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Tractor:
Models
IS4000Z/D31
IS4000Z/KAV27 IS4000Z w/ 27 HP Kawasaki Engine
Ferris Industries
5375 North Main Street
Munnsville, NY 13409
800-933-6175
IS4000Z Series
Zero-Turn Riding Mower
Description
IS4000Z w/ 31 HP B&S,D Engine
OPERATOR'S
MANUAL
Mower Deck:
Models
Description
4000/72
72" Mower Deck
4000/61
61" Mower Deck
22470
Rev. No. 04
Rev. Date: 9/2003
TP 100-7002-04-4Z-F
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Table of Contents
Troubleshooting
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Summary of Contents for Ferris IS4000Z/D31
- Page 1 Zero-Turn Riding Mower Tractor: Models Description IS4000Z/D31 IS4000Z w/ 31 HP B&S,D Engine IS4000Z/KAV27 IS4000Z w/ 27 HP Kawasaki Engine Ferris Industries 5375 North Main Street Munnsville, NY 13409 800-933-6175 OPERATOR’S MANUAL IS4000Z Series Mower Deck: Models Description 4000/72 72” Mower Deck 4000/61 61”...
- Page 2 This warranty shall apply ONLY if the warranty registration form has been completed and returned to Ferris Industries, Inc. within 20 days from the date of delivery. Ferris Industries, Inc. (Ferris) warrants, in accordance with the provisions below, to the original purchaser for the period of twenty-four (24) months from the date of delivery of a Ferris mower that the mower is free from defects in material or workmanship.
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Page 3: Table Of Contents
WARNING Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. © Copyright 2003 Ferris Industries All Rights Reserved. Printed in USA. TP 100-7002-04-4Z-F Table of Contents Troubleshooting, Adjustments & Service ...22 Troubleshooting the Rider ...22... -
Page 4: Identification Numbers
Identification Numbers When contacting your Authorized Dealer for replacement parts, service, or information YOU MUST HAVE THESE NUMBERS. FERRIS FERRIS INDUSTRIES, INC. UNNSVILLE, NY 13409 ADE IN THE USA ODEL NO. SERIAL NO. 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. -
Page 5: Operation
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- in text signifies important cautions or warnings which must be followed. -
Page 6: Slope Operation
Safety Rules & Information SLOPE OPERATION Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not drive on it. -
Page 7: Safety Decals
• 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. -
Page 8: Features & Controls
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. Figure 1. -
Page 9: Safety Interlock System
• Operator is not on the seat. Test 2 — Engine SHOULD crank if: • PTO switch is NOT engaged, AND • Parking brake is engaged, AND (IS4000Z/D31 only) • Motion control handles are locked in the NEUTRAL position, AND • Operator is on the seat. -
Page 10: Operating The Zero Turn Rider
Operating the Zero Turn Rider GENERAL OPERATING SAFETY Before first time operation: • Be sure to read all information in the Safety and Operation sections before attempting to operate this tractor and mower. • Become familiar with all of the controls and how to stop the unit. -
Page 11: Starting The Engine
WARNING If you do not understand how a specific control functions, or have not yet thoroughly read the FEATURES & CONTROLS section, do so now. Do NOT attempt to operate the tractor without first becoming familiar with the location and function of ALL controls. -
Page 12: Zero Turn Driving Practice
Operating the Zero Turn Rider ZERO TURN DRIVING PRACTICE The lever controls of the Zero Turn rider are responsive, and learning to gain a smooth and efficient control of the rider’s forward, reverse, and turning movements will take some practice. Spending some time going through the maneuvers shown and becoming familiar with how the unit acceler- ates, travels, and steers —... -
Page 13: Advanced Driving
Practice Turning Around a Corner While traveling forward allow one handle to gradually return back toward neutral. Repeat several times. NOTE: To prevent pivoting directly on the tire tread, it is best to keep both wheels going at least slightly forward. Executing Turns Figure 6. -
Page 14: Storage
Operating the Zero Turn Rider 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. - Page 15 Notes...
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Page 16: Regular Maintenance
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. SAFETY ITEMS Check Safety Interlock System Check Rider Brakes... -
Page 17: Checking/Adding Fuel
CHECKING / ADDING FUEL To add fuel: 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. -
Page 18: Check Antifreeze Level
If the lights are not visible, or the buzzer can not be heard, please contact your Ferris dealer. Figure 11A. Engine Coolant and Overflow (IS4000Z/D31) Coolant Overflow Reservoir Reservoir Cap Figure 11B. Engine Coolant and Overflow (IS4000Z/KAV27) Coolant Overflow Reservoir Reservoir Cap Figure 12. Radiator Screens (IS4000Z/D31 shown) Radiator Screens... -
Page 19: Lubrication
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 •... - Page 20 Regular Maintenance LUBRICATION (CON’T.) Figure 16. Control Handle Pivots & Seat Pivots RE-PACK RE-PACK RE-PACK BEARINGS BEARINGS BEARINGS ANUALLY ANUALLY ANUALLY Figure 18. Front Caster & Wheel Figure 17. Gearbox Drive Idler Pivot Figure 19. Rear Suspension Lubrication (Both upper & lower a-arms)
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Page 21: Battery Maintenance
BATTERY MAINTENANCE (Note: The tractor uses a standard BCI58 battery) 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. -
Page 22: Servicing The Mower Blades
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). - Page 23 Notes...
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Page 24: Troubleshooting Adjustments & Service
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. The troubleshooting guide below lists the most common problems, their causes and remedies. -
Page 25: Troubleshooting The Mower
Rider Troubleshooting Continued. PROBLEM Engine runs, but rider will not drive. Rider drive belt slips. Brake will not hold. Rider steers or handles poorly. TROUBLESHOOTING THE MOWER PROBLEM Mower will not raise. Mower cut is uneven. Mower cut is rough looking. Engine stalls easily with mower engaged. -
Page 26: Seat Adjustment
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. GROUND SPEED CONTROL LEVER ADJUSTMENT The control levers can be adjusted in three ways. -
Page 27: Parking Brake Adjustment
PARKING BRAKE ADJUSTMENT 1. Disengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. 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. -
Page 28: Suspension Height Adjustment
Troubleshooting, Adjustment & Service 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. -
Page 29: Mower Deck Leveling Adjustment
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”... -
Page 30: Pto Clutch Adjustment
Troubleshooting, Adjustment & Service Figure 35. PTO Clutch Adjustment Adjustment Window (Qty. 3, one shown) Adjustment Nut PTO CLUTCH ADJUSTMENT Check the PTO clutch adjustment after the initial 50 hour break-in period and then after every 250 hours of opera- tion. -
Page 31: Neutral Adjustment
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. 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. -
Page 32: Belt Removal & Replacement
Troubleshooting, Adjustment & Service BELT REMOVAL & REPLACEMENT Mower Drive Belt Removal & Replacement To avoid damaging belts, DO NOT PRY BELTS OVER PULLEYS. 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. -
Page 33: Clutch Drive Belt
Clutch Belt Removal 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. 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. -
Page 34: Pump Drive Belt Replacement
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. 2. Remove the clutch belts (see CLUTCH BELT REMOVAL for instructions). -
Page 35: Gearbox Maintenance
GEARBOX MAINTENANCE 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. -
Page 36: Battery Service
Troubleshooting, Adjustment & Service BATTERY SERVICE WARNING Keep open flames and sparks away from the battery; the gasses coming from it are highly explosive. Ventilate the battery well during charging. Checking Battery Voltage A voltmeter can be used to determine condition of bat- tery. - Page 37 THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES Starter Switch Starting Vehicle Battery To Ground MAKE CERTAIN VEHICLES DO NOT TOUCH Figure 44. Jump Starting WARNING Any procedure other than the preceding could result in: (1) personal injury caused by electrolyte squirting out the battery vents, (2) personal injury or property damage due to battery explosion, (3) damage to the charging system of the...
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Page 38: Lawn Care
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.”... -
Page 39: How High To Mow The Grass
HOW HIGH TO MOW THE GRASS Often cutting height is a matter of personal prefer- ence. Typically, you should mow the grass when it is is between three and five inches high. The proper cutting height range for a specific lawn will depend upon several factors, including the type of grass, the amount of rainfall, the... -
Page 40: When And How Often To Mow
Lawn Care & Mowing Information WHAT MOWING PATTERNS TO USE 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. -
Page 41: Mowing Methods
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. - Page 42 Lawn Care & Mowing Information 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: COMPOSTING...
- Page 43 SOLUTIONS FOR COMMON MOWING PROBLEMS 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 Blades are not sharp Blades are worn down too far Engine speed is too slow Ground speed is too fast Deck is plugged with grass...
- Page 44 Lawn Care & Mowing Information 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 Deck is not leveled correctly Blades are dull or worn Blades are damaged Deck is clogged with grass clippings Deck shell is damaged...
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Page 45: Technical Manuals
Choke Fast (Throttle) Slow (Throttle) Throttle Fuel 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 —... - Page 46 Notes LC-9...
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