will shut off fuel flow to  
the engine.  
Mower blades and mower drive belt should come to a  
complete stop within seven seconds after electric PTO  
switch is turned off (or operator rises off seat). 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 handles must be locked in the NEUTRAL  
position after the operator returns to the seat in order to  
start the engine.  
O. Left Tank Selection Valve  
Turning the handle to the desired position determines  
which section of the left-hand tank will be supplying fuel.  
With the handle pointing towards the right, it will draw  
fuel from the primary section of the fuel tank. With the  
handle pointing towards the left, it will draw from the  
reserve section of the tank. With the handle pointing  
towards the operator, it will shut off fuel flow to the tank  
selection shut off valve.  
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
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Operating  
the Zero Turn Rider  
GENERAL OPERATING SAFETY  
Before first time operation:  
DANGER  
OPERATING ON SLOPES CAN BE  
DANGEROUS  
• Be sure to read all information in the Safety and  
Operation sections before attempting to operate this  
tractor and mower.  
Never operate on slopes greater than 30 percent  
(16.7°) which is a rise of three feet vertically in 10  
feet horizontally.  
• Become familiar with all of the controls and how to  
stop the unit.  
• Drive in an open area without mowing to become  
accustomed to the unit.  
Operate the unit at a slow ground speed when  
driving onto slope.  
Use extra caution when operating on slopes with  
rear-mounted grass catcher, and when changing  
directions. DO NOT START OR STOP ON A  
SLOPE.  
CHECKS BEFORE STARTING  
• Check that crankcase is filled to full mark on dipstick.  
See the engine Operators Manual for instructions  
and oil recommendations.  
• Check the radiator fluid level. See engine’s operators  
manual for instructions.  
WARNING  
Never allow passengers to ride on the unit.  
• Check the hydraulic oil level. Refer to regular main-  
tenance section, page 15.  
Turn the key switch to the on position, but do not  
start the engine. The Warning Buzzer for both the  
water temperature and oil pressure should be heard,  
and the Indicator lights on the indicator for both the  
water temperature and oil pressure should be illumi-  
nated. The lights and warning buzzer should go off  
when the engine starts.  
Before leaving the operators 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.  
• Make sure all nuts, bolts, screws and pins are in  
place and tight.  
• Adjust the seat position, and make certain you can  
reach all controls from the operators position.  
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.  
• Fill the fuel tanks with fresh fuel. Refer to engine  
manual for fuel recommendations.  
8
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Operating the Zero Turn Rider  
MOWING  
WARNING  
1. Engage the parking brake. Make sure the PTO  
switch is disengaged, the motion control handles are  
locked in the NEUTRAL position and the operator is  
on the seat.  
If you do not understand how a specific control  
functions, or have not yet thoroughly read the  
FEATURES & CONTROLS section, do so now.  
2. Start the engine (see STARTING THE ENGINE).  
3. Set the mower cutting height.  
Do NOT attempt to operate the tractor without  
first becoming familiar with the location and  
function of ALL controls.  
4. Engage the PTO by pulling up on the PTO switch (E,  
Figure 1).  
STARTING THE ENGINE  
5. Set the throttle to FULL.  
1. While sitting in the operators seat, engage the park-  
ing brake and make sure the PTO switch is disen-  
gaged and the motion control handles are locked in  
the NEUTRAL position.  
6. Begin mowing. See the Lawn Care Section for tips  
on mowing patterns, lawn care, and trouble shooting  
information.  
7. When finished, slow engine down and shut off the  
PTO.  
2. NOTE: A warm engine may not require choking.  
Set the engine throttle control (H, Figure 1) to FAST  
throttle position. Then fully close the choke (I, Figure  
1) by pulling the knob OUT fully.  
8. Stop the engine (see STOPPING THE TRACTOR  
AND ENGINE).  
PUSHING THE RIDER BY HAND  
3. Insert the key into the ignition switch (C, Figure 1)  
and turn it to START.  
DO NOT TOW RIDER  
4. After the engine starts, gradually open the choke  
(push knob down fully).  
Towing the unit will cause hydraulic pump  
and wheel motor damage. Do not use  
another vehicle to push or pull this unit.  
Warm up the engine by running it for at least a minute  
before engaging the PTO switch or driving the rider.  
1. See Figure 2 to locate the hydraulic release valves.  
5. After warming the engine, ALWAYS operate the  
2. To open the dump valves, turn the right-hand release  
valve, which is located on top of the right-hand  
pump, counter-clockwise 2 full turns MAX. Then turn  
the left-hand release valve, which is located on the  
bottom of the left-hand pump, counter-clockwise 2  
full turns MAX.  
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 RIDER.  
3. Disengage the parking brake. The tractor can now  
be pushed by hand.  
STOPPING THE RIDER  
1. Returning the ground speed control levers (A, Figure  
1) to the middle position will stop tractor movement.  
Pivot the levers outward and lock them in NEUTRAL.  
4. After moving the tractor, re-engage the pumps (drive  
position) by turning the release valves clockwise and  
tighten to 80-120 in/lbs.  
2. Disengage the PTO by pushing down on the PTO  
switch (E, Figure 1).  
3. Engage the parking brake by pulling the handle (D,  
Figure 1) up until it locks into position.  
4. Move the throttle control (H, Figure 1) to mid-throttle  
position and turn the ignition key to OFF. Remove  
the key.  
A
Figure 2. Hydraulic Release Valve Location  
A. Hydraulic Release Valve (Right-hand side shown)  
9
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Operating the Zero Turn Rider  
Smooth Travel  
ZERO TURN  
The lever controls of the  
Zero Turn rider are  
RESPONSIVE .  
DRIVING PRACTICE  
The lever controls of the Zero Turn rider are responsive,  
and learning to gain a smooth and efficient control of the  
rider’s forward, reverse, and turning movements will take  
some practice.  
The BEST method of  
handling the ground  
speed control levers is in  
three steps — as shown  
in Figure 3.  
Spending some time going through the maneuvers  
shown and becoming familiar with how the unit acceler-  
ates, travels, and steers — before you begin mowing —  
is absolutely essential to getting the most out of the Zero  
Turn rider.  
FIRST place your hands  
onto the levers as shown.  
Locate a smooth, flat area of your lawn — one with  
plenty of room to maneuver. (Clear the area of objects,  
people and animals before you begin.) Operate the unit  
at mid-throttle during this practice session (ALWAYS  
operate at full throttle when mowing), and turn slowly to  
prevent tire slippage and damage to your lawn.  
SECOND, to go forward  
gradually push the levers  
forward with your palms.  
We suggest you begin with the Smooth Travel procedure  
to the right, and then advance through the forward,  
reverse, and turning maneuvers.  
THIRD, to speed up move  
the levers farther forward.  
To slow down smoothly,  
slowly move the levers  
toward neutral.  
You must release the parking brake prior to moving the  
control levers inward.  
Figure 3. Move Control  
Levers Gradually  
BASIC DRIVING  
Forward Travel Practice  
Reverse Travel Practice  
Gradually move both ground speed control levers —  
evenly FORWARD from neutral. Slow down and repeat.  
LOOK DOWN & BEHIND, then gradually move both  
ground speed control levers evenly BACK from neutral.  
Slow down and repeat.  
NOTE: Straight forward travel takes practice. If neces-  
sary, top speed can be balance-adjusted — see the  
Speed Balancing Adjustment in the Adjustments section  
near the back of this manual.  
NOTE: Practice backing up for several minutes before  
attempting to do so near objects. The rider turns sharply  
in reverse as well as forward, and backing up straight  
takes practice.  
Reverse  
Travel  
Forward  
Travel  
Figure 4. Forward Travel  
Figure 5. Forward Travel  
10  
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Operating the Zero Turn Rider  
Practice Turning Around a Corner  
Practice Turning In Place  
While traveling forward allow one handle to gradually  
return back toward neutral. Repeat several times.  
To turn in place, “Zero Turn,” gradually move one ground  
speed control lever forward from neutral and one lever  
back from neutral simultaneously. Repeat several times.  
NOTE: To prevent pivoting directly on the tire tread, it is  
best to keep both wheels going at least slightly forward.  
NOTE: Changing the amount each lever is pulled—forward  
or back, changes the “pivot point” you turn on.  
Turning  
In-Place  
Executing  
Turns  
Figure 6. Turning Around a Corner  
Figure 7. Turning in Place  
ADVANCED DRIVING  
Executing an End-Of-Row Zero  
Turn  
Your Zero Turn Rider’s unique ability to turn  
in place allows you to turn around at the end  
of a cutting row rather than having to stop  
and Y-turn before starting a new row.  
For example, to execute a right end-of row  
Zero Turn:  
1. Slow down at the end of the row.  
2. Move the RIGHT ground speed control  
lever forward slightly while moving the  
LEFT ground speed control lever back to  
center and then slightly back from center.  
3. Begin mowing forward again.  
This technique turns the rider LEFT and  
slightly overlaps the row just cut —eliminating  
the need to back up and re-cut missed grass.  
As you become more familiar and experi-  
enced with operating the Zero Turn rider, you  
will learn more maneuvers that will make  
your mowing time easier and more enjoyable.  
Remember, the more you practice, the  
better your control of the Zero Turn will  
be!  
Figure 8. Executing an End-Of-Row Turn  
11  
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Operating the Zero Turn Rider  
11. Drain fuel system completely or add a gasoline stabiliz-  
er 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 trav-  
el to distant sources of ignition and ignite, causing risk  
of explosion and fire.  
STORAGE  
Temporary Storage (30 Days Or Less)  
Remember, the fuel tank will still contain some gasoline, so  
never store the unit indoors or in any other area where fuel  
vapor could travel to any ignition source. Fuel vapor is also  
toxic if inhaled, so never store the unit in any structure used  
for human or animal habitation.  
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.  
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 unau-  
thorized 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.  
WARNING  
• If the unit can’t be stored on a reasonable level surface,  
chock the wheels.  
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.  
• Clean all grass and dirt from the mower.  
• If temperature is expected to drop below 35 degrees,  
refer to Long Term Storage, Item 2.  
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:  
Handle gasoline carefully. It is highly flammable  
and careless use could result in serious fire  
damage to your person or property.  
1. Drain crankcase oil while engine is hot and refill with a  
grade of oil that will be required when unit is used  
again.  
Drain fuel outdoors into an approved container  
and away from open flame or sparks.  
2. Use an Antifreeze tester to check the cooling system’s  
level of protection. Read the instructions on the  
Antifreeze container for the appropriate ratio of water to  
Antifreeze for your geographical area.  
STARTING AFTER  
LONG TERM STORAGE  
Before starting the unit after it has been stored for a long  
period of time, perform the following steps.  
3. Prepare the mower deck for storage as follows:  
a. Remove mower deck from the unit.  
b. Clean underside of mower deck.  
1. Remove any blocks from under the unit.  
2. Install the battery if it was removed.  
3. Unplug the exhaust outlet and air cleaner.  
c. Coat all bare metal surfaces with paint or light coat of  
oil to prevent rusting.  
4. Clean external surfaces and engine.  
4. Fill the fuel tank with fresh gasoline. See engine manu-  
al for recommendations.  
5. Prepare engine for storage. See engine owner’s  
manual.  
5. See engine owner’s manual and follow all instructions  
for preparing engine after storage.  
6. Clean any dirt or grass from cylinder head cooling fins,  
engine housing and air cleaner element.  
6. Check crankcase oil level and add proper oil if neces-  
sary. If any condensation has developed during stor-  
age, drain crankcase oil and refill.  
7. Cover air cleaner and exhaust outlet tightly with plastic  
or other waterproof material to keep out moisture, dirt  
and insects.  
7. Check coolant level, refer to “Check Antifreeze Level” on  
page 16.  
8. Completely grease and oil unit as outlined in the  
Regular Maintenance section.  
8. Check Hydraulic oil level, refer to “Check Hydraulic Oil  
Level” section on page 15.  
9. Clean up unit and apply paint or rust preventative to any  
areas where paint is chipped or damaged.  
9. Inflate tires to proper pressure.  
10. 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.  
10. 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  
12  
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Notes  
13  
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Regular  
Maintenance  
MAINTENANCE SCHEDULE & PROCEDURES  
The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of  
your operating time. Determining operating time is easily accomplished by observing the hour meter.  
See  
Page  
Before  
Before  
Every  
Every  
Every  
Spring  
& Fall  
SAFETY ITEMS  
First Use Each Use 5 Hours 25 Hours 100 Hours  
Check Safety Interlock System  
Check Rider Brakes  
7
X
X
X
X
23  
24  
Check Mower Blade Stopping Time  
X
X
See  
Page  
Before  
Before  
Every  
Every  
Every  
Spring  
& Fall  
NORMAL CARE ITEMS  
First Use Each Use 5 Hours 25 Hours 100 Hours  
Check Rider/Mower for loose hardware  
Check Engine Oil Level  
Check Engine Air Filter  
Change Engine Oil & Filter **  
Lubricate Rider & Mower  
Check Tire Pressure  
15*  
15*  
15*  
17  
14  
15  
15  
17  
18  
15*  
16  
16  
16  
16  
29  
X
X
X
X
X
X
X
***X  
***X Every 50 Hours  
***X  
***X  
***X  
***X  
X
X
X
Check Hydraulic Fluid  
Check Fuel Filter  
Clean Battery & Cables  
Clean & Sharpen Mower Blades  
Inspect Spark Plug  
X
X
X
Check Coolant Level  
X
Change Coolant  
X
X
Check & Clean Radiator Screens  
Check Warning Buzzer & Lights  
Check Gearbox Oil Level ****  
X
X
X
X
* See the engine manufacturer's owner's manual.  
** Change original engine oil after first 5 hours of operation.  
*** More often in hot (over 85° F: 30° C) weather or dusty operating conditions.  
**** Change gearbox oil after first 100 hrs. and every 500 hrs. thereafter (see Gearbox Maintenance).  
CHECK TIRE PRESSURES  
Tire Pressure should be checked periodically, and main-  
tained 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  
Front  
Rear  
Pressure  
25 psi (172 kPa)  
18 psi (124 kPa)  
Figure 9. Checking Tire Pressure  
14  
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Regular Maintenance  
CHECKING / ADDING FUEL  
WARNING  
To add fuel:  
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.  
1. Remove the fuel cap.  
2. Fill the tank to the bottom of the fill tube. This will  
leave room in the tank for fuel expansion. Refer to  
your engine manual for specific fuel recommenda-  
tions.  
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.  
3. Install and hand tighten the fuel cap.  
4. Repeat same process for opposite tank.  
FUEL FILTER  
The fuel filter is located in the fuel line between fuel shut  
off valve and the fuel pump. If filter is dirty or clogged,  
replace as follows:  
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.  
1. Shut off the fuel valve.  
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.  
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.  
OIL & FILTER CHANGE  
Refer to engine owners manual.  
CHECK / CHANGE AIR FILTER  
Refer to engine owners manual.  
REPLACE SPARK PLUG  
Refer to engine owners manual.  
B
A
CHECK HYDRAULIC OIL LEVEL  
NOTE: Do not open the hydraulic oil reservoir unless oil  
is being added.  
1. Visually check that the hydraulic oil level is filled to  
the recess area (C, Figure 10) of the hydraulic oil  
reservoir (A, Figure 10).  
C
3. If necessary, remove the reservoir cap (B, Figure 10)  
and add either Mobil 1™, 15W-50 synthetic oil or  
Castrol Syntec™ 5W-50 oil. DO NOT use conven-  
tional oils. Make sure area around the filler neck is  
free of dust, dirt, or other debris.  
Figure 10. Checking Hydraulic Oil Level  
A. Hydraulic Oil Reservoir  
B. Cap  
C. Tank Recess  
15  
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Regular Maintenance  
CHECK ANTIFREEZE LEVEL  
The engine coolant level and quality should be checked  
before each use, when the engine is cool and off.  
B
A
1. Check the coolant in the overflow reservoir (A,  
Figures 11A & 11B). Coolant should be between the  
“FULLand “LOW” marks on the tank.  
2. If coolant level is below the “LOW” on the overflow  
reservoir, add coolant by shutting off the engine,  
allowing the engine to cool, removing the reservoir  
cap (B, Figures 11A & 11B) and adding coolant.  
Refer to Antifreeze container for proper mix ratio of  
Antifreeze and distilled water.  
CHANGE ANTIFREEZE  
See engine owners manual for specific antifreeze proce-  
dures. The antifreeze drain valve is located at the base  
of the right-hand side of the radiator.  
Figure 11A. Engine Coolant and Overflow  
(IS4000Z/D31)  
A. Coolant Overflow Reservoir  
B. Reservoir Cap  
CLEAN RADIATOR SCREENS  
Clean the radiator screens before each use to allow  
proper air-flow through radiator and engine compart-  
ment.  
B
A
1. Open the hood  
2. Slide both radiator screens (A, Figure 12) up and out  
of the mounting tracks.  
3. Clean all dirt, grass, and debris from the screens.  
4. Reinstall the screens.  
CHECK WARNING LIGHTS AND  
BUZZER.  
1. Turn the ignition key to the ON position, but DO NOT  
start the engine.  
Figure 11B. Engine Coolant and Overflow  
(IS4000Z/KAV27)  
A. Coolant Overflow Reservoir  
B. Reservoir Cap  
2. View the warning light gauge. The red lights contain-  
ing each symbol for water temperature and oil pres-  
sure should be illuminated and the warning buzzer  
should also be on.  
Once the engine is running, the buzzer and the warning  
lights should turn off. During operation, if the buzzer or  
warning lights come on, this indicates either high coolant  
temperature or low oil pressure.  
If the lights are not visible, or the buzzer can not be  
heard, please contact your Ferris dealer.  
A
Figure 12. Radiator Screens  
(IS4000Z/D31 shown)  
A. Radiator Screens  
16  
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Regular Maintenance  
LUBRICATION  
Lubricate the unit at the locations shown in FIgure 13  
through 19 as well as the following lubrication points  
Grease:  
• front caster wheel axles  
• motion control pivots  
• suspension a-arms  
• rear deck mounts  
• deck lift pivots  
• deck lift foot pedal  
• blade spindles  
Use grease fittings when present. Disassemble  
parts to apply grease to moving parts when grease  
fittings are not installed.  
Figure 13. Deck Lift Pedal & Pivots  
Not all greases are compatible. Ferris Red Grease  
(P/N 22285) is recommended, automotive-type high-  
temperature, lithium grease may be used when this  
is not available.  
Oil:  
• control handle pivots  
• floor plate hinge  
• discharge chute hinge  
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 fit-  
tings and surfaces clean both before and after lubri-  
cation.  
Figure 14. Deck Lift Linkage Pivots  
Figure 15. Deck Lubrication  
(72” mower deck shown, same locations for 61” mower deck)  
17  
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Regular Maintenance  
LUBRICATION (CON’T.)  
Figure 16. Control Handle Pivots & Seat Pivots  
Figure 17. Gearbox Drive Idler Pivot  
RE-PACK  
BEARINGS  
ANUALLY  
Figure 18. Front Caster & Wheel  
Figure 19. Rear Suspension Lubrication  
(Both upper & lower a-arms)  
18  
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Regular Maintenance  
BATTERY MAINTENANCE  
(Note: The tractor uses a standard BCI58 battery)  
A
B
Checking the Battery Fluid  
1. Raise the seat plate to access battery..  
2. Remove the battery filler cap (A, Figure 20). Fluid  
must be even with the split ring full mark. If not, add  
distilled water.  
3. Reinstall the filler cap.  
Cleaning the Battery and Cables  
1. Disconnect the cables from the battery, negative  
cable first (C).  
C
2. Remove the battery and clean the compartment with  
a solution of baking soda and water.  
Figure 20. Battery Compartment  
A. Vent Cap(s)  
B. Positive (+) Cable & Terminal  
C. Negative (-) Cable & Terminal  
3. Clean the battery terminals and cable ends with a  
wire brush until shiny.  
4. Reinstall the battery and reattach the battery cables,  
positive cable first (B).  
WARNING  
Be careful when handling the battery. Avoid  
spilling electrolyte. Keep flames and sparks away  
from the battery.  
5. Coat the cable ends and battery terminals with petro-  
leum jelly or non-conducting grease.  
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.  
19  
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Regular Maintenance  
SERVICING THE MOWER BLADES  
1. Blades should be sharp and free of nicks and dents.  
If not, sharpen blades as described in following  
steps.  
2. To remove blade for sharpening, use a wood block to  
hold blade while using two 15/16” wrenches to  
removing the blade mounting bolt and nut (Figure  
21).  
3. Use a file to sharpen blade to fine edge. Remove all  
nicks and dents in blade edge. If blade is severely  
damaged, it should be replaced.  
LOOSEN  
4. Balance the blade as shown in Figure 22. Center the  
blade’s hole on a nail lubricated with a drop of oil. A  
balanced blade will remain level.  
Figure 21. Removing the Blade  
5. Reinstall each blade with the tabs pointing up toward  
deck as shown in Figure 23. The five (5) blade spac-  
ers, blade, washer and bolt must be reinstalled in the  
exact same order in which they were removed.  
Secure with a bolt and hex nut. Use a wooden block  
to prevent blade rotation and torque bolts to 70 ft.lbs.  
(94 N.m.).  
Nail  
WARNING  
For your personal safety, 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.)  
Figure 22. Balancing The Blade  
B
A
TIGHTEN  
Figure 23. Installing The Blade  
A. 4x4 Wood Block  
B. Flat Washer  
C. Blade Bolt  
20  
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Notes  
21  
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Troubleshooting  
Adjustments & Service  
TROUBLESHOOTING  
While normal care and regular maintenance will extend  
the life of your equipment, prolonged or constant use  
may eventually require that service be performed to  
allow it to continue operating properly.  
WARNING  
To avoid serious injury, perform maintenance on  
the tractor or 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 instruc-  
tions on how to perform most of these minor adjust-  
ments and service repairs yourself. If you prefer, all of  
these procedures can be performed for you by your local  
authorized dealer.  
TROUBLESHOOTING THE RIDER  
PROBLEM  
CAUSE  
REMEDY  
Engine will not turnover or start.  
1. Parking brake not engaged.  
2. PTO (electric clutch) switch  
in ON position.  
1. Engage parking brake.  
2. Place in OFF position.  
3. Out of fuel.  
3. If engine is hot, allow it to cool, then refill  
the fuel tank.  
4. Engine flooded.  
5. Fuse blown.  
4. Move throttle control out of CHOKE position.  
5. Replace fuse.  
6. Battery terminals require  
cleaning.  
6. Clean the battery terminals  
7. Battery discharged or dead.  
8. Wiring loose or broken.  
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.  
9. Solenoid or starter motor faulty.  
10. Safety interlock switch  
faulty.  
11. Spark plug(s) faulty, fouled  
or incorrectly gapped.  
12. Water in fuel.  
11. Clean and gap or replace.  
See engine manual.  
12. Drain fuel & refill with fresh fuel.  
13. Drain fuel & replace with fresh fuel.  
13. Gas is old or stale.  
Engine starts hard or runs poorly. 1. Fuel mixture too rich.  
1. Clean air filter. Check choke adjustment  
(throttle control).  
2. Spark plug faulty, fouled, or  
incorrectly gapped.  
2. Clean and gap or replace.  
(See engine manual.)  
Engine knocks.  
1. Low oil level.  
2. Using wrong grade oil.  
1. Check/add oil as required.  
2. See engine manual.  
Excessive oil consumption.  
1. Engine running too hot.  
1. Clean radiator screens and  
air cleaner.  
2. Using wrong weight oil.  
3. Too much oil in crankcase.  
2. See engine manual.  
3. Drain excess oil.  
Engine exhaust is black.  
1. Dirty air filter.  
2. Engine choke control  
is in closed position.  
1. Replace air filter. See engine manual.  
2. Open choke control.  
22  
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Troubleshooting, Adjustment & Service  
Rider Troubleshooting Continued.  
PROBLEM  
CAUSE  
REMEDY  
Engine runs, but rider will  
not drive.  
1. Hydraulic dump valve(s)  
in “open” position.  
1. Turn dump valve(s) clockwise to close.  
2. Belt is broken.  
3. Drive belt slips.  
4. Brake is not fully released.  
2. See Drive Belt Replacement.  
3. See problem and cause below.  
4. See authorized service dealer  
Rider drive belt slips.  
1. Clutch is out of adjustment.  
2. Pulleys or belt greasy or oily.  
3. Belt stretched or worn.  
1. See authorized service dealer.  
2. Clean as required.  
3. Replace belt.  
Brake will not hold.  
1. Brake is incorrectly adjusted.  
2. Brake caliper pads worn.  
1. See Brake Adjustment.  
2. Replace with new brake pads.  
Rider steers or handles poorly.  
1. Steering linkage is loose.  
2. Improper tire inflation.  
1. Check and tighten any loose connections.  
2. See Regular Maintenance Section.  
TROUBLESHOOTING THE MOWER  
PROBLEM  
CAUSE  
REMEDY  
Mower will not raise.  
1. Lift linkage not properly attached 1. See authorized service dealer for repair.  
or damaged.  
Mower cut is uneven.  
1. Mower not leveled properly.  
2. Rider tires not inflated  
equally or properly.  
1. See Mower Adjustment.  
2. See Regular Maintenance Section.  
Mower cut is rough looking.  
1. Engine speed too slow.  
2. Ground speed too fast.  
3. Blades are dull.  
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.  
4. Mower drive belt slipping  
because it is oily or worn.  
5. Blades not properly fastened  
to arbors.  
5. See Servicing the Mower Blades.  
Engine stalls easily with  
mower engaged.  
1. Engine speed too slow.  
2. Ground speed too fast.  
3. Cutting height set too low.  
1. Set to full throttle.  
2. Decrease Ground Speed.  
3. Cut tall grass at maximum cutting  
height during first pass.  
4. Discharge chute jamming  
with cut grass.  
4. Cut grass with discharge pointing toward  
previously cut area.  
Excessive mower vibration.  
1. Blade mounting screws  
are loose.  
1. Tighten to 45-55 ft.lbs. (61-75 N.m.).  
2. Mower blades, arbors,  
or pulleys are bent.  
3. Mower blades are out  
of balance.  
2. Check and replace as necessary.  
3. Remove, sharpen, and balance blades.  
See Maintenance Section.  
4. Belt installed incorrectly.  
4. Reinstall Correctly.  
Excessive belt wear or breakage. 1. Bent or rough pulleys.  
1. Repair or replace.  
2. Using incorrect belt.  
2. Replace with correct belt.  
Mower or Hydraulic Pump  
drive belts slips or fails to  
drive.  
1. Idler pulley spring broken or not  
properly attached.  
2. Mower drive belt broken.  
1. Repair or replace as needed.  
2. Replace drive belt.  
23  
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Troubleshooting, Adjustment & Service  
SEAT ADJUSTMENT  
See Figure 24. The seat can be adjusted forward and  
back. Move the lever forward, position the seat as  
desired, and release the lever to lock the seat into posi-  
tion.  
Seat Adjustment  
Lever  
GROUND SPEED CONTROL LEVER  
ADJUSTMENT  
The control levers can be adjusted in three ways. The  
alignment of the control levers, the placement of the  
levers (how close the ends are to one another) and the  
height of the levers can be adjusted.  
Figure 24. Seat Adjustment  
To Adjust the Handle Alignment  
Loosen the mount hardware (A, Figure 25) and pivot the  
lever(s) (C, Figure 25) to align with each other.  
To Adjust the Handle Placement  
C
Loosen the jam nuts and adjust the placement bolt (B,  
Figure 25) in or out to properly adjust the lever end  
spacing.  
B
A
To Adjust the Handle Height  
Remove the mounting hardware (A, Figure 25) and  
reposition the handle either up or down from its original  
position. You will need to readjust the handle alignment  
as described above.  
Figure 25. Control Lever Adjustment  
A. Alignment Hardware  
B. Placement Hardware  
C. Ground Speed Control Lever  
SPEED BALANCING ADJUSTMENT  
If the rider veers to the right or left when the ground  
speed control levers are in the maximum forward posi-  
tion, the top speed of each of these levers can be bal-  
anced by turning the adjustment bolt(s) (A, Figure 19).  
Only adjust the speed of the wheel that is traveling  
faster.  
To Reduce the Speed of the Faster Wheel  
A
B
1. Loosen the jam nut (B, Figure 26).  
2. Turn the top speed adjustment screw (A, Figure 26)  
CLOCKWISE to reduce the speed.  
3. Retighten the jam nut when adjustment is complete.  
WARNING  
DO NOT adjust the tractor for a faster overall  
Figure 26. Top Speed Adjustment  
(Left-hand side shown. Arrow pointing towards front.)  
A. Top Speed Adjustment Screw  
B. Jam Nut  
speed forward or reverse than it was designed for.  
24  
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Troubleshooting, Adjustment & Service  
PARKING BRAKE ADJUSTMENT  
FRONT  
1. Disengage the PTO, stop the engine, block the front  
wheels, remove the ignition key, and engage the  
parking brake.  
A
2. Remove both fuel tanks.  
3. Locate the upper brake spring (A, Figure 27).  
4. With the parking brake engaged, measure the com-  
pressed spring length. The spring should be  
2” to 2-1/8” (5,0cm - 5,4cm) when compressed.  
5. If the spring is not within this range, jack up the rear  
of the machine and secure with jackstands. Remove  
both drive tires.  
Figure 27. Parking Brake Adjustment  
A. Upper Brake Spring  
6. Locate the lower brake spring (A, Figure 28), adjust-  
ment nuts (B, Figure 28) and adjustment link (C,  
Figure 28).  
A
7. Release the parking brake and turn the adjustment  
nuts to compress or release the upper spring. Lock  
the nuts against the adjustment link (C, Figure 28).  
NOTE: Do not adjust the upper brake spring to be short-  
er than 2” when compressed. This may damage the  
caliper case.  
B
If this does not correct the braking problem, see  
your dealer.  
C
Figure 28. Parking Brake Adjustment  
A. Lower Brake Spring  
B. Adjustment Nuts  
C. Adjustment Link  
25  
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SUSPENSION HEIGHT ADJUSTMENT  
If the rider tilts either side-to-side or front-to-rear, this  
adjustment will level the frame with the ground.  
Although this adjustment may not be necessary, it may  
be required if additional weight (ie. a grass catcher) is  
added to the frame or a drive tire is replaced.  
NOTE: Perform this adjustment on a hard, level surface  
such as a concrete floor. Making this adjustment will  
affect the mower cutting height. For fine cutting height  
adjustment, see Mower Deck Leveling Adjustment.  
To level the frame, first measure the frame height:  
Figure 29. Front Frame Measurement  
1. The measurement to the top side of the front frame  
rails, just behind the springs and shocks should be  
20-5/8” (52,4cm) for each side (see arrow in Figure  
29).  
2. The measurement to the top of the rear frame rails,  
at the widest point on the frame behind the drive  
tires should be 21-3/8” (54,3cm) for each side (see  
arrow in Figure 30).  
3. Loosen the jam nuts and adjust the square-head  
allen screw located above each spring.  
4. After adjusting all four (4) springs, recheck the meas-  
urements and adjust if necessary.  
Figure 30. Rear Frame Measurement  
MOWING HEIGHT ADJUSTMENT  
B
See Mower Deck Leveling Adjustment to ensure that the  
actual cutting height is consistent with the cutting height  
adjustment pin placement.  
The cutting height adjustment pin (A, Figure 31) controls  
the mower cutting height. The cutting height is  
adjustable between 1-3/4” (4,4cm) and 5” (12,7cm) in  
1/4” (0,64cm) increments.  
Depress the deck lift foot pedal (B, Figure 31), placing  
the majority of the force on the top edge of the pedal  
until it locks into the “TRANSPORT” position.  
C
A
Place the cutting height adjustment pin in the desired  
cutting height. Depress the deck lift foot pedal, placing  
the majority of the force on the bottom edge of the pedal  
to release the pedal from the “TRANSPORT” position.  
Figure 31. Cutting Height Adjustment  
A. Cutting Height Adjustment Pin  
B. Deck Lift Foot Pedal  
C. Cutting Height Selection Decal  
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MOWER DECK LEVELING  
ADJUSTMENT  
1. Place the cutting height quick pin in the 4” setting.  
2. Measure the front and back edges of the mower  
deck. It should measure 4-1/2” (11,4cm) from the  
ground to the front lower edge of the mower deck  
and 3-5/8” (9,2cm) from the back lower edge to the  
ground. These measurements should be made par-  
allel to the frame of the tractor, in-line with the outer  
blade spindle housings on both sides of the mower  
deck (see Figure 32)  
3. If the measurements taken do not match the dimen-  
sions specified, adjust the front and rear hanger  
assemblies.  
Figure 32. Height Measurement Location  
(72” deck shown)  
4. Using a 3/4” wrench and socket, adjust the front and  
rear hanger assemblies (Figure 33) until the meas-  
urements are achieved, making sure the deck lift  
pedal arm is still resting against the quick pin.  
A
B
C
D
Figure 33. Deck Hanger Assembly  
A. 1/2” Bolt  
B. Upper Pivot  
C. Lower Pivot  
D. 1/2” Nylon Lock Nut  
DECK LIFT SPRING ADJUSTMENT  
1. After performing the mower deck leveling adjustment,  
place the cutting height quick pin in the 3-1/2” set-  
ting.  
A
B
2. Measure the length of the deck lift spring (A, Figure  
34). This should be 12” (30,5cm) for the 72” deck or  
13-3/8” (34cm) for the 61” deck. Be sure to measure  
the spring only.  
72” Deck:  
12” (30,5cm)  
61” Deck:  
13-3/8” (34cm)  
3. If not, loosen the jam nuts (B, Figure 34) and adjust  
the spring to the desired length. Tighten the jam  
nuts.  
Figure 34. Spring Length Adjustment  
A. Deck Lift Spring  
4.Perform this adjustment to both spring rods.  
B. Jam Nuts  
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Troubleshooting, Adjustment & Service  
A
B
B
B
C
Figure 36. Adjust PTO Clutch  
A. Window  
B. Adjustment Nut  
B
A
C. .016” - .018” (0,40mm - 0,45mm) Feeler Gauge  
Figure 35. PTO Clutch Adjustment  
A. Adjustment Window (Qty. 3, one shown)  
B. Adjustment Nut  
PTO CLUTCH ADJUSTMENT  
WARNING  
To avoid serious injury, perform adjustments only  
with engine stopped, key removed and tractor on  
level ground.  
Check the PTO clutch adjustment after the initial 50 hour  
break-in period and then after every 250 hours of opera-  
tion. Also perform the following procedure if the clutch is  
slipping or will not engage, or if a new clutch has been  
installed.  
Blade Brake Check  
1. Remove key from ignition switch and disconnect  
spark plug wires to prevent the possibility of acciden-  
tal starting while the PTO is being adjusted.  
Mower blades and mower drive belt should come to a  
complete stop within five (5) seconds after electric PTO  
switch is turned off.  
2. See Figure 35. Note the position of the 3 adjustment  
windows (A) in the side of the brake plate and the  
nylock adjustment nuts (B).  
1. With parking brake engaged, PTO disengaged and  
an operator in the seat, start the engine engine.  
2. Look down through the gap between the left side of  
the floor and frame rail and observe the PTO 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.  
3. Insert a .016” - .018” (0,40mm - 0,45mm) feeler  
gauge (C) through each window, positioning the  
gauge between the rotor face and the armature face  
as shown in Figure 36.  
4. Alternately tighten the adjustment nuts (B, Figure 35)  
until the rotor face and armature face just contacts  
the gauge.  
3. If the mower drive belt does not stop within five (5)  
seconds, perform the PTO Clutch Adjustment. If the  
belt still does not stop within five (5) seconds, see  
your dealer.  
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 loosen-  
ing the adjustment nuts.  
NOTE: The actual air gap between the rotor and arma-  
ture may vary even after performing the adjustment pro-  
cedure. This is due to dimensional variations on compo-  
nent parts, and is an acceptable condition.  
6. Check the mower blade stopping time. The mower  
blades and mower drive belt should come to a com-  
plete stop within five (5) seconds after the electric  
PTO switch is turned off.  
28  
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NEUTRAL ADJUSTMENT  
WARNING  
Before checking mower, shut off PTO and engine.  
Allow all moving parts to stop. Remove ignition  
key, then disconnect the spark plug wire and  
fasten it away from the spark plug.  
B
A
If the tractor “creeps” while the ground speed control  
levers are locked in NEUTRAL, then it may be neces-  
sary to adjust the control linkage.  
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.  
Figure 37. Neutral Adjustment  
(Left-hand side shown)  
A. Control Linkage  
2. Loosen the jam nut (B, Figure 37) and turn the  
adjustment linkage (A) to adjust. If the machine  
creeps forward, turn the linkage CLOCKWISE (while  
standing at the rear of the machine, facing forward),  
if the machine creeps backward, turn the linkage  
COUNTER-CLOCKWISE.  
B. Jam Nut  
3. Lock the jam nut (B) when neutral is achieved.  
NOTE: This adjustment should not be performed while  
the machine is running. It may take several attempts to  
achieved neutral, depending upon how much the  
machine creeps.  
29  
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Troubleshooting, Adjustment & Service  
BELT REMOVAL & REPLACEMENT  
Mower Drive Belt Removal & Replacement  
To avoid damaging belts, DO NOT  
PRY BELTS OVER PULLEYS.  
A
B
1. Park the tractor on a smooth, level surface such as a  
concrete floor. Disengage the PTO, engage the  
parking brake, turn off the engine, and remove the  
ignition key.  
Figure 38. Mower PTO Belt  
A. Belt Tension Spring  
B. Spring Compression Nut  
2. Remove the hairpin clip and clevis pin and remove  
the deck lift foot pedal. Lift the floor plate to gain  
access to the PTO drive belt.  
D
B
C
3. Loosen the spring compression nut (B, Figure 38) to  
release the belt tension.  
4. Slide the drive belt over the edge of the spring-  
loaded idler pulley and remove belt from all pulley  
grooves.  
5. Remove the old belt and replace with a new one.  
Make sure the V-side of the belt runs in the pulley  
grooves (Figure 39).  
A
A
D
D
A
6. Install the drive belt on the gearbox pulley, the spin-  
dle pulleys and idler pulleys. Tighten the spring com-  
pression nut (B, Figure 38) until the belt tension  
spring (A, Figure 38) is compressed to 1-5/8”  
(4,12cm) long.  
Figure 39. Mower PTO Belt Routing  
A. Spindle Pulley  
B. PTO Drive Belt  
C. Spring-loaded Idler Pulley  
D. Stationary Idler Pulley  
7. Run the mower under no-load condition for approxi-  
mately 5 minutes to break in the belt.  
30  
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Clutch Belt Removal  
A
B
1. Park the tractor on a smooth, level surface such as a  
concrete floor. Disengage the PTO, engage the  
parking brake, turn off the engine, and remove the  
ignition key.  
C
D
2. Remove the rear skid plate by removing the bolts  
that fasten the skid plate to the bumper and slide the  
plate forward until it drops from the mounts.  
3. Remove the rear belt shield and rear guard support.  
4. Remove the bumper.  
E
E
5. Remove the nylon lock nut (A, Figure 40) to release  
the belt tension and unhook the clutch belt idler  
spring (C) from the screw hook (B). Set the screw  
hook aside.  
F
6. Remove the 5/16” bolt, washers and nut (D) that fas-  
ten the rubber pad to the clutch and unplug the  
clutch from the electrical harness. Note the order  
that the hardware is oriented before removing.  
Figure 40. Clutch Belt Removal & Replacement  
A. 3/8” Nylon Lock Nut  
B. Screw Hook  
C. Clutch Belt Idler Spring  
D. Clutch Anchor Hardware  
E. Gearbox Mount Hardware  
F. Gearbox  
7. Loosen the four (4) nylon lock nuts (E) that mount  
the gear box to the pump plate.  
8. Pushing upward on the gearbox (F), remove the  
clutch belts from the gearbox pulley grooves.  
9. Pulling the belts over the top of the clutch, remove  
the clutch belts from the clutch pulley grooves and  
pull around the idler pulley.  
Clutch Belt Replacement & Adjustment  
1. Install the clutch belts over the top of the clutch, into  
the grooves of the crankshaft pulley and around the  
idler pulley.  
2. Pushing upward on the gearbox (F), place the clutch  
belts in the grooves of the gear box pulley.  
3. Push the gearbox down as far as possible and tight-  
en the four (4) nylon lock nuts (E). Make sure the  
bottom pulley on the gearbox is parallel with the  
frame.  
4. Hook the spring clutch belt idler spring on the screw  
hook and reinstall the screw hook into the anchor.  
Adjust the screw hook until the spring measures  
4-3/4” (12,1cm) to the outside of the loops on the  
spring (see Figure 41).  
Figure 41. Idler Spring Measurement  
5. Reinstall the clutch anchor pad to the clutch with the  
hardware (D) previously removed. Make sure the  
hardware is in the same order as is was before being  
removed, with the smaller washer(s) between the  
clutch pad and the clutch.  
6. Reinstall the bumper, rear hood support, rear belt  
shield and skid plate.  
31  
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Troubleshooting, Adjustment & Service  
Pump Drive Belt Removal  
1. Park the tractor on a smooth, level surface such as a  
concrete floor. Disengage the PTO, engage the  
parking brake, turn off the engine, and remove the  
ignition key.  
A
2. Remove the clutch belts (see CLUTCH BELT  
REMOVAL for instructions).  
3. Using a 1/2” breaker bar, place the square end in the  
square hole located in the middle of the idler arm  
(A, Figures 42). Carefully rotate the breaker bar  
counter-clockwise, which will relieve the tension on  
the belts exerted from the idler arm.  
WARNING  
Figure 42. Pump Belt Removal & Replacement  
A. Pump Drive Idler Arm  
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.  
4. Remove the belts from the right-hand and left-hand  
pump drive pulley grooves.  
5. Carefully release the tension on the breaker bar until  
the idler arm stops against the left-hand pump drive  
pulley.  
6. Remove the belts from the crankshaft pulley grooves  
and pull over the top of the clutch.  
Pump Drive Belt Replacement  
1. Place the belts over the clutch into the crankshaft  
pulley grooves.  
2. Carefully rotate the idler arm with the breaker bar  
counter-clockwise (see Figure 42) and wrap the belts  
around the bottom side of the idler arm pulley and  
place the belts in the left-hand pump pulley grooves.  
4. While holding the breaker bar firmly, place the belts  
in the right-hand pump pulley grooves.  
5. Carefully release the tension on the breaker bar.  
6. Inspect the belt path making sure that all belts are  
properly seated in the pulley grooves.  
7. Reinstall the clutch belts (see CLUTCH BELT  
REPLACEMENT & ADJUSTMENT for instructions).  
32  
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Troubleshooting, Adjustment & Service  
GEARBOX MAINTENANCE  
A
Top  
Check Gearbox Oil Level  
1. Remove fill plug (A, Figure 43) on gearbox.  
2. Once plug is removed, oil should seep out of fill plug  
hole. If no oil drains out, fill with SAE 80-90 weight  
gear oil until oil starts to seep from hole, then  
replace fill plug.  
Changing Gearbox Oil  
NOTE: The gearbox lubricant should be changed after  
the first 100 hrs. or 30 days of operation, then after 500  
hours or 12 months.  
Front  
B
1. Remove the mower deck drive belt (see MOWER  
DRIVE BELT REMOVAL & REPLACEMENT for  
instructions).  
Figure 43. Gearbox Oil Level  
A. Fill Plug  
2. Rotate the the mower deck drive pulley on the gear-  
box so the drain plug is aligned with the opening  
between the pulley spokes.  
B. Drain Plug  
3. Place a container under the gearbox drain hole and  
remove the drain plug (B).  
4. Replace drain plug and fill with SAE 80-90 weight  
gear oil until oil starts to seep from hole, then  
replace fill plug.  
5. Using a parts solvent, thoroughly clean any excess  
oil from the pulley faces and groove.  
6. Reinstall the mower deck drive belt (see MOWER  
DRIVE BELT REMOVAL & REPLACEMENT for  
instructions).  
33  
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Troubleshooting, Adjustment & Service  
6. Charge the battery until fully charged (until the spe-  
cific 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.  
BATTERY SERVICE  
WARNING  
Keep open flames and sparks away from the  
battery; the gasses coming from it are highly  
explosive. Ventilate the battery well during  
charging.  
Checking Battery Voltage  
JUMP STARTING WITH AUXILIARY  
(BOOSTER) BATTERY  
A voltmeter can be used to determine condition of bat-  
tery. When engine is off, the voltmeter shows battery  
voltage, which should be 12 volts. When engine is run-  
ning, the voltmeter shows voltage of charging circuit  
which normally is 13 to 14 volts.  
Jump starting is not recommended. However, if it must  
be done, follow these directions. Both booster and dis-  
charged batteries should be treated carefully when using  
jumper cables. Follow the steps below EXACTLY, being  
careful not to cause sparks. Refer to Figure 44.  
A dead battery or one too weak to start the engine may  
not mean the battery needs to be replaced. For exam-  
ple, 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.  
1. Both batteries must be of the same voltage.  
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 batter-  
ies in both vehicles. Make certain vehicles do not  
touch each other.  
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.  
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.  
4. Connect positive (+) cable to positive post of dis-  
charged battery (wired to starter or solenoid).  
5. Connect the other end of same cable to same post  
marked positive (+) on booster 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.  
6. Connect the second cable negative (-) to other post  
of booster battery.  
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 bat-  
tery. Wait a few minutes, then attempt to start the  
engine of the vehicle with the discharged battery.  
3. Always unplug or turn the charger off before attach-  
ing or removing the clamp connections.  
9. If the vehicle does not start after cranking for thirty  
seconds, STOP PROCEDURE. More than thirty sec-  
onds seldom starts the engine unless some mechan-  
ical adjustment is made.  
4. Carefully attach the clamps to the battery in proper  
polarity (usually red to [+] positive and black to [-]  
negative).  
5. While charging, periodically measure the tempera-  
ture 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.  
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.  
11. Remove the other cable by disconnecting at the dis-  
charged battery first and then disconnect the oppo-  
site end from the booster battery.  
12. Discard the damp cloths that were placed over the  
battery vent caps.  
34  
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Troubleshooting, Adjustment & Service  
THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES  
To  
To  
Starter  
Switch  
Starter  
Switch  
Jumper Cable  
Starting  
Vehicle  
Battery  
Discharged  
Vehicle  
Battery  
Jumper Cable  
To Ground  
Engine  
Block  
MAKE CERTAIN VEHICLES DO NOT TOUCH  
Figure 44. Jump Starting  
WARNING  
WARNING  
Any procedure other than the preceding could  
result in:  
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.  
(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.  
When removing or installing battery cables, dis-  
connect the negative cable FIRST and reconnect  
it LAST. If not done in this order, the positive ter-  
minal can be shorted to the frame by a tool.  
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.  
To avoid engine damage, do not disconnect bat-  
tery while engine is running. Be sure terminal  
connections are tight before starting.  
35  
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Lawn Care  
& Mowing Information  
• 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  
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:  
• 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 cli-  
mates, 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 resi-  
dential 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.)  
HOW TO WATER YOUR LAWN  
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.  
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 AND WHEN TO WATER,  
FERTILIZE & AERATE  
HOW TO FERTILIZE 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 over-  
fertilizing 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.  
Every lawn’s watering needs are unique and are depen-  
dent 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  
AERATING 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.  
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.  
TP 600-7000-01-UV-FD  
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Lawn Care & Mowing Information  
HOW HIGH TO  
Cut less than  
MOW THE GRASS  
1/3  
Often cutting height is a  
matter of personal prefer-  
ence. Typically, you should  
mow the grass when it is is  
between three and five  
Optimal  
cutting point  
at less than  
1/3 from top  
of grass blade  
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.  
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).  
1 inch  
NOTE: We cover some specific mowing instructions for  
mulching and broadcasting later in this Lawn Care section.  
Proper Cutting Height  
Cut Here On  
First Pass  
Cut  
Tall Grass Requires Incremental Cutting  
For extremely tall grass, set the cutting height at maxi-  
mum for the first pass, and then reset it to the desired  
height and mow a second or third time.  
Here On  
Second  
Pass  
Don’t cover the grass surface with a heavy layer of  
clippings. Consider using a grass collection system  
and starting a compost pile.  
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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 appear-  
ance.  
l For a truly professional cut, mow across the lawn in  
one direction, then recut the lawn by mowing perpen-  
dicular to the previous cut.  
Note: 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 cut-  
ting 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.  
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.  
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Lawn Care & Mowing Information  
MOWING METHODS  
Proper Broadcast Mowing  
Broadcasting, or side-discharging, disperses fine clip-  
pings 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 cut-  
ting efficiency of the blades and prevents many common  
cutting problems.  
slowing down you are mowing too fast, use a slower  
ground speed.  
HOW MUCH GRASS TO CUT OFF WHEN BROADCASTING  
ALWAYS use an appropriate ground speed for the thick-  
ness 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.  
Proper Mulching  
Mulching consists of a mower  
deck which cuts and recuts clip-  
pings into tiny particles and  
HOW MUCH GRASS TO MULCH  
Mulching Action  
The best mulching action typical-  
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 parti-  
cles decompose rapidly into by-  
products your lawn can use.  
blade. This provides short clip-  
pings which decompose properly  
(much more quickly than longer  
UNDER PROPER CONDI-  
clippings). The ideal cutting  
TIONS, your mulching mower will virtually eliminate  
noticeable clippings on the lawn surface.  
height will vary with climate, time of year, and quality of  
your lawn. We recommend that you experiment with both  
the cutting height and ground speed until you achieve  
the best cut. Start with a high cutting height and using  
progressively lower settings until you find a cutting height  
that is matched to your mowing conditions and prefer-  
ences.  
NOTE: When mulching under heavy cutting conditions, a  
rumbling sound may be present and is normal.  
MULCHING REQUIRES EXCELLENT MOWING  
CONDITIONS  
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 horse-  
power than broadcasting, using a slower ground speed is  
vitally important for proper mulching operation.  
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Lawn Care & Mowing Information  
• Reduce the evaporation of water from your lawn.  
• Provide a cushioning layer to reduce lawn wear.  
• Moderate soil temperature.  
TIPS On Dealing With Clippings  
Clippings are beneficial to your lawn. A common mis-  
conception 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:  
• Clippings act as a safe, non-polluting and inexpen-  
sive 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.  
COMPOSTING  
The best way to recycle excess clippings and leave your  
lawn looking immaculate is to collect them with an effi-  
cient 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 pur-  
chase 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.  
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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  
Sharpen your blades  
Replace your blades  
Always mow at full throttle  
Slow down  
Ground speed is too fast  
Deck is plugged with grass  
Not overlapping cutting rows enough  
Not overlapping enough when turning  
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  
Level the deck correctly  
Check and inflate the tires  
Replace the blades  
Deck shell is damaged  
Mower spindle is bent or loose  
Blades are installed incorrectly  
Repair or replace the deck  
Repair or replace the spindle  
Reinstall the blades correctly  
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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  
Level the deck correctly  
Sharpen or replace the blades  
Replace the blades  
Deck is clogged with grass clippings  
Deck shell is damaged  
Mower spindle is bent or loose  
Blades are installed incorrectly  
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  
Roll or level the lawn  
Raise the cutting height  
Slow down  
Deck is not leveled correctly  
Tire pressure is low or uneven  
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  
Sharpen your blades  
Replace your blades  
Always mow at full throttle  
Slow down  
Ground speed is too fast  
Deck is plugged with grass  
Clean out the mower  
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Common International Symbols  
PTO Clutch  
Choke  
Fast (Throttle)  
Slow (Throttle)  
Parking Brake  
Brake  
Throttle  
Fuel  
Mower Cutting  
Height Adjustment  
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 replace-  
ment part numbers and quantities used. Important assembly notes and  
special torque values are included in these manuals.  
Model:  
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 in your request.  
Serial No.:  
Your Name:  
Address:  
City, State, Zip:  
Visa/Mastercard No.:  
Card Expiration Date:  
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Notes  
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