Simplicity ZT2352T, ZT2148T, ZT2348T User Manual

Print Instructions for Print Vendors (Paper Manuals)

PAR

TS MANUAL

TOTAL PAGE COUNT: Less than 80

Paper Size: • 11 x 17

• Body - 50 lbs brilliant white offset or equivalent.

• Cover - on 80 lbs coated, pre-printed “grid” cover stock (NOTE: If total order quantity is less than 100 pieces, use uncoated cover stock)

Press: • Body - 1-color, 2-sided

• Cover imprint - 1-color, 2-sided

Bindery: • Fold & Staple (2X), Face Trim, 3-Hole Drill

TOTAL PAGE COUNT: 80 or greater

Paper Size: • 8-1/2 x 11

• Body - 50 lbs brilliant white offset or equivalent.

• Cover - on 80 lbs coated, pre-printed “grid” cover stock (NOTE: If total order quantity is less than 100 pieces, use uncoated cover stock)

Press: • Body - 1-color, 2-sided

• Cover imprint - 1-color, 2-sided

Bindery: • Perfect Bind, Face Trim (3 knife), 3-Hole Drill

GENERAL

COVERS: • Covers are located at the beginning of this package.

• Back cover is the page IMMEDIATELY AFTER the front cover.

• If supplied, the “Hardware Identification & Torque Specifications” is located IMMEDIATELY AFTER the back cover. This page MUST be printed on the INSIDE of the BACK cover.

• Check the front cover for the individual part number (typically a 2xxxx or 182xxxx number).

• Check the front cover for the document number (TP 4xx - xxxx - xx - xx - xx)

BODY: •ODD number pages are ALWAYS right hand pages, and EVEN number are ALWAYS left hand

pages.

General: • This instruction page is NOT part of the manual and must NOT be printed.

• Pages labeled with the text “THIS PAGE INTENTIONALLY BLANK” are placement pages ONLY, and should NOT be printed.

If you have any further questions regarding this manual, please contact Ken Cehonski in Ferris Industries Engineering Department at (315) 495-0100 ext. 249.

THIS PAGE INTENTIONALLY BLANK

Colt

Zero-Turn Riding Mower

with 2-Wheel Independent Suspension

TM

22996

Revision 06 Rev. 4/2004

TP 400-7090-06-CT-D

Model Number: Description:

ZT2148T COLT, 2W-IS, w/ 21 HP Kohler & 48” Mower Deck ZT2348T COLT, 2W-IS, w/ 23 HP Kohler & 48” Mower Deck ZT2352T COLT, 2W-IS, w/ 23 HP Kohler & 52” Mower Deck

PARTS MANUAL

mowers are built by Ferris Industries, a Simplicity company.

Ferris Industries

5375 North Main Street Munnsville, NY 13409 800-933-6175

TM

Ferris Industries

5375 North Main Street Munnsville, NY 13409

Hardware Identification & Torque Specifications

Common Hardware Types

Hex Head Capscrew

Carriage Bolt

Standard Hardware Sizing

When a washer or nut is identified as 1/2”, this is the

nominal size

second number is present it represents the When a bolt or capscrew is identified as 1/2 - 16 x 2” , this

means the second number represents the example), and the final number is the bolt or screw (2 inches long in this example).

, meaning the

nominal size

inside diameter

, or

body diameter

threads per inch

body length

Washer

Lockwasher

Hex Nut

is 1/2 inch; if a

threads per inch.

is 1/2 inch; the

(16 in this

of the

The guides and ruler furnished below are designed to help you select the appropriate hardware and tools.

0

Nut, 1/2”

Inside

1/4 3/4

1/2

Diameter

1

1/4 3/4

1/2

Screw, 1/2 x 2

Body

Diameter

Body

Length

2

1/4 3/4

1/2

3

1/4 3/4

1/2

Torque Specification Chart

FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%)

Hardware Grade

Size Of Hardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm.

8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 11 15.0 17 23.1 25 34.0 5/16-24 12 16.3 19 25.8 27 34.0 3/8-16 20 27.2 30 40.8 45 61.2 3/8-24 23 31.3 35 47.6 50 68.0 7/16-14 30 40.8 50 68.0 70 95.2 7/16-20 35 47.6 55 74.8 80 108.8 1/2-13 50 68.0 75 102.0 110 149.6 1/2-20 55 74.8 90 122.4 120 163.2 9/16-12 65 88.4 110 149.6 150 204.0 9/16-18 75 102.0 120 163.2 170 231.2 5/8-11 90 122.4 150 204.0 220 299.2 5/8-18 100 136 180 244.8 240 326.4 3/4-10 160 217.6 260 353.6 386 525.0 3/4-16 180 244.8 300 408.0 420 571.2 7/8-9 140 190.4 400 544.0 600 816.0 7/8-14 155 210.8 440 598.4 660 897.6 1-8 220 299.2 580 788.8 900 1,244.0 1-12 240 326.4 640 870.4 1,000 1,360.0

1. These torque values are to be used for all hardware excluding: locknuts, self-tapping screws, thread forming screws, sheet metal screws and socket head setscrews.

2. Recommended seating torque values for locknuts:

a. For prevailing torque locknuts:

use 65% of Grade 5 torque.

b. For flange whizlock nuts and screws:

use 135% of Grade 5 torque.

3. Unless otherwise noted on assembly drawings, all torque values must meet this specification.

No

Marks

SAE Grade 2 SAE Grade 5 SAE Grade 8

3.4

3.5

4.9

5.5

in/lbs

41 43 60 68

in/lbs in/lbs

19 20 27 31 66 76

2.1

2.3

3.1

3.5

7.6 8 10.9 12 16.3

8.6 10 13.6 14 19.0

30 31 43 49

NOTES

4.6

4.9

6.8

7.7

Wrench & Fastener Size Guide

1/4

1/4” Bolt or Nut

Wrench—7/16”

5/16

5/16” Bolt or Nut

Wrench—1/2”

4

3/8

3/8” Bolt or Nut

Wrench—9/16”

7/16

7/16” Bolt or Nut

Wrench (Bolt)—5/8”

Wrench (Nut)—11/16”

1/2

1/2” Bolt or Nut

Wrench—3/4”

THIS PAGE INTENTIONALLY BLANK

1

TP 400-7090-01-CT-D

Table of Contents

RIDER COMPONENTS

Main Frame, Suspension & Caster Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Floor & Brake Cover Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Seat & Seat Mount Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Fuel Tank, Mount & Bumper Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Fuel Supply Hose & Tank Replacement Part Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Control Cover & Mount Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Instrument Panel Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Headlight Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Engine & PTO Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Pump Drive Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Motion Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Motion Control - Neutral Return Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Hydraulic Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 & 32

Reservoir Mount & Battery Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 & 36

Parking Brake Group-Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Parking Brake Group-Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Deck Lift Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Tire & Wheel Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Electrical Service Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46-57

Decals - Brand, Model, Safety & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

MOWER DECK COMPONENTS

48” & 52” Mower Decks - Housings, Covers, Spindles & Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

48” & 52” Mower Decks - Belts, Pulleys & Idler Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

48” & 52” Mower Decks - Rear Mount Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

48” & 52” Mower Decks - Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

REFERENCE INFORMATION:

Torque Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

2

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

Main Frame, Suspension & Caster Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

1

26

3

4

5

27

2

25

8

7

23

24

4

6

21

4

8

3

2

23

17

22

19

7

11

20

3

8

2

14

1

9

10

11

13

12

15

18

10

13

4

16

2

See Wheels & Tires Group

3

17

3

TP 400-7090-03-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

REF NO. PART NO. QTY. DESCRIPTION

Main Frame, Suspension & Caster Group

Footnotes:

1 22842 2 SHOCK & SPRING ASSEMBLY 2 25013-16 4 CAPSCREW, Hex Hd, 3/8-16 x 2 3 25156 4 WASHER, 3/8 4 25096 4 NUT, Hex, Nylon Lock, 3/8-16 5 3847953 1 MAIN FRAME 6 3847457 1 UPPER SHOCK MOUNT 7 25160 3 WASHER, 3/4 8 25284 5 NUT, Hex, Nylon Lock, 3/4-16

9 46093 2 SPACER, .75 x 1.50 x 1.00 10 22039 4 BALL JOINT, 3/4-16 11 47461 6 SPACER, .76 x 1.00 x .25 12 25265-32 2 CAPSCREW, Hex Hd, 3/4-16 x 4 13 25093 4 NUT, Hex, Jam, 3/4-16 14 25095 2 NUT, Hex, Nylon Lock, 1/4-20 15 22673 2 RUBBER BUMPER 16 3847445 1 SUSPENSION ARM-LH 17 3847049 2 CASTER YOKE 18 25265-24 2 CAPSCREW, Hex Hd, 3/4-16 x 3 19 25265-48 1 CAPSCREW, Hex Hd, 3/4-16 x 6 20 47489 1 SPACER, .75 x 1.00 x 2.38 21 22852 1 PIVOT BEARING 22 21072 2 SEAL, Grease 23 20884 4 BEARING, T apered Roller 24 3847452 1 SUSPENSION ARM-RH 25 25104 2 NUT, Hex, SLotted, 3/4-16 26 21073 2 CAP 27 25203-10 2 Pin, Cotter

4

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

Floor & Brake Cover Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

11

9

1

2

3

7

8

6

4

7 8

7

8

5

8

12

11

10

6

12

5

TP 400-7090-03-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

REF NO. PART NO. QTY. DESCRIPTION

Floor & Brake Cover Group

Footnotes:

1 3847069 1 BRAKE COVERPANEL

2 25013-16 2 CAPSCREW, Hex Hd, 3/8-16 x 2

3 25156 2 WASHER, 3/8

4 47125 2 SPACER, .39 x 1.00 x .88

5 25128 2 NUT, Hex, Serrated Flange, 3/8-16

6 22308 4 BODY CLIP, 5/16-18

7 25011-8 6 CAPSCREW, Hex Hd, 5/16-18 x 1

8 25155 6 WASHER, 5/16

9 3847480 1 FLOOR PLATE 10 47483 1 SAFETY WALK 11 47139 2 SAFETY WALK 12 25127 2 NUT, Hex, Serrated Flange, 5/16-18

6

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

Seat & Seat Mount Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

1

17

16

12

13

14

15

2

3

4

5

6

7

8

9

10

11

12

7

TP 400-7090-03-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

REF NO. PART NO. QTY. DESCRIPTION

Seat & Seat Mount Group

Footnotes:

* - See Electrical Schematic for switch part number

1 22973 1 SEAT, Derby (complete)

* 20930-3 1 SEAT ADJUSTER RAILS (set of 2) 2 3847744 1 SEATMOUNT 3 46470 1 SEAT STOP ROD 4 20047 1 COLLAR, 5/16 Set 5 25095 2 NUT, Hex, Nylon Lock, 1/4-20 6 22673 2 RUBBER BUMPER 7 25013-48 1 CAPSCREW, Hex Hd, 3/8-16 x 6 8 25156 1 WASHER, 3/8 9 46586 1 SPACER, .38 x .50 x 5.06

10 22798 1 SPRING, Compression 11 25326 1 WASHER, 3/8 x 2 12 25096 3 NUT, Hex, Nylon Lock, 3/8-16 13 25029 2 NUT, Hex, #10-24 14 * 1 SWITCH (see electrical schematic) 15 25179-4 2 SCREW, #10-24 x 1/2 16 25057 4 NUT, Hex, Nylon Lock, 5/16-18 17 25013-32 2 CAPSCREW, Hex Hd, 3/8-16 x 4

8

TP 400-7090-00-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 123 & below) ZT2352T (S/N 123 & below)

Fuel Tank, Mount & Bumper Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

3

2

1

4

5

2

8

20

19

3

6

21

6

7

9

10

6

13

6

14

11

12

15

8

9

14

10

11

17

14

16

9

12

13

8

9

14

8

9

8

14

18

8

9

TP 400-7090-00-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 123 & below) ZT2352T (S/N 123 & below)

REF NO. PART NO. QTY. DESCRIPTION

Fuel Tank, Mount & Bumper Group

Footnotes:

For fuel tank replacement parts, see Fuel Supply Hose & Tank Replacement Parts Groups

1 3847347 1 FUEL TANK TIE BAR 2 25299-6 4 SCREW, Allan Hd, 1/4-20 x 3/4 3 45496 2 CAP, Fuel Tank w/ Gauge 4 45494 1 FUEL TANK-RH, Complete (see footnote) 5 3847348 1 TIE BAR MOUNT-RH 6 25011-6 4 CAPSCREW, Hex Hd, 5/16-18 x 3/4 7 25095 4 NUT, Hex, Nylon Lock, 1/4-20 8 25013-10 12 CAPSCREW, Hex Hd, 3/8-16 x 1-1/4 9 25156 12 WASHER, 3/8

10 3847938 2 REAR MOUNT BRACKET 11 25155 4 WASHER, 5/16 12 25011-10 4 CAPSCREW, Hex Hd, 5/16-18 x 1-1/4 13 22394 4 RUBBER BUSHING 14 25128 12 NUT, Hex, Serrated Flange, 3/8-16 15 3847917 1 TANKMOUNT-RH 16 3847851 1 BUMPER 17 3847485 2 COUNTERWEIGHT (52” model only) 18 3847920 1 TANKMOUNT-LH 19 45495 1 FUEL TANK-LH, Complete (see footnote) 20 22395 4 RUBBER ISOLATOR 21 3847349 1 TIE BAR MOUNT-LH

10

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 124 & above) ZT2348T ZT2352T (S/N 124 & above)

Fuel Tank, Mount & Bumper Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

3

2

1

4

5

2

19

18

3

6

7

8

6

20

6

11

9

10

11

12

15

11

16

13

8

13

14

9

13

14

10

17

14

13

11

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 124 & above) ZT2348T ZT2352T (S/N 124 & above)

REF NO. PART NO. QTY. DESCRIPTION

Fuel Tank, Mount & Bumper Group

Footnotes:

For fuel tank replacement parts, see Fuel Supply Hose & Tank Replacement Parts Groups

1 3847347 1 FUEL TANK TIE BAR 2 25299-6 4 SCREW, Allan Hd, 1/4-20 x 3/4 3 45496 2 CAP, Fuel Tank w/ Gauge 4 47904 1 FUEL TANK-RH, complete (see footnote) 5 3847348 1 TIE BAR MOUNT-RH 6 25011-6 4 CAPSCREW, Hex Hd, 5/16-18 x 3/4 7 25095 4 NUT, Hex, Nylon Lock, 1/4-20 8 22394 4 RUBBER BUSHING 9 25155 4 WASHER, 5/16

10 25011-10 4 CAPSCREW, Hex Hd, 5/16-18 x 1-1/4 11 25128 12 NUT, Hex, Serrated Flange, 3/8-16 12 3847924 1 TANKMOUNT-RH 13 25156 12 WASHER, 3/8 14 25013-10 12 CAPSCREW, Hex Hd, 3/8-16 x 1-1/4 15 3847851 1 BUMPER 16 3847485 2 COUNTERWEIGHT (52” model only) 17 3847923 1 TANKMOUNT-LH 18 47903 1 FUEL TANK-LH, complete (see footnote) 19 22395 4 RUBBER ISOLATOR 20 3847349 1 TIE BAR MOUNT-LH

12

TP 400-7090-00-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 123 & below) ZT2352T (S/N 123 & below)

Fuel Supply Hose & Tank Replacement Part Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

LH Fuel Tank RH Fuel Tank

3

4

2

1

5

9

10

Components

Tank

876

9

10

Tank

Components

Connect to Engine

13

TP 400-7090-05-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 123 & below) ZT2352T (S/N 123 & below)

REF NO. PART NO. QTY. DESCRIPTION

Fuel Supply Hose & Tank Replacement Part Group

Footnotes:

1 22030 1 VALVE, Fuel Shut Off 2 20835 6 CLAMP, Hose 3 50831-55 1 HOSE, 55” 4 50831-50 1 HOSE, 50” 5 50831-36 1 HOSE, 36” 6 50833-51 1 WIRE LOOM, 51” 7 50833-33 1 WIRE LOOM, 33” 8 50833-24 1 WIRE LOOM, 24” 9 1726400 2 RUBBER BUSHING

10 1674231 2 ELBOW FITTING

14

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 124 & above) ZT2348T ZT2352T (S/N 124 & above)

Fuel Supply Hose & Tank Replacement Part Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

3

4

2

1

5

876

9

10

11

12

11

LH Fuel Tank RH Fuel Tank

13

Tank

Components

10

9

Tank

Components

11

12

11

13

Connect to Engine

15

TP 400-7090-05-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T (S/N 124 & above) ZT2348T ZT2352T (S/N 124 & above)

REF NO. PART NO. QTY. DESCRIPTION

Fuel Supply Hose & Tank Replacement Part Group

Footnotes:

1 22030 1 VALVE, Fuel Shut Off 2 20835 6 CLAMP, Hose 3 50831-42 1 HOSE, 42” 4 50831-50 1 HOSE, 50” 5 50831-23 1 HOSE, 23” 6 50833-35 1 WIRE LOOM, 35” 7 50833-40 1 WIRE LOOM, 40” 8 50833-22 1 WIRE LOOM, 22” 9 1726400 2 RUBBER BUSHING

10 23061 2 ELBOW FITTING 11 23069 4 CLAMP, Hose 12 50925-20 2 HOSE, 20” 13 23067 2 FITTING, Screen

16

TP 400-7090-01-CT-D

The above parts group applies to the following Model Nos.:

ZT2148T ZT2348T ZT2352T

Control Cover & Mount Group

NOTE: Unless noted otherwise, use the standard hardware torque specification chart.

20

2

1

3

4

See Fuel Tank

See Instrument

Panel Group

3

4

& Mount Group

5

21

14

6

15

7

3

4

10

8

9

11

12

13

See Fuel Tank

& Mount Group

5

19

8

3

4

5

8

15

16

9

4

5

4

3

17

8

3

4

3

4

3

18

5

4

3