Ferris 400S Series Manual

Not for
Reproduction

Not for
Reproduction
2 ferrismowers.com
Quick Setup List
Setup Procedures
  Uncrate the unit.
  Install the parking brake handle.
  Connect bottom shock mount bolts.
  Connect the battery cables.
  Install the ground speed control levers.
  Install the seat.
  Check engine oil level.
  Check / Fill transmission oil level.
  Check tire pressures.
  Check blade bolt and pulley bolt torque.
  Check and level the mower deck.
  Check the mower deck drive belt.
  Lubricate all grease and oil points.
  Check / Add fuel.
  Start the engine
PERFORM THE SAFETY CHECKS
  Check forLOOSE HARDWARE.
  Check allOPERATOR CONTROLS.
  PerformSAFETY INTERLOCK SYSTEM CHECK.
Register Product
  To register the product: log ontowww.thepowerportal.com, select the appropriate brand, click “Sales &
Marketing”, select the “Product Registration” link, and then select “New Product Registration”. Fill out and submit
the online product registration form.
Ferris is a registered trademark of Briggs & Stratton
Corporation.

Not for
Reproduction
3
Setup Procedures
The items in this section provide the information necessary
to fully assemble, test, and prepare the unit, that these
instructions were included with, for delivery to your customer.
The Quick Setup List provided on page 2 of this booklet
to help you identify and check that the items have been
performed.
Uncrating
1. Install the parking brake handle (A, Figure1) onto the
parking brake lever (B) located on the instrument control
panel using the #8 X 3/8" bolt (C) and #8 hex nut (D).
Note:The parking brake handle, parking brake handle
mounting hardware, and seat mounting hardware are in a zip
lock bag wire tied to the bottom side of the seat plate on the
unit.
1
2. Locate the transmission release levers (A, Figure2) on
the rear of the machine beneath the bumper. There is
one transmission release lever on each transmission.
The transmission release levers open and close the
transmission bypass valves.

2
3. To open the transmission bypass valve (bypass position)
(B), pull the transmission release lever out towards the
rear of the rider and push it towards the rear tire. Repeat
this process for the other side of the rider.
4. Disengage the parking brake.
5. Be sure there are no sharp objects to puncture the unit's
tires. Roll the unit forward off of the bottom skid.
6. After moving the rider, close the bypass valve (run
position) (C) by pushing the transmission release lever
towards the center of the machine and then pushing it
towards the front of the rider. Repeat this process for the
other side of the rider.
Note:Both transmission release levers must be in the same
position.
7. Cut the cable ties that secures the foam around the
body of the rear shocks. Remove the foam from the rear
shocks.
8. Remove the bolts, (A, Figure3), washers (B), and nylock
flange nuts (C) from the bottom hole of the rear shocks
(D).

Not for
Reproduction
4 ferrismowers.com
3
9. Center a jack underneath the rear bumper (E) of the
machine and raise the rear of the machine until the holes
in the bottom of the shocks align with the holes in the rear
suspension cradle (F).
10. Put the bolt through the washer, the shock, the rear
suspension cradle and secure using the nylock flange
nut. Repeat the process for the other side of the
machine.
11. Lower the rear bumper of the machine and remove the
jack.
Connect the Battery Cables
WARNING
Battery acid can cause severe burns. Wear protective
gear when handling the battery.
Open flames and sparks can cause battery to explode.
BATTERY SAFETY RULES:
• Battery acid causes severe burns. Avoid contact with
skin.
• Wear eye protection when handling the battery.
• To avoid an explosion, keep flames and sparks away
from the battery, especially while charging.
• When installing the battery cables, connect the
positive (+) cable first and negative (-) cable last.
If not done in this order, the positive terminal can be
shorted to the frame by a tool.
1. Connect the red positive battery cable (B, Figure 1)
to the positive battery post. Make sure that the cable
boot completely covers the positive terminal, so that the
terminal cannot touch the insulator pad (C).
4
2. Connect the black negative battery cable (A) to the
negative battery post.
Install the Ground Speed Control Levers
This procedure is only necessary if the ground speed control
levers are not factory-installed on your unit.
1. Install the ground speed control lever (A, Figure 5) to the
control lever base (B) using the bolts (C) and nuts (D) that
were included with the levers.
5
2. Repeat the process on the other side of the unit.
3. Align the control levers with each other and then tighten
the mounting hardware to 13 lb-ft (18 Nm).
Install the Seat
This procedure is only necessary if the seat is not factory-
installed on your unit.
1. Unpack the seat.
2. Install the seat (A, Figure 6) onto the seat mount plate (B)
with the retaining nuts (C) provided. Hand tighten the four
(4) retaining nuts.

Not for
Reproduction
5
6
3. Position the seat so that it's back two mounting bolts are
1/2" (1,27 cm) from the back end of the rear slots and
then fully tighten the four retaining nuts.
4. Lower the seat down into position and use the seat's
adjustment lever to position the seat fully in it's rear
position. If the seat contacts the machine's engine, loosen
the four retaining nuts and move the seat forward until it
clears the engine. Re-tighten the retaining nuts.
5. Connect the wire harness (D) to the seat switch (E) that is
located in the bottom of the seat.
Check the Engine Oil Level
This model has different engine options. Use Figure 7 to
determine if your model is equipped with a Briggs & Stratton
Commercial Turf Series engine (A, Figure 7) or a Kawasaki
FR engine (B).
7
1. Use the dipstick (C) to check the engine oil level. If
necessary add engine oil through the engine oil fill (D).
Check the engine manufacturer’s owner’s manual for the
oil recommendations.
Check / Fill Transmission Oil Level
This unit is equipped with two transmission oil tanks. One
transmission oil tank only supplies oil to one transmission.
The level of oil in both transmission tanks must be checked,
and if necessary, filled.
Oil Type: 20W-50 conventional detergent motor oil.
1. Location the transmission oil tanks (A, Figure 8).

Not for
Reproduction
6 ferrismowers.com
8
2. Check the oil level when the unit is cold. The oil should be
up to the "FULL COLD" mark (B). If the oil is below this
level, proceed to step #3.
3. Before removing the tank caps (C), make sure the area
around the tank cap and fill neck of the tank is free of
dust, dirt, or other debris. Remove the tank cap.
4. Add oil up to the "FULL COLD" mark.
5. Reinstall the tank caps.
6. After adding oil to the tanks, it may be necessary to purge
air from the hydraulic system. If the unit is not driving
properly, see your dealer.
Check Tire Pressures
Tire pressure should be checked periodically, and maintained
at the levels shown in the chart. Note that these pressures
may differ slightly from the "Max Inflation" stamped on the
side-wall of the tires. The pressures shown in the chart
provide proper traction and extend tire life.
Tire Pressure
Front 22 psi (1,52 bar)
Rear 12 psi (0,83 bar)
Check Blade Bolt and Pulley Bolt Torque
WARNING
Avoid injury! Mower blades are sharp.
• Mower blades are sharp. For your personal safety, do
NOT handle mower blades with bare hands.
• Careless or improper handling of blades may result in
serious injury.
• Blade mounting bolts must each be installed with a
washer and then securely tightened. Torque blade
mounting bolt to 50 - 60 ft. lbs. (68 - 81 Nm).
1. Lock the mower deck in it's highest cutting position.
2. Check to make sure that the blades are installed with
the airlifts (A, Figure 9) pointing up towards the deck as
showing in Figure 9.
9
3. Check that the blade in fully seated on the spindle shaft
and that a washer (B) is installed between the blade and
the mounting bolt (C).
4. Check that each blade mounting bolt is torqued to 50 -
60 ft. lbs. (68 - 81 Nm) while holding onto the appropriate
pulley bolt (D) with a wrench.
5. Check that each pulley bolt is torqued to 50 - 60 ft. lbs.
(68 - 81 Nm) while holding onto the appropriate blade
mounting bolt with a wrench.

Not for
Reproduction
7
Deck Leveling Adjustment
WARNING
Wear heavy gloves when handling or working around
cutting blades. Blades are extremely sharp and can cause
severe injury.
1. Park the machine on a flat, level surface such as a
concrete floor. Engage the parking brake, disengage the
PTO, turn the ignition switch to OFF, and remove the
ignition key.
2. Set the mower deck to the 3" (7,6 cm) cutting height.
3. Turn the front caster wheels so that they are facing front-
to-back.
4. Verify that the tires pressures are correct.
5. Verify that the mower blades are flat, and not bent or
broken. A bent or broken blade must be replaced.
6. Position the two outside mower blades so that they are
facing front-to-back.
7. Measure the distance between the outside tips of the
blades (A, Figure 10) and the ground (B).
10
• The front measurements (C) should equal 3" (7,6
cm).
• The rear measurements (D) should equal 3-1/4" (8,3
cm).
8. If the front measurements were incorrect, turn the
adjustment nuts (A, Figure 11) until the measurements
are correct. Turning the nut clockwise will raise the deck,
counter-clockwise will lower the deck.
11
9. If the rear measurements were incorrect the rear hanger
chains (B) will need to be adjusted.
• If the difference between the measurement and
3-1/4" (8,3 cm) is equal to or greater than 3/8" (0,95
cm) , the placement of the hanger chains needs to be
changed.
• If the difference between the measurement and
3-1/4" (8,3 cm) is less than 3/8" (0,95 cm), skip to
step #13.
10. Place blocking underneath all four corners of the mower
deck until all tension is relieved from the deck hangers.
11. Remove the hardware (C) that secures the hanger chains
to the lift arms (D).
• If the measurement was less than 3-1/4" (8,3 cm)
move the hardware to the next upper hole (E).
• If the measurement was more than 3-1/4" (8,3 cm)
move the hardware to the next lower hole (E).
12. Remove the blocking from underneath the mower deck.
13. Loosen the jam nuts (F) and turn the fine adjustment bolts
(G) to adjust the deck height until the measurement is
achieved. Tighten the jam nuts against the clevises (H).
14. Verify that all four measurements are correct.
Check the Mower Deck Drive Belt

NOTICE To avoid damaging belt,do not pry over
pulleys.
1. Lower the mower deck to its lowest cutting position.
2. Remove the left hand spindle cover (A, Figure12and13)
and the right handle spindle cover (B) from the mower
deck to gain access to the mower deck drive belt (C).


Not for
Reproduction
8 ferrismowers.com
44" Mower Deck:
12
48" Mower Deck:
13
3. Check the routing of the belt.

•44" Mower Deck:Make sure that the V-side of the
deck drive belt runs in the grooves of the left and right
spindle pulleys (A & B, Figure12- exposed when
mower deck guards were removed) and the PTO
clutch pulley (E). Make sure that the back side of
the belt contacts the face of the rear stationary idler
pulley (F), and the adjustable idler pulley (G).
•48" Mower Deck:Make sure that the V-side of the
deck drive belt runs in the grooves of the left and
right spindle pulleys (A & B,Figure13- exposed
when mower deck guards were removed), the center
spindle pulley (F) and the PTO clutch pulley (E).
Make sure that the back side of the belt contacts the
face of the front stationary idler pulley (G), the rear
stationary idler pulley (H), and the adjustable idler
pulley (I).
WARNING
Use extreme caution when rotating the idler arm, due to
the increased tension in the spring as the idler arm is being
rotated. Injury may result if the idler arm is prematurely
released while the spring is under tension.
4. If the belt is not properly seated rotate the idler arm
(D,12and13)counter-clockwisewhich will relieve the
tension on the belt exerted from the idler arm.
5. Re-seat the belt and carefully release the tension on the
idler arm.
6. Set the mower deck to the 3" (7,6 cm) cutting height.
7. Measure the coil-to-coil length of the belt tensioning
spring (A, Figure14). The coil-to-coil measurement
(B) should equal6" (15,2 cm).If the measurement is
not correct, the spring will need to be adjusted. If the
measurement is correct, skip to step #11.
14
8. Loosen the jam nut (C) on the spring anchor eye bolt (D).
9. Turn the adjustment nut (E) until the measurement
of6" (15,2 cm)is achieved.
10. Tighten the jam nut.
11. Re-install the spindle covers and the floor pan.
12. Run the mower deck under no-load condition for about
five (5) minutes to break in the new belt.
Lubrication
Lubricate the unit at the locations shown in
Figures15,16,17, and18as well as the following lubrication
points.
Grease:
• Mower deck spindles (A, Figure15).

Not for
Reproduction
9
• Rear transmission cradle pivots (A, Figure16).
• Front caster wheel axles (A, Figure18).
Use grease fitting when present. Disassemble parts to apply
grease to moving parts when grease fittings are not installed.
Not all greases are compatible. Red grease (p/n 5022285)
is recommended, automotive-type high-temperature, lithium
grease may be used when this is not available.
Oil:
• Discharge chute pivots (B, Figure15).
• Ground speed control lever and neutral linkage rod pivots
(A, Figure17).
• Seat plate pivots (B, Figure16).
• Deck lift linkage pivots (C, Figure16).
Generally, all moving metal parts should be oil where contact
is made with other parts.
Keep oil and grease off of belts and pulleys. Remember to
wipe grease fittings and surfaces clean both before and after
lubrication.
15
16
17

Not for
Reproduction
10 ferrismowers.com
18
Adding Fuel
WARNING
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or death.
When Adding Fuel
• Turn engine off and let engine cool at least 3 minutes
before removing the fuel cap.
• Fill fuel tank outdoors or in well-ventilated area.
• Do not overfill fuel tank. To allow for expansion of the
fuel, do not fill above the bottom of the fuel tank neck.
• Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
• Check fuel lines, tank, cap, and fittings frequently for
cracks or leaks. Replace if necessary.
• If fuel spills, wait until it evaporates before starting
engine.
1. Clean the fuel cap area of dirt and debris. Remove the
fuel cap (A, Figure19).
2. Fill the fuel tank with fuel. To allow for expansion of the
fuel, do not fill above the bottom of the fuel tank neck (B).
3. Reinstall the fuel cap.
19
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.
1. While sitting in the operator's seat, engage the parking
brake and make sure the PTO switch is disengaged and
the ground speed control levers are locked in the neutral
position.
2. A warm engine may not require choking. Set the
engine throttle control to FAST 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
START.
4. After the engine starts, gradually open the choke (push
knob down fully). Reduce to half throttle speed and allow
engine to warm. Warm up the engine by running it for
atleast a minute before engaging the PTO switch or
driving the rider.
5. After warming the engine always operate the 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.
Perform the Safety Checks
WARNING
Disengage the PTO, stop the engine, set the parking
brake, and wait for moving parts to stop before leaving the
operator’s position for any reason.