Reproduction. Not for. Quick Setup List. Dealer Setup & Adjustment Instructions. Evolution Series - Compact ZTR with 52 Mower Deck

Transcription

1 ealer Setup & djustment Instructions Ferris Evolution Series ompact Zero-Turn Riding Mower with 52 Mower eck This ealer Setup Instruction covers the following products: Model No.: escription EVKV EVKV2252 TTENTION SETUP PERSONNEL: The safety warnings provided in this guide and in the operator s manual included with the unit contain important information that must be obeyed when assembling, setting-up, operating, servicing, transporting, or storing the unit. These warnings are highlighted by the safety alert triangle symbol shown above, which signifies that an important safety message is being provided. You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all times while working on or around this unit and all other outdoor power equipment. Quick Setup List Sections and items denoted by the Setup symbol provide the information necessary to fully assemble, test, and prepare the units described above for delivery to your customers. Quick Setup List is provided on page 2 of this booklet to help you identify and check that the items have been performed. dditional information concerning functional tests, general adjustment procedures, and the location of normal lubrication points are included in these instructions. lthough all required lubrication and normal adjustments on factory-assembled components are done at the factory, this additional information is provided to assist you in ensuring that each unit is delivered to the customer in proper working order. Page Setup Procedure Steps to Perform 2 Uncrating Remove rate & anding. Loosen Hydraulic Release Valves. Release Parking rake and Roll Tractor forward off skid. Tighten Hydraulic Release Valves. 2 attery Installation onnect attery. 3 heck Fluid Levels heck Engine Oil Level. heck Hydraulic Oil Level. heck Tire Pressure. 4 heck Mower ssembly heck lade olt Torque. heck eck Lift Rod Timing. heck & Level Mower eck. heck PTO rive elt. heck lade lignment (36 Models). heck Mower eck rive elt (48 Models). 9 Lubrication & Fuel Preparation Lubricate all grease & oil points. dd fuel. Start the Engine. 11 SFETY HEK heck for LOOSE HRWRE. heck all OPERTOR ONTROLS. Perform SFETY INTERLOK SYSTEM HEK. Register Product To register the product: log onto com, select the appropriate brand, click My Resources, select the Product Registration and Rebate icon and then the New Product Registration / Rebate tab. Fill out and submit the online product registration form Rev. 1

2 Uncrating 1. Using a reciprocating utility saw or equivalent, cut crate away from bottom skid. Remove crate. Remove shrink-wrap plastic. IMPORTNT NOTE When cutting crate from bottom skid, use caution around tractor tires and mower rollers. 2. ut the nylon banding that secures the unit to the crate. 3. Open the hydraulic release valves. To open the release valves, turn the release valve, which is located on front of the pump, OUNTER- LOKWISE 2 full turns MX. See Figure 1 for valve location. 4. Push the parking brake lever forward (, Figure 2) to release parking brake. 5. e sure there are no nails or sharp objects on bottom skid to puncture the tractor s tires. Roll the tractor forward off the bottom skid. 6. fter moving the tractor, re-engage the pumps (drive position) by turning the release valves clockwise and tighten to in/lbs ( Nm). attery Installation Removing the Fender The right hand fender (, Figure 3) must be removed to gain access to the battery. 1. Unscrew the three (3) wing bolts () that secure the fender to the unit. 2. Remove the fender from the unit WRNING TTERY SFETY RULES attery acid causes severe burns. void contact with skin. Wear eye protection while handling the battery. To avoid an explosion, keep flames and sparks away from battery, especially while charging. When installing battery cables, ONNET THE POSITIVE (+) LE FIRST and negative (-) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool. Figure 1. Hydraulic System y-pass. Hydraulic Release Valve (left-hand pump shown) Figure 2. isengaging the Parking rake (lever shown in disengaged position). Parking rake Lever Figure 3. Removing the Fender. Fender. Wing olts 2

3 onnecting the attery 1. onnect the red positive battery cable (, Figure 4) to the positive battery post. 2. onnect the black negative battery cable () to the negative battery post. heck Fluid Levels heck Engine Oil Level 1. Use the dipstick (, Figure 5) to check the engine oil level. If necessary add engine oil. heck engine manufacturer s owner s manual for oil recommendations. heck Hydraulic Oil Level 1. efore removing the reservoir cap, make sure the area around the reservoir cap and fill neck of the reservoir is free of dust, dirt, or other debris. 2. Unscrew the reservoir cap (, Figure 6). 3. Look down the filler neck of the hydraulic oil reservoir () and observe the oil level. When cold, the oil level should be approximately 4 (10 cm) below top of the filler neck. 4. If necessary, add either Mobil 1, 15W-50 synthetic oil or astrol Syntec 5W-50 oil. O NOT use conventional oils. 5. Reinstall the reservoir cap. 6. Re-position the fender (, Figure 7) back on the unit. 7. Secure the fender to the unit using the three (3) wing bolts (). Figure 4. attery Maintenance. Negative (-) attery able. Positive (+) attery able Figure 6. Servicing the Hydraulic System. Reservoir ap. Reservoir Figure 5. Pre-start hecks. Oil ipstick Figure 7. Installing the Fender. Fender. Wing olts 3

4 heck Tire Pressures Tire pressure should be checked periodically, and maintained at the levels shown in the chart. Note that these pressures may differ slightly from the Max Inflation stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire life. heck Mower ssembly Figure 8. hecking Tire Pressure Tire Pressure psi bar Front N/ Rear 18 1,24 heck Torque - Mower lades WRNING Mower blades are sharp. For your personal safety, do not handle mower blades with bare hands. areless or improper handling of blades may result in serious injury. lade mounting bolts must each be installed with a flat washer then securely tightened. Torque blade mounting bolts to 70 ft. lbs. (94 Nm) 1. Park machine on a flat, level surface and engage the parking brake. 2. Lock the deck lift pedal in the TRNSPORT position. 3. heck that blades are installed with the air lifts pointing up toward deck as shown in Figure Wedge a wooden block between the mower blade and the mower deck housing to keep the mower blade from turning and torque bolts to 70 ft. lbs. (94 Nm.). Figure 9. heck lade Torque. Mower lade Mounting olt. Flat Washer. Mower lade ir Lift (Points Up For Installation). 4 X 4 Wooden lock 4

5 djust eck Lift Rod Timing 1. Park machine on a flat, level surface. isengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar). 2. To check the deck lift rod timing, measure and record the distance between the lift pivots and the rod pivots. Repeat for other side of unit. See Figure If the measurements for the lift pivots and rod pivots are equal, no further adjustment is required. If the measurements are NOT equal (greater than 1/8 (3,17 mm) difference), adjustment is required, continue with Step Lower the mower deck to the lowest cutting position. 5. lock up the mower deck until all of the hanger chains are slack. See Figure Refer to Figure 12. To adjust the lift rod, loosen the jam nut on the front ball joint then remove the 1/2 hardware fastening the ball joint to the lift pivot arm. Turn the ball joint LOKWISE to shorten the distance between the rod pivots or OUNTER- LOKWISE to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2 hardware previously removed. Tighten the jam nut against the lift rod. 7. Remove the blocks from under the mower deck. 8. djust the cutting height to the desired position. Figure 10. Measure the Lift Pivots and Rod Pivots. First Measurement. Second Measurement Figure 11. lock Positions Figure 12. djust the Lift Rod Lengths. djustment Point 5

6 heck & Level the Mower eck NOTE: efore adjusting the deck level, the deck lift rod timing must be checked and/or adjusted. 1. Park machine on a flat, level surface. isengage the PTO, stop the engine and engage the parking brake. Rear tires must be inflated to 18 psi (1,24 bar). 2. djust the mower deck in the 4 (10,2 cm) position. 3. Place 2 x 4 blocks under each corner of the mower deck with the 3-1/2 sides vertical. See Figure Loosen the nuts and allow the front of the deck to rest on the 2 x 4 s. Slide the chains down in the slots until the chains are tight and tighten the nuts. See Figure Repeat this process on the rear of the deck. 6. Remove all 2 x 4 blocks from under the mower deck. 7. For your safety, O NOT handle mower blades with bare hands. Position the outside mower blades so that they face front-to-back (Figure 15). UTION void injury! Mower blades are sharp. lways wear gloves when handling blades or working near blades. 8. Measure from the front tip of the blade from the cutting edge to the ground. Measure from the rear tip of the blade from the cutting edge to the ground. Repeat this process for the other side of the machine. oth measurements should be 4 (10,2 cm), If the measurements are greater than 1/8 (3,17 mm) of what they should be adjust the deck height until they are correct. Figure X 4 Locations Figure 14. Hanger hain djustment. Front djustment Point. Rear djustment Point Figure 15. hecking the lade Height djustment eck Lift ssist Spring The deck lift assist springs (, Figure 16) are factory set to provide optimal lifting performance. lthough it is fastened with a multi-position anchor, this is NOT N JUSTMENT POINT. o NOT attempt to adjust the spring length or lifting performance will be compromised. Figure 16. eck Lift ssist Springs Location. eck Lift ssist Springs 6

7 NOTIE heck the PTO rive elt To avoid damaging belts, O NOT pry belts over pulleys. 1. Park the unit on a smooth, level surface such as a concrete floor. isengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the mower deck guard. 3. Position the mower deck in the TRNSPORT position. WRNING 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. Make sure the V-side of the belt runs in the pulley grooves (Figure 17). 5. If belt is not properly seated, use a 1/2 breaker bar, and place the square end in the square hole located in the end of the idler arm (, Figures 18). arefully rotate the breaker bar LOKWISE, which will relieve the tension on the belt exerted from the idler arm. 6. Re-seat belt and carefully release the tension on the breaker bar. HEKING THE PTO RIVE ELT ILER TENSIONER SPRING LENGTH 1. Set the mower deck at its middle cutting height. 2. Measure the coil to coil length of the PTO drive belt tensioner spring (, Figure 19). It should measure 7-1/4 (18.42 cm). If it does not, perform the djusting the PTO rive elt Idler Tensioner Spring Length. JUSTING THE PTO RIVE ELT ILER TENSIONER SPRING LENGTH 1. Loosen the jam nut () on the eyebolt (). 2. Turn the adjustment nut () until a measurement of 7-1/4 (18.42 cm) is achieved. 3. Tighten the jam nut. Figure 17. PTO rive elt Routing. PTO rive elt. PTO lutch Pulley. Front Idler Pulley. Idler rm Pulley E. Left Spindle Pulley Figure 18. Removing the PTO rive elt. Idler rm. Left Spindle Pulley. PTO rive elt 7-1/4 (18,42 cm) E Figure 19. PTO rive elt Idler Tensioner Spring. PTO rive elt Idler Tensioner Spring Length. Jam Nut. Eyebolt. djustment Nut 7

8 heck the Mower eck rive elt E NOTIE To avoid damaging belts, O NOT pry belts over pulleys. 1. Park the unit on a smooth, level surface such as a concrete floor. isengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the mower deck guard. 3. Lower the mower deck to its lowest cutting position. 4. Make sure the V-side of the belt runs in the pulley grooves (Figure 20). WRNING 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. 5. If belt is not properly seated, use a 1/2 breaker bar, and place the square end in the square hole located in the end of the idler arm (, Figures 21). arefully rotate the breaker bar OUNTER-LOKWISE, which will relieve the tension on the belt exerted from the idler arm. 6. Re-seat belt and carefully release the tension on the breaker bar. HEKING THE EK RIVE ELT ILER TENSIONER SPRING LENGTH 1. Set the mower deck at its middle cutting height. 2. Measure the coil to coil length of the deck drive belt tensioner spring (, Figure 22). It should measure 7-1/4 (18.42 cm). If it does not, perform the djusting the eck rive elt Idler Tensioner Spring Length. JUSTING THE EK RIVE ELT ILER TENSIONER SPRING LENGTH 1. Loosen the jam nut () on the eyebolt (). 2. Turn the adjustment nut () until a measurement of 7-1/4 (18.42 cm) is achieved. 3. Tighten the jam nut. Figure 20. Mower eck elt Routing. Mower eck rive elt. Stationary Idler Pulley. Spring-loaded Idler Pulley. Spindle Pulleys E. Left Spindle Pulley Figure 21. Mower eck elt Removal. Idler rm. Left Spindle Pulley Figure 22. eck rive elt Idler Spring Length. eck rive elt Idler Tensioner Spring Length. Jam Nut. Eyebolt. djustment Nut 7-1/4 (18,42 cm) 8

9 Lubrication Lubricate the unit at the locations shown in Figure 23 through 27 as well as the following lubrication points. Grease: front caster wheel axles & yokes deck lift pivot blocks mower deck & pump drive idler arm operator compartment front pivots Figure 24. Mower eck Lubrications Points Use grease fittings when present. isassemble parts to apply grease to moving parts when grease fittings are not installed. Not all greases are compatible. Red Grease (p/n ) is recommended, automotive-type hightemperature, lithium grease may be used when this is not available. Oil: control handle pivots deck rollers deck lift pivots discharge chute hinge Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Remember to wipe fittings and surfaces clean both before and after lubrication. Lubricating the Front asters: NOTE: Front casters should be lubricated annually. 1. Remove the 1/4-28 bolt (, Figure 27) screwed into the front caster and install a 1/4-28 grease fitting. 2. Grease the front caster. 3. Remove the 1/4-28 grease fitting and reinstall the 1/4-28 bolt. 4. Repeat the process for the other side of the machine. Figure 25. eck Lift System Figure 26. eck Lift Rods Figure 23. Front aster & Wheel. 1/4-28 olt Figure 27. Ground Speed ontrol Levers 9

10 dding Fuel To add fuel: 1. Remove the fuel cap (, Figure 28). 2. Fill the tank to the bottom of the filler neck. This will allow for fuel expansion. NOTE: o not overfill. Refer to your engine manual for specific fuel recommendations. 3. Install and hand tighten the fuel cap. Starting The Engine 1. While sitting in the operator s seat, engage the parking brake and make sure the PTO switch is disengaged and the ground speed control levers are in the NEUTRL position. 2. Set the engine throttle control to FST throttle position. Then fully close the choke by pulling the knob OUT fully. 3. Insert the key into the ignition switch and turn it to STRT. 4. fter the engine starts, gradually open the choke (push knob down fully). Reduce to half throttle speed and allow the engine to warm up. Warm up the engine by running it for at least a minute before engaging the PTO switch or driving the rider. 5. fter warming the engine, LWYS operate the unit at FULL THROTTLE when mowing. Figure 28. dding Fuel. Fuel ap 10

11 Perform Safety hecks WRNING isengage the PTO, stop the engine, set the parking brake, and wait for moving parts to stop before leaving operator s position for any reason. If the tractor does not pass the test, do not operate tractor. Under no circumstance should you attempt to defeat the purpose of the safety system. Functional Tests 1. heck the tractor for loose bolts, screws, nuts, etc. 2. Start the engine and check all controls for proper operation: ground speed control levers, parking brake, throttle cable, electric PTO clutch, etc. 3. Stop the engine and check for fluid leaks: oil, fuel and hydraulic oil. 4. If any control fails to operate properly during testing or seems to be out of adjustment, check and readjust it according to the following djustments section. Safety Interlock System This unit is equipped with safety interlock switches. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with safety devices. heck their operation regularly. OPERTIONL SFETY HEKS TEST 1 ENGINE SHOUL NOT RNK IF: PTO switch is engaged, OR Parking brake is not engaged, OR Ground speed control levers are not in the NEUTRL position. TEST 2 ENGINE SHOUL RNK IF: PTO switch is NOT engaged, N Parking brake is engaged, N Ground speed control levers are locked in the NEUTRL position. TEST 3 ENGINE SHOUL SHUT OFF IF: Operator rises off seat with PTO engaged, OR Operator rises off seat with parking brake disengaged. Operator moves the ground speed control levers out of their neutral positions before disengaging the parking brake. TEST 4 LE RKE HEK Mower blades and mower drive belt should come to a complete stop within seven (7) seconds after the electric PTO switch is turned off (or operator rises off seat). If the mower drive belt does not stop within seven (7) seconds, see your dealer. NOTE: Once the engine has stopped, PTO switch must be turned off, parking brake must be engaged, and the ground speed control levers must be in the NEUTRL position after the operator returns to the seat in order to start the engine. WRNING 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. 11

12 djustment Procedures Seat djustment The height of the seat (, Figure 29) can be adjusted either up or down and the position of the seat can be adjusted forward or back to accomidate the operator s comfort level. 1. Remove the seat height adjustment hardware (). 2. Position the seat at the desired height and distance and reinstall and tighten the seat adjustment hardware. Figure 29. Seat Height djustment. Seat. Seat Height djustment Hardware Neutral djustment If the unit creeps while the ground speed control levers are in the NEUTRL position, then it may be necessary to adjust the linkage adjuster rods. 1. Park the machine on a flat, level surface such as a concrete floor. isengage the PTO, engage the parking brake and turn off the engine. UTION This adjustment should not be performed while the machine is running. 2. Loosen the jam nut (, Figure 30). 3. Turn the linkage rod adjuster () to adjust the neutral of the machine: If the machine creeps forward, turn the linkage rod adjuster LOKWISE. If the machine creeps backwards, turn the linkage rod adjuster OUNTER-LOKWISE. 4. Retighten the jam nut when adjustment is complete. 5. Start the engine. 6. isengage the parking brake and make sure all controls are in the NEUTRL position. 7. If the machine still creeps repeat the NEUTRL JUSTMENT procedure. It may take several attempts to achieve neutral depending on how much the machine creeps. Figure 30. Neutral djustment. Jam Nut. Linkage Rod djuster. ontrol Ramp Rod 12

13 Speed alancing djustment If the unit veers to the right or left when the ground speed control levers are in either the maximum forward or reverse position, the top speed of the ground speed control levers can be adjusted. Only adjust the speed of the wheel that is travelling faster. TO REUE THE FORWR SPEE OF THE FSTER WHEEL: oarse djustment 1. Loosen the inner jam nut (, Figure 31). 2. Turn the adjustment nut () LOKWISE to reduce the speed. 3. Retighten the securing nut. NOTE: If you cannot achieve the proper adjustment using the oarse djustment Procedure proceed to the Fine djustment Procedure. Fine djustment 1. Loosen the jam nut (, Figure 32). 2. Loosen and remove the eyebolt hardware () that secures they eyebolt () to the ground speed control lever arm (). 3. Turn the eyebolt LOKWISE to reduce the speed. 4. Reinstall the eyebolt to the ground speed control lever arm with the eyebolt hardware. 5. Retighten the jam nut when the adjustment is complete. TO REUE THE REVERSE SPEE OF THE FSTER WHEEL: 1. Loosen the securing nut (, Figure 33). 2. Turn the top speed adjustment bolt () OUNTER- LOKWISE to reduce the speed. WRNING o NOT adjust the tractor for a faster overall speed forward or reverse than it was designed for. 3. Retighten the securing nut when adjustment is complete. Figure 31. Speed alancing oarse djustment. Inner Jam Nut. djustment Nut Figure 32. Speed alancing Fine djustment. Jam Nut. Eyebolt Hardware. Eyebolt. Ground Speed ontrol Lever rm Figure 33. Reverse Speed alancing djustment. Securing Nut. Top Speed djustment olt 13

14 Parking rake djustment The parking brake system consists of two range selector plates and two parking brake springs which are located by the rear wheels of the unit. If the parking brake needs to be adjusted the range selector plates must be adjusted first, and then the length of the parking brake springs must be set. JUSTING THE RNGE SELETOR PLTE 1. isengage the PTO, engage the parking brake, stop the engine and remove the ignition key. 2. hock the front tires to prevent the machine from moving. Jack up the rear of the machine and secure with jackstands. 3. Remove both of the rear wheels. 4. isengage the parking brake. 5. Remove the range selector hardware (, Figure 34). 6. Loosen the range selector pivot hardware () just enough so that you can pivot the range selector plate (). 7. Pivot the range selector plate towards the front of the machine as far as you can and insert the range selector hardware in the nearest hole. 8. With the parking brake disengaged, attempt to pull the brake hub () off of the unit. If their is resistance when you remove the brake hub from the unit, continue with step # 9. If their is no resistance when you remove the brake hub off the unit, place the brake hub back on the unit and skip to step # Remove the range selector hardware and pivot the range selector plate until you can insert the range selector hardware in the next lowest numbered hole. 10. Re-check the hub for resistance by pulling the brake up on and off the unit again. If their is resistance move the range selector hardware in the next lowest number hole until you can pull the brake hub on and off without resistance. Place the hub back on the unit. 11. Tighten the range selector hardware () and the range selector pivot hardware (), 12. Reinstall the rear wheel. 13. Repeat the process for the other side of the unit. 14. Remove the jack and jack stands from underneath the machine. Figure 34. djusting the Range Selector Plate. Range Selector Hardware. Range Selector Pivot Hardware. Range Selector Plate. rake Hub

15 JUSTING THE PRKING RKE SPRING 1. Locate the two (2) brake springs (, Figure 35). 2. With the parking brake engaged, measure the compressed spring length. The spring should be 2-3/8 (6 cm) when compressed. 3. If the spring length does not equal the measurement, the spring length will need to be adjusted. 4. isengage the parking brake. 5. Loosen the set collar () and slide it away from the back of the parking brake bracket (). 6. Turn the adjustment nut () to compress or release the spring. 5. Engage the parking brake and re-measure the spring. ontinue this process until the compressed spring length measures 2-3/8 (6 cm). 6. Position the set collar 1/4 (.64 cm) away from the parking brake bracket and tighten. If this does not correct the braking problem, see your Ferris dealer. 1/4 (.64 cm) 2-3/8 (6 cm) Figure 35. Parking rake djustment. rake Spring. Set ollar. Parking rake racket. djustment Nut 15

16 Suspension djustment The front shock assemblies (, Figure 36) and the operator compartment shock assembly () can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to maintain the ride height. Use less pre-load for light weight operators. Use more pre-load for heavy weight operators. TO JUST THE SPRING PRE-LO: 1. Park the machine on a flat, level surface. isengage the PTO, stop the engine and engage the parking brake. WRNING Use two hands when adjusting the shock springs. This will prevent the wrench from slipping while pressure is being applied. 2. See Figure 36. Using the supplied spanner wrench (P/N ), insert the tip of the wrench into the notch in the pre-load adjuster. While holding the wrench with both hands, turn LOKWISE to decrease the pre-load, turn OUNTER-LOKWISE to increase the pre-load. FRONT SHOK SSEMLIES Figure 36. Suspension djustment. Front Shock ssemblies. Operator ompartment Shock ssembly OPERTOR OMPRTMENT SHOK SSEMLY riggs & Stratton Power Products Group, LL. opyright 2012 riggs & Stratton orporation Milwaukee, WI, US. ll Rights Reserved. Ferris is trademark riggs & Stratton orporation, Milwaukee, WI, US. riggs & Stratton Power Products Group, LL North Main Street Munnsville, NY (800)