Dealer Setup & Adjustment Instructions

Transcription

1 ealer Setup & djustment Instructions Ferris IS5100Z Series - aterpillar iesel Engine - IS5100Z Series - aterpillar iesel Engine - This ealer Setup Instruction covers the following products: Zero-Turn Rider Mower eck Model No. escription: Model No.: escription: IS5100Z / IS5100Z33E /61RE IS5100Z /72RE NSI-EXP /72E /72R Zero-Turn Rider w/ Mower eck IS5100Z IS5100Z3361RE IS5100Z IS5100Z3372R IS5100Z3361 NSI-EXP 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. 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. TLE OF ONTENTS SETUP PROEURES Quick Setup List...2 Uncrating...3 attery Installation...4 Tractor ssembly...4 Motion ontrol Handle ssembly...4 Seat ssembly...4 Roll ar ssembly...5 ssemble Retainer Pins...5 ssemble Top Loop...5 Install the Roll ar...5 Install Safety ecals (NSI-EXP / E Models)...6 heck Fluid levels...7 heck Engine Oil Level...7 heck Hydraulic Oil Level...7 heck ntifreeze Level...7 heck Tire Pressure...8 Mower ssembly...8 heck Torque - Mower lades...8 Install the ischarge hute...8 Install eflector (Rear ischarge Models Only)...9 Install eck Pusher ars...9 Install the Mower eck...10 djust eck Lift Rod Timing...11 Level the Mower eck...12 Install eck rive elt S/N: & elow...13 Install eck rive elt S/N: & bove...15 dding Fuel...16 Lubrication...16 Priming the Fuel System...17 Starting The Engine...18 Perform Safety hecks...18 Functional Tests...18 Safety Interlock System...18 JUSTMENT PROEURES Seat djustment...19 Motion ontrol Handle djustment...19 Speed alancing djustment...19 Neutral djustment...20 Neutral Position & Return Spring djustment...20 Neutral Position djustment...20 Return Spring djustment...20 Parking rake djustment...21 Suspension djustment...22 Operating the Locking Hood Rev.: F

2 IS5100Z Series - aterpillar iesel Engine - Quick Setup List Setup Procedure Steps to Performs 3 Uncrating Remove rate & anding. Loosen Hydraulic Release Valves. Infl ate Rear Tires. Install Rear umper in Operating Position. Release Parking rake and Roll Tractor Forward off Skid. Tighten Hydraulic Release Valves. 4 attery Installation Install & Secure attery. 4 Tractor ssembly ssemble the Motion ontrol Handles. ssemble the Seat. 5 Roll ar ssembly ssemble the Retainer Pins. ssemble the Top Loop. Install the Roll ar. Install Safety ecal (NSI-EXP / E Models Only) 7 heck Fluid Levels heck Engine Oil Level. heck Hydraulic Oil Level. heck ntifreeze Level. heck Hydraulic Release Valve. heck Tire Pressure. 8 Mower ssembly heck lade olt Torque Install the ischarge hute Install efl ector (Rear ischarge Models Only) Install eck Pusher ars Install Mower eck djust eck Lift Rod Timing. Level Mower eck. Install eck rive elt. 16 Lubrication & dd fuel. Fuel Preparation Lubricate all Grease & Oil Points. Prime the Fuel System. Start the Engine. 18 SFETY HEKS heck for LOOSE HRWRE. heck all OPERTOR ONTROLS. Perform SFETY INTERLOK SYSTEM HEK. Register Product To register the product: log onto select the appropriate brand, click My Resources, select the Product Registration and Rebate icon and then the New Product Registration / Rebate tab. Fill out and submit the online product registration form. 2

3 IS5100Z Series - aterpillar iesel Engine - Uncrating 1. Using a reciprocating utility saw or equivalent, cut crate away from bottom skid. Remove crate. Remove shrink-wrap plastic. 2. ut banding from front and rear tractor axles. ut banding from mower rollers. Remove mower deck from the bottom skid. IMPORTNT NOTE When cutting crate from bottom skid, use caution around tractor tires and mower rollers. Figure 1. Hydraulic Release Valve Location. Hydraulic Release Valve (Right-hand side shown) 3. Open the hydraulic release valves. To open the release valves, turn the right-hand release valve, which is located on top of the right-hand pump, counter-clockwise 2 full turns MX. Then turn the lefthand release valve, which is located on the bottom of the left-hand pump, counter-clockwise 2 full turns MX. See Figure 1 for valve location. 4. Inflate rear tires to 18 psi (1,24 bar). 5. Remove the rear bumper from the shipping position (, Figure 2). With same hardware, install the bumper in operating position (). Tighten the hardware securely. 6. Push down on parking brake lever (, Figure 3) to release parking brake. 7. 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. 8. fter moving the tractor, re-engage the pumps (drive position) by turning the release valves clockwise and tighten to in/lbs ( N.m.). Figure 2. umper Install. Operating Position. Shipping Position Figure 3. isengaging the Parking rake (lever shown in disengaged position). Parking rake Lever 3

4 IS5100Z Series - aterpillar iesel Engine - attery Installation Install attery 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. 1. Raise the seat plate to expose the battery compartment. 2. onnect the red positive battery cable (, Figure 4) to the positive battery post. 3. onnect the black negative battery cable () to the negative battery post. Figure 4. attery Installation. Negative able. Positive able. Hold-own Strap Tractor ssembly Motion ontrol Handle ssembly 1. Remove the handles and mounting hardware from the handle bar box. 2. ssemble the control handles to the square bases using the 5/16-18 x 1 bolts, lock washers and flat washers. There are two sets of holes available for the handle height. ssemble the handles in the same set of holes for both sides. NOTE: There are a LEFT-HN and a RIGHT-HN control handle. When assembled to the base, the handle should tilt forward as shown in Figure 5. Seat ssembly 1. Unpack the seat. 2. Install the seat onto the seat mount plate and secure with the 5/16-18 nylock flange nuts. Figure 5. ontrol Handle Installation (right-hand side shown). 5/16-18 x 1 olts, Lock Washers and Flat Washers 4

5 IS5100Z Series - aterpillar iesel Engine - Roll ar ssembly ssemble Retainer Pins 1. Unpack the roll bar and hardware from the box. 2. ssemble the foam ring (, Figure 6) onto the retainer pin (). 3. Loop the snap end of the lanyard () through the retainer pin handle and snap together. 4. Install the lanyard anchor () onto the lanyard. 5. Install the clevis pin (E) onto the loop end of the lanyard as shown in Figure 6. Snap End Figure 6. ssemble the Retainer Pins. Foam Ring. Retainer Pin. Lanyard. Lanyard nchor E. levis Pin Loop End E ssemble the Top Loop 1. Install the plastic cap (, Figure 7) into the end of the top loop tube (). Repeat for other end of tube. 2. Make sure the rubber stop () is properly seated against the inside of the pivot mount. See Figure 7. Install the Roll ar 1. Make sure the roll bar sockets are clear of any obstructions, wires, foreign objects, etc. 2. Install the roll bar upright tubes () into the sockets as shown in Figure 8. Loosely install the 1/2-13 x 4 bolts and hex side lock nuts (, Figure 8). NOTE: See Figure 9 for proper upright tube orientation. Figure 7. ssemble the Top Loop. Top Loop Tube. Plastic ap. Rubber Stop Figure 8. Installing Roll ar. Upright Tubes (LH Side Shown). 1/2-13 x 4 olts & 1/2-13 Hex Side Lock Nuts 5

6 IS5100Z Series - aterpillar iesel Engine - 3. Install the top loop (, Figure 10) onto the upright tubes (). From the outside, install the 1/2 x 3 bolt () through the retainer pin assembly (), then through the top lop and upright tube and shown in FIgure 9. Loosely install the 1/2 side lock nut (E). Repeat for other side. 4. Tighten the 1/2 hardware securing the upright tubes to the frame (see Figure 8). Tighten the hardware until there no movement in the upright tubes. 5. Tighten the 1/2 x 3 bolts and hex side lock nuts ( & E) securing the top loop () to the upright tubes (). o not over-tighten. The top loop should pivot snugly with the retainer pins removed. 6. Raise the top loop () until the rubber stops (F) contact the upright tubes. 7. Push or pull the top of the roll bar forward against the rubber stops and install the retainer pins and hair pin clips to secure the roll bar in the raised position. Figure 9. Proper Orientation of Upright Tubes E E F Figure 10. Install Top Loop. Top Loop. Upright Tube. 1/2 x 3 olt G.5. Retainer Pin ssembly E. 1/2 Side Lock Nut F. Rubber Stop Install The Safety ecals (NSI-EXP / E Model Only) 1. Remove the black and yellow E safety decals( &, Figure 11) from the publication packet. 2. Install safety decal part no () over existing decal located below pivot point of the roll bar () of RH upright tube. Install safety decal part no () over existing decal located above the pivot point of the roll bar () of RH upright tube. Repeat procedure for LH upright tube. 6 Figure 11. Install E Safety ecals (LH Side Shown). Part No Part No Pivot Point of the Roll ar

7 heck Fluid Levels IS5100Z Series - aterpillar iesel Engine - heck Engine Oil 1. Use the dipstick (, Figure 12) to check the engine oil level. If necessary add engine oil. heck engine manufacturer s owner s manual for oil recommendations. See (, Figure 15) for oil fill cap location. heck Hydraulic Oil Level NOTE: o 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 (, Figure 13) of the hydraulic oil reservoir. 3. If necessary, remove the reservoir cap (, Figure 13) and add either Mobil 1, 15W-50 synthetic oil or astrol Syntec 5W-50 oil. O NOT use conventional oils. Make sure area around the filler neck is free of dust, dirt, or other debris. heck ntifreeze Level The engine coolant level and quality should be checked before each use, when the engine is cool and off. 1. Remove the radiator pressure cap (, Figure 14) to check the fluid level. 2. oolant level should be 1/2 (13mm) below the bottom of the filler tube. If coolant level is low, add coolant until level is 1/2 (13mm) below the bottom of the filler tube. Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water. See engine owners manual for antifreeze specifications. 3. heck the coolant level in the radiator overflow bottle (, Figure 15). If coolant level is low, add coolant until level is at the FULL line. Proper coolant mix is a 50/50 mixture of ethylene glycol and distilled water. See engine owners manual for antifreeze specifications. Figure 12. heck Engine Oil Level. ipstick Figure 13. Hydraulic Oil Reservoir. Tank Recess ( FULL level). ap Figure 15. heck and Fill. Radiator Overflow ottle. Oil Fill ap Figure 14. heck ntifreeze Level. Radiator Pressure ap 7

8 IS5100Z Series - aterpillar iesel Engine - 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. Mower ssembly 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 N.m.) Tire Pressure psi bar Front 25 1,72 Rear 18 1,24 Figure 16. hecking Tire Pressure 1. heck that blades are installed with the tabs pointing up toward deck as shown in Figure 17. Torque bolts to 70 ft.lbs. (94 N.m.). Install the ischarge hute Figure 17. heck lade Torque E 1. Install the discharge chute (, Figure 18) onto the mower deck () as shown in Figure 1 using the pivot rod (). 2. Secure the discharge chute to the mower deck using two (2) 5/16 washers () and nylon nuts (E). The mower deck should never be run without the discharge chute installed and positioned in the down position. NGER E mputation and Thrown Object Hazard To avoid injury from rotating blades, stay clear of deck edge and keep others away. o not mow without discharge chute or entire grass catcher in place. Figure 18. Install ischarge hute. ischarge hute. Mower eck. Pivot Rod. 5/16 Washers E. Nylon Nuts 8

9 Install eflector (Rear ischarge Models Only) 1. Install the rear deflector as shown in Figure 19 and secure with the supplied hardware. IS5100Z Series - aterpillar iesel Engine - 61 Model 72 Model Install eck Pusher ars heck the pusher bar length from the outside of the cross tube to the center of the ball joint. This should be 16-5/8 (42,2cm). See insert in Figure 20. djust if necessary prior to installing the pusher bars onto the deck. 1. Holding the pusher bar (, Figure 20) in place, insert the mount pin () through the bracket and the pusher bar. On the 72 Rear ischarge Models: Pusher ar Mount Pins must be installed from the inside to the outside of the deck. Figure 19. Install eflector (Rear ischarge Models Only) F G 2. Secure the mount pin to the mower deck bracket with a 5/16 x 1 bolt (), 5/16 flat washer () and serrated flange nut (E) provided. 3. Install and tighten the 3/8-16 X 1 bolt (F) and the.39 X 1.25 X.100 washer (G) into the end of the mount pin (). Repeat for other side. Figure 20. Install Pusher ars. eck Pusher ar. Mount Pin. 5/16-18 x 1 olt. 5/16 Flat Washer E. 5/16-18 Serrated Flange Nut F. 3/8-16 X 1 olt G..39 X 1.25 X.100 Washer E 9

10 IS5100Z Series - aterpillar iesel Engine - Install the Mower eck 1. Park machine on a flat, level surface and engage the parking brake. 2. Lock the deck lift pedal in the 6 (15,2cm) position. Place the deck height adjustment pin in the 4 (10,2cm) position and lower the deck lift pedal until the arm contacts the pin. Secure in place if necessary. 3. enter the mower deck under the tractor frame. 4. Fasten the ball joints to the pusher bar mounts using the 3/4 bolt, washer, rod end seals, and the 3/4 nut (see Figure 21). Using a 1-1/16 wrench and 1-1/8 socket, tighten the assembly. Repeat for other side. 5. See Figure 22. Place blocking underneath the deck to raise it up. 6. Install the deck hanger chains to the pivots on the zero-turn rider. For the front hangers: remove the cotter pins (, Figure 23) from the clevis pins () and remove the clevis pins from the shackles (). enter the shackles on the hanger pivots and secure in place by routing the clevis pins through the shackles and hanger pivots, then secure with the cotter pins. For the rear hangers: Loosen the nylock nuts () from the deck hanging bolts (E), and route the bolts through the hanger pivots, then secure with the nylock nuts. E Figure 21. eck Pusher ar Installation. 3/4 Nylon Lock Nut. Rod End Seal. Pusher ar all Joint. 3/4 Washer E. 3/4 olt Figure x 4 Locations E Figure 23. eck Hanger hain Installation 10

11 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); front tires to 25 psi (1,72 bar). 2. heck the inner lift rod timing: measure and record the distance between the inner lift pivots and the inner rod pivots. Repeat for other side of unit. See Figure heck the outer lift rod timing: measure and record the distance between the outer lift pivots and the outer rod pivots. Repeat for other side of unit. See Figure If the measurements for the inner rods are equal, and the measurements for the outer rods are equal, no further adjustment is required. If the measurements are NOT equal (greater than 1/8 (3,17mm) difference), adjustment is required, continue with Step Lock the deck lift pedal in the 6 (15,2cm) position. Remove the cutting height adjustment pin (, Figure 25) and lower the mower deck. 6. To ensure that the deck is in the lowest position, push the pedal by hand towards the rear of the unit and install the height adjustment pin in the 3 (7.6 cm) position to hold in place. 7. lock up the mower deck until all hanger chains are slack. 8. Refer to Figure 26. To adjust the inner lift rod, loosen the jam nut on the front ball joint then remove the 1/2 hardware fastening the ball joint the the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2 hardware previously removed. Tighten the jam nut against the lift rod. 9. Refer to Figure 26. To adjust the inner lift rod, loosen the jam nut on the front ball joint then remove the 1/2 hardware fastening the ball joint the the lift pivot arm. Turn the ball joint clockwise to shorten the distance between the rod pivots or counterclockwise to lengthen the distance between the rod pivots. Reinstall the ball joint on the lift pivot arm and secure with the 1/2 hardware previously removed. Tighten the jam nut against the lift rod. 10. Remove blocks from under the mower deck. 11. Lift mower deck and reinstall adjustment pin in desired mowing height. IS5100Z Series - aterpillar iesel Engine - Inner Rod Measure 2nd Measure 1st Measure 2nd Measure 1st Outer Rod Figure 24. Measure the Inner & Outer Lift Rods Figure 25. eck Lift Pedal. Height djustment Pin Inner Rod djust Here Figure 26. djust the Inner & Outer Lift Rods djust Here Outer Rod 11

12 IS5100Z Series - aterpillar iesel Engine - 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); front tires to 25 psi (1,72 bar). 2. Lock the deck lift pedal in the 6 (15,2 cm) position. Place the deck height adjustment pin in the 4 (10,2 cm) position and lower the deck lift pedal until the arm contacts the pin. 3. Place 2 x 4 blocks under each corner of the mower deck with the 3-1/2 sides being vertical. Place a 1/4 (0,64 cm) spacer on top of the rear 2 x 4 blocks. See Figure For front deck level adjustment: djust the front eyebolts until the chains are tight and the deck is still resting on the 2 x 4 s. Tighten jam nuts. See Figure For rear deck level adjustment: For adjustment over 1/2 (1,27 cm) move the lower hanger chain mounting bolt (, Figure 28) to appropriate hole in mount () to take up most of the slack. For adjustments less then 1/2 (1,27cm) loosen the jam nuts () and turn the adjustment bolts () until the chains are tight and the rear of the deck is resting on the 2 x 4 s and 1/4 spacers. Tighten the jam nuts. 6. Remove all 2 x 4 blocks and 1/4 spacers from under the mower deck. 10. For your safety, O NOT handle mower blades with bare hands. Position the outside mower blades so that they face front-to-back (Figure 29). 11. 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. The front measurements should be 4 (10,2 cm). The rear measurements should be 4-1/4 (10,8 cm). Figure x 4 Locations djust Here Figure 28. eck Level djustment. Jam Nut. djustment olt. Lower Hanger hain Mount. Lower Hanger hain Mounting olt djust Here 72 R Figure 29. hecking The lade Height Measurement 12

13 Install eck rive elt S/N: & elow To avoid damaging belts, O NOT PRY ELTS OVER PULLEYS. IS5100Z Series - aterpillar iesel Engine - 1. See Figure 30. Remove the height adjustment pin and lower deck. 2. Loosen the 5/16 bolts securing the mower deck guards and remove the guards. 3. elt is partially installed on the deck pulleys. Make sure the V-side of the belt runs in the pulley grooves (Figure 31). 4. Install the drive belt on the gearbox pulley, the spindle pulleys and idler pulleys. Figure 30. Lowering eck. Height djustment Pin Side ischarge Model Only: Using a 3/4 combination wrench, rotate the spring-loaded idler pulley (, Figure 32) OUNTER-LOKWISE and slide the drive belt over the edge of the stationary idler pulley (). Make sure the V-side of the belt runs in the pulley grooves (Figure 31). arefully release the tension on the wrench. WRNING Use extreme caution when rotating the idler pulley with the wrench, due to the increased tension in the spring as the idler pulley is being rotated. Injury may result if the wrench is prematurely released while the spring is under tension. 61 & 72 Side ischarge Model 5a. 61 Rear ischarge & 72 Models: Using a 3/4 combination wrench, rotate the spring-loaded idler pulley (, Figure 32) LOKWISE and slide the drive belt over the edge of the stationary idler pulley (). Make sure the V-side of the belt runs in the pulley grooves (Figure 31). arefully release the tension on the wrench. 6. Reinstall the mower deck guards and tighten the 5/16 hardware to secure in place. Raise deck and reinstall height adjustment pin (Figure 30) at desired mowing height. 61 & 72 Rear ischarge Models Figure 31. Mower PTO elt Routing. Spindle Pulley. PTO rive elt. Spring-loaded Idler Pulley. Stationary Idler Pulley 13

14 IS5100Z Series - aterpillar iesel Engine - 61 Side ischarge Model Only 61 Rear ischarge & 72 Models Figure 32. Mower PTO elt. Spring-loaded Idler Pulley. Idler Spring. Stationary Idler Pulley heck the Mower elt Tensioner Spring Length: 1. Lower the mower deck to its lowest cutting position. 2. Measure the coil length (E, Figure 33) of the spring (). The measurement should equal the measurement as indicated in the chart. If it does not, adjust the mower belt spring length. E Mower elt Idler Spring Length inch cm 61 Mower eck Mower eck 6-1/ djusting the Mowr elt Spring Length: 1. Loosen the jam nut () on the anchor eyebolt (). 2. Turn the adjustment nut () until the measurement as indicated in the chart is achieved. 3. Retighten the jam nut. Figure 33. Mower elt Idler Spring Length. Mower elt Tensioner Spring. nchor Eyebolt. Jam Nut. djustment Nut E. Measurement 14

15 Install eck rive elt S/N: & bove To avoid damaging belts, O NOT PRY ELTS OVER PULLEYS. IS5100Z Series - aterpillar iesel Engine - F 1. Lower the mower deck to its lowest cutting position. 2. Remove the mower deck guards and floor pan to gain access to the mower deck belt. 3. Install the drive belt (, Figure 34). Make sure the V-side of the belt runs in the pulley grooves of the spindle pulleys (), and the gearbox pulley. Make sure that the flat side of the belt contacts the face of the front stationary idler pulley(s) (E), the adjustable idler pulley (F) WRNING Use extreme caution when rotating the idler pulley with the wrench, due to the increased tension in the spring as the idler pulley is being rotated. Injury may result if the wrench is prematurely released while the spring is under tension. 4. Use a 1/2 breaker bar, and place the square end in one of the opening in the idler arm () and carefully rotate the breaker bar clockwise, and install the belt on the rear stationary idler pulley (). 5. arefully release the tension on the breaker bar. heck the Mower elt Tensioner Spring Length: 1. Lower the mower deck to its 3-1/2 (8.9 cm) position. 2. Measure the coil length (, Figure 35) of the spring (). The measurement should equal 12 (30 cm). If not, adjust the mower belt spring length. djusting the Mower elt Spring Length: 1. Loosen the jam nut (, Figure 35) on the anchor eyebolt (). 2. Turn the adjustment nut (E) until the measurement 12 (30 cm) is achieved. 3. Retighten the jam nut. 4. Re-install the mower deck guards and floor pans. E E Figure 34. Mower eck rive elt E Figure 35. Mower elt Tensioner Spring Length 15

16 IS5100Z Series - aterpillar iesel Engine - dding Fuel 1. Turn fuel shut off valves, located on the bottom of the fuel tanks, to the ON position. 2. Remove the fuel cap (, Figure 36). 3. 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 recommendations. 4. Install and hand tighten the fuel cap. 5. Repeat same process for opposite tank. NOTE: The fuel tanks are tied together through a tee in the supply lines. y filling only one tank, the level will balance between the two tanks, effectively having 1/2 tank of fuel for each side. Figure 36. Fill Fuel Tank. Fuel ap Lubrication Lubricate the unit at the locations shown in Figure 37 through 41. Grease: 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: Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Remember to wipe fittings and surfaces clean both before and after lubrication. Figure 38. eck Lubrication Figure 39. ontrol Handle Pivots & Seat Pivots Figure 37. eck Lift Linkage Pivots Figure 40. Gearbox rive Idler Pivot 16

17 Lubricating the Front aster Interval: nnually 1. Remove the 1/4-28 bolt (, Figure 41) 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. IS5100Z Series - aterpillar iesel Engine - Figure 41. Front aster & Wheel. 1/4-28 olt Priming The Fuel System Priming the fuel system fills the fuel filters and removes any air bubbles from the fuel system. This must be performed before the first use, after any fuel filter maintenance or if the fuel system is run dry. On the water separator: 1. Using a 1/2 wrench, loosen the vent screw (, Figure 42) on the water separator 2-3 revolutions. 2. Unscrew the priming hand pump () located on top of the water separator. Operate the hand pump up and down until fuel that is free of air flows from the vent. 3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). O NOT OVER TIGHTEN! On the engine fuel filter: 1. Using the appropriate size wrench, loosen the vent screw () on the engine fuel filter 2-3 revolutions. 2. Operate the hand pump up and down until fuel that is free of air flows from the vent. 3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). O NOT OVER TIGHTEN! On the engine injector pump: 1. Using a 13 mm wrench, loosen the vent screw () on the fuel inlet 2-3 revolutions. 2. Operate the hand pump up and down until fuel that is free of air flows from the vent. 3. Tighten the vent screw to 4.5 ft/lbs (6 N.m.). O NOT OVER TIGHTEN! 4. Tighten the priming fuel pump finger tight. 5. Start the engine. (See STRTING THE ENGINE). If the engine will not start, further priming is necessary. If the engine starts but misfires or continues to emit smoke, further priming is necessary. 6. If the engine starts but runs rough, continue to run the engine at low idle until the engine runs smoothly. Figure 42. Fuel System Priming. Water Separator Vent Screw. Priming Hand Pump. Engine Fuel Filter Vent Screw. Injector Pump Vent Screw 17

18 IS5100Z Series - aterpillar iesel Engine - Starting The Engine 1. While sitting in the operators seat, engage the parking brake and make sure the PTO switch is disengaged and the ground speed control levers are locked in the neutral position. 2. Set the throttle to middle position (set throttle to FULL when starting in cold weather) 3. Turn the key to the HET position. Hold the key to turn the glow plug indicator light on and activate the glow plugs. 4. Wait until the glow plug indicator light turns off, then turn the key to STRT. If the engine does not start immediately, move the throttle control to FULL. NOTE: o not crank the engine continuously for more than 30 seconds. llow the starter motor to cool for two minutes before cranking the engine again. 5. fter the engine starts, move the engine throttle control to SLOW. Warm up the engine by running it for at least a minute. 6. Move the throttle to FULL before engaging the PTO switch or driving the machine. 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: motor oil, fuel, hydraulic oil, and antifreeze. 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. SFETY INTERLOK 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. Operational SFETY hecks 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 NEUTRL position, OR Operator is not on the seat. Test 2 Engine SHOUL crank if: PTO switch is NOT engaged, N Parking brake is engaged, N Motion control handles are locked in the NEUTRL position, N Operator is on the seat. Test 3 Engine should SHUT OFF if: Operator rises off seat with PTO engaged, OR Operator rises off seat with parking brake disengaged. Operator moves motion control handles inward before disengaging parking brake. Test 4 lade rake heck Mower blades and mower drive belt should come to a complete stop within seven (7) seconds after electric PTO switch is turned off (or operator rises off seat). If 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 motion control handles must be locked 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. Under no circumstance should you attempt to defeat the purpose of the safety interlock system. 18

19 djustment Procedures Seat djustment IS5100Z Series - aterpillar iesel Engine - Seat djustment Lever See Figure 43. The seat can be adjusted fore and aft. Move the lever forward, position the seat as desired, and release the lever to lock the seat into position. Ground Speed Lever djustment 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. HNLE LIGNMENT Loosen the mount hardware (, Figure 44) and pivot the lever(s) () fore or aft to align with each other. HNLE PLEMENT Loosen the jam nuts and adjust the placement bolt (, Figure 44) in or out to properly adjust the lever end spacing. HNLE HEIGHT Remove the mounting hardware () and reposition the handle either up or down from its original position. You will need to readjust the handle alignment as described above. Speed alancing djustment If the rider veers to the right or left when the ground speed control levers are in the maximum forward position, the top speed of each of these levers can be balanced by turning the adjustment bolt(s) (, Figure 45). Only adjust the speed of the wheel that is traveling faster. To Reduce the Speed of the Faster Wheel 1. Loosen the jam nut (). 2. turn the top speed adjustment bolt LOKWISE to reduce the speed. 3. Retighten the jam nut when adjustment is complete. Figure 43. Seat djustment Figure 44. ontrol Lever djustment. lignment Hardware. Placement Hardware. Ground Speed ontrol Lever Figure 45. Top Speed djustment. Top Speed djustment olt. Jam Nut WRNING O NOT adjust the tractor for a faster overall speed forward or reverse than it was designed for. 19

20 IS5100Z Series - aterpillar iesel Engine - Neutral djustment If the tractor creeps while the ground speed control levers are locked in NEUTRL, then it may be necessary to adjust the control linkage. NOTE: Perform this adjustment on a hard, level surface such as a concrete floor. 1. isengage the PTO, engage the parking brake and turn off the engine. 2. Loosen the jam nuts (, Figure 46) and turn the adjustment linkage () to adjust. If the machine creeps forward, turn the linkage LOKWISE (while standing at the rear of the machine, facing forward), if the machine creeps backward, turn the linkage OUNTER-LOKWISE. 3. Lock the jam nuts () when neutral is achieved. NOTE: This adjustment should not be performed while the machine is running. It may take several attempts to achieve neutral, depending upon how much the machine creeps. Figure 46. Neutral djustment (Left-hand side shown). ontrol Linkage. Jam Nuts Neutral Position and Return Spring djustment To determine if it is necessary to adjust the neutral position, perform the following steps. 1. isengage the PTO, engage the parking brake and turn off the engine. 2. Move the ground speed control levers in the operating position, pull levers rearward and release. 3. Move the ground speed control levers towards the neutral position. If the levers do not align with the notches in the neutral lock plate, it is necessary to adjust the reverse return bolts (, Figure 47). Neutral Position djustment 1. Loosen the jam nut (, Figure 47) locked against the clevis. 2. Turn the reverse return bolt () clockwise to adjust handle rearward, counter-clockwise to adjust handle forward. 4. Pull lever rearward and release to check position again. djust as necessary to align levers with notches. 5. Once the lever alignment has been adjusted, lock jam nut against the clevis. Figure 47. Neutral Spring Return djustment. Reverse Return olt. Reverse Return Spring. Spring Position Nut. Jam Nut Return Spring djustment fter adjusting the neutral position, lock the levers in the neutral position and measure the reverse return spring (, Figure 47) length. This should be 2-3/8 (6,03 cm) long. If not, hold the reverse return bolt () with a wrench while turning the spring position nut () until the measurement is achieved. 20

21 IS5100Z Series - aterpillar iesel Engine - Parking rake djustment 1. isengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. 2. Locate the upper brake spring (, Figure 48) through the opening under the fuel tanks. 3. With the parking brake engaged, measure the compressed spring length. The spring should be 2 to 2-1/8 (5,0-5,4cm) when compressed. 4. If adjustment is required, disengage the parking brake and turn the adjustment nut (). 5. Engage the parking brake and re-measure the spring. 2" - 2-1/8" (5,0-5,4cm) FRONT UTION o not adjust the spring to be shorter than 2 (5,0cm) when compressed. This may damage the brake caliper. Figure 48. Parking rake djustment. Upper rake Spring. djustment Nut 21

22 IS5100Z Series - aterpillar iesel Engine - Suspension djustment The 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 adjust the spring pre-load: 1. Park machine on a flat, level surface. isengage the PTO, stop the engine and engage the parking brake. 2. See Figure 49. 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. Make sure that for each pair of shocks (, or, Figure 49) that the lefthand and right-hand are set to the same amount of pre-load. NOTE: Spanner wrench is located under the seat. Rear tires must be removed to adjust the rear suspension. FRONT WRNING Use two hands when adjusting the shock springs. This will prevent the wrench from slipping while pressure is being applied. RER Figure 49. djust Spring Pre-Load 22

23 IS5100Z Series - aterpillar iesel Engine - Operating the Locking Hood (E/NSI-EXP Models) Unlocking and Opening the Hood This unit is equipped with a locking hood latch that must be released prior to opening the hood. 1. Using a screw driver turn the hood latch lock (, Figure 50) counter-clockwise a 1/2 turn to release the lock. 2. Pull the hood latch () towards the rear of the machine to release the hood latch. 3. Open the hood latch. losing and Locking the Hood 1. lose the hood. 2. Using a screw driver, press the hood latch lock towards the front of the machine and turn clockwise a 1/2 turn to lock the hood Figure 50. Unlocking and Opening the Hood Latch. Hood Lock Latch. Hood Latch 23

24 IS5100Z Series - aterpillar iesel Engine - riggs & Stratton Power Products Group, LL. opyright 2016 riggs & Stratton orporation Milwaukee, WI, US. ll Rights Reserved. FERRIS is a trademark of riggs & Stratton orporation, Milwaukee, WI, US. riggs & Stratton Power Products Group, LL North Main Street Munnsville, NY (800)