Simplicity ZT2561 User Manual

OPERATOR’S MANUAL

1822576

Rev. 11/2001

TP 100-7011-03-SL-D

Stallion

Zero-Turn Riding Mower

Model:

ZT2561

mowers are built by Ferris Industries, a Simplicity company.

Ferris Industries

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

Ferris Industries

5375 North Main Street Munnsville, NY 13409

DERBY LIMITED WARRANTY

IMPORTANT

This warranty shall apply ONLY if the warranty registration form has been completed and returned to Ferris Industries, Inc. within 20 days from the date of delivery.

Ferris Industries, Inc. (Ferris) warrants, in accordance with the provisions below, to the original purchaser for the period of twenty-four (24) months, twelve (12) months for commercial use, from the date of delivery of a Derby mower that the mower is free from defects in material or workmanship. Derby’s obligation under this warranty is to repair or replace, at Derby’s election, without charge and at the place of business of a dealer authorized to handle Derby mowers, any par t or par ts of the machine which, in the judgment of Derby, prove to be defective.

THIS WARRANTY AND DERBY’S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE, and all other obligations or liabilities of Derby for incidental and consequential damages resulting from the design, manufacture, sale or use of the machine. No person is authorized to make any warranty or assume for Derby any liability not strictly in accordance with this warranty.

This warranty shall not apply to any mower par t which, in the judgment of Derby, has been altered or tampered with in any way or has been subjected to misuse, neglect or accident, or has had the serial numbers altered, effaced or removed. This warranty does not apply to component parts not manufactured by Derby (motors, tires, belts) except to the extent of their individual manufacturer’s guarantees.

Ferris Industries, Inc. is continually striving to improve its products, and therefore reserves the right to make improvements or change when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

FERRIS

WARNING

Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer,birth defects, or other reproductive harm.

Table of Contents

Identification Numbers .......................................2

Safety Rules & Information................................3

Features & Controls............................................6

Control Functions ....................................................6

Safety Interlock System..........................................7

Operating the Tractor ..........................................8

General ...................................................................8

Checks Before Starting...........................................8

Starting the Engine .................................................9

Stopping the Rider..................................................9

Mowing....................................................................9

Pushing the Rider by Hand.....................................9

Zero Turn Driving Practice ....................................10

Storage..................................................................12

Starting After Long Term Storage.........................12

Regular Maintenance........................................14

Maintenance Schedule .........................................14

Checking Tire Pressures.......................................14

Checking/Adding Fuel ...........................................15

Fuel Filter..............................................................15

Oil & Filter Change ...............................................15

Check / Change Air FIlter .....................................15

Check Hydraulic Oil Level.....................................15

Lubrication ............................................................16

Battery Maintenance.............................................16

Checking Battery Fluid ......................................16

Cleaning the Battery and Cables.......................16

Servicing the Mower Blades.................................17

Troubleshooting, Adjustments & Service.......19

Troubleshooting the Tractor...................................19

Troubleshooting the Mower...................................20

Seat Adjustment....................................................21

Ground Speed Control Lever Adjustment.............21

Speed Balancing Adjustment................................21

Parking Brake Adjustment ....................................22

Suspension Height Adjustment.............................22

PTO Clutch Adjustment ........................................23

Blade Brake Check...............................................23

Neutral Adjustment ...............................................24

Neutral Spring Return Adjustment........................24

Mower Adjustments ..............................................25

Cutting Height Adjustment .................................25

Deck Leveling Adjustment .................................25

Hydraulic Pump Drive Belt Replacement..............26

Mower Belt Replacement......................................26

Battery Service .....................................................27

Checking the Battery Voltage ............................27

Charging A Completely Discharged Battery ......27

Jump Starting with

Auxiliary (Booster) Battery .............................27

Lawn Care & Mowing Information...............LC-1

International Symbols ...................................LC-8

Technical Manuals .........................................LC-8

NOTE: In this manual, “left” and “right” are referred to as seen from the operating position.

TP 100-7011-03-SL-D

IDENTIFICATION TAG LOCATIONS

Identification Numbers

When contacting your Authorized Dealer for replacement parts, service, or information YOU MUST HA

VE THESE NUMBERS.

IDENTIFICATION NUMBERS

Record your model name, unit and mower deck serial numbers and engine serial number in the space provided for easy reference.

• The Tractor I.D. tag is located on the inside of the main frame rail, behind the deck height plate.

• For location of Engine Serial Number, refer to the Engine Owner’s Manual.

Be sure to fill out and return the Warranty Registration Card supplied with your unit.

ENGINE REFERENCE DATA

Model Description Name

Unit MODEL Number

PRODUCT REFERENCE DATA

Unit SERIAL Number

Dealer Name

Date Purchased

Engine Make/Model

Engine ID/Serial Number

Mower Deck MODEL Number

Mower Deck SERIAL

Number

Tractor

identification tag

XXXXXXX XXXXXXX

N/A

FERRIS

FERRIS INDUSTRIES, INC.

MUNNSVILLE, NY 13409

MADE IN THE USA

MODEL NO.

SERIAL NO.

Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of unit, severe personal injury or death to you, or bystanders, or damage to proper ty or equipment.

This mowing deck is capable of amputating hands and feet and thr

owing objects.

The triangle

in text signifies important cautions or warnings which must be followed.

Safety Rules

& Information

WARNING

Never operate on slopes greater than 30 percent (16.7°) which is a rise of three feet vertically in 10 feet horizontally.

Select slow ground speed before driving onto slope. Use extra caution when operating on slopes with rearmounted grass catcher.

Mow UP and DOWN the slope, never across the face, use caution when changing directions and DO NOT START OR STOP ON SLOPE.

GENERAL OPERATION

• Read, understand, and follow all instructions in the manual and on the unit before starting.

• Only allow responsible adults, who are familiar with the instructions, to operate the unit.

• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade(s).

• Be sure the area is clear of other people before mowing. Stop unit if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while travelling in reverse.

• Be aware of the mower discharge direction and do not point it at anyone.Do not operate the mower without either the entire grass catcher or the deflector in place.

• Slow down before turning.

• Never leave a running unit unattended. Always

disengage the PTO, set parking brake, stop engine, and remove keys before dismounting.

• Tur n off the PTO switch to disengage the blades when not mowing.

• Stop engine before removing grass catcher or unclogging chute.

• Mow only in daylight or good artificial light.

• Do not operate the unit while under the influence of

alcohol or drugs.

• Watch for traffic when operating near or crossing roadways.

• Use extra care when loading or unloading the unit into a trailer or truck.

• Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot

back up the slope or if you feel uneasy on it,do not drive on it

• See your authorized dealer for recommendations of available weights to improve stability.

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts, or bumps. Uneven terrain could

overturn the unit. Tall grass can hide obstacles.

• Use slow speed. Choose a low gear so that you will not have to stop or shift while on the slope.

• Use extra care with grass catchers or other attachments.These can change the stability of the unit.

• Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.

Do Not

•

Do not

start or stop on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.

•

Do not

turn on slopes unless necessary, and then, turn slowly and gradually uphill, if possible.

•

Do not

mow near drop-offs, ditches, or embankments.The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

•

Do not

mow on wet grass.Reduced traction could cause sliding.

•

Do not

try to stabilize the unit by putting your foot on the ground.

•

Do not

use grass catcher on steep slopes.

Safety Rules & Information

CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them.

• Keep children out of the mowing area and under the watchful care of another responsible adult.

• Be alert and tur n unit off if children enter the area.

• Before and during reverse operation, look behind and

down for small children.

• Never carry children.They may fall off and be seriously injured or interfere with safe unit operation.

• Never allow children to operate the unit.

•

Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

TRANSPORTING AND STORAGE

• Always observe safe refueling and fuel handling practices when refueling the unit after transportation or storage.

• Always follow the engine manual instructions for storage preparations before storing the unit for both short and long term per iods.

• Always follow the engine manual instructions for proper start-up procedures when returning the unit to service.

• Never store the unit or fuel container inside where there is an open flame or pilot light, such as in a water heater.Allow unit to cool before storing.

SERVICE AND MAINTENANCE

• Use extra care when handling gasoline and other fuels.They are flammable and vapors are explosive.

a) Use only an approved container. b) Never remove fuel cap or add fuel with the engine

running. Allow engine to cool before refueling. Do not smoke.

c) Never refuel the unit indoors.

• Never run a unit in an enclosed area.

• Keep nuts and bolts, especially blade attachment

bolts, tight and keep equipment in good condition.

• Never tamper with safety devices. Check their proper operation regularly.

• Keep unit free of grass, leaves, or other debris buildup.Clean up oil or fuel spillage.

• Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

• Never make adjustments or repairs with the engine running unless specified otherwise in the engine manufacturer’s manual.

• Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recom- mended parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing them.

• Check brake operation frequently. Adjust and service as required.

• Use only factory authorized replacement parts when making repairs.

• Always comply with factory specifications on all settings and adjustments.

• Only authorized service locations should be utilized for major service and repair requirements.

• Never attempt to make major repairs on this unit unless you have been properly trained.Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturer’s warranty.

SAFETY DECALS

This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing.

Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit.

All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed.Personal bodily injury can result when these instructions are not followed.The information is for your safety and it is important! The safety decals below are on your rider and mower.

If any of these decals are lost or damaged, replace them at once. See your local dealer for replacements.

These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation.

Safety Rules & Information

Decal - Danger

Part No. 1704276

Decal - Danger

Part No. 1704277

Decal - Danger

Part No. 22143

Decal - Warning/Danger

Part No. 45560

Decal - Operation & Controls

Part No. 45559

Decal - Caution

Part No. 46481

To Start Engine:

Seat must be occupied, PTO Switch OFF , P arking Brak e ON and both control handles are locked in Neutral.

To Stop Engine:

Engage Parking Brake, Throttle at half to full, turn Ignition Switch Off.

Before Leaving Machine:

Turn PTO s witch off , shut off engine , remove key, and set Parking Brake

GROUND SPEED AND STEERING LEVERS

Right lever controls speed and direction of right drive wheel. Notch is neutral lock. Left lever controls speed and direction of left drive wheel. Notch is neutral lock. Steer by slowing the lever in the direction of the turn.

PARKING BRAKE LEVER

Pull to set Parking Brake. Push to release Parking Brake.

DECK LIFT PEDAL

Push to raise deck.

CUTTING HEIGHT ADJUSTMENT PIN

OPERATION

To Operate PTO Clutch:

Operator must be in seat. Pull up to Engage. Push down to Disengage.

When Operator Leaves Seat:

Engine will shut off if PTO is on. Engine will shut off of Parking Brake is off. Engine will shut off if both control levers are not locked in neutral.

DO NOT TOW!

Damage may result to Hydrostatic Transmission.

DANGER

ROTATING CUTTING BLADE

Do not put hands or feet

under mower deck while blade is rotating.

DANGER

ROTATING PARTS UNDER ENGINE. KEEP HANDS AND FEET CLEAR. STOP ENGINE BEFORE SERVICING.

1704276

DANGER

ROTATING CUTTING BLADE

Do not operate mower without deflector or entire grass catcher in place.

1704277

Features & Controls of the Zero Turn Rider

CONTROL FUNCTIONS

The information below briefly describes the function of individual controls. Starting, stopping, driving, and mowing require the combined use of several controls applied in specific sequences. To learn what combination and sequence of controls to use for various tasks see the OPERATION section.

A. Ground Speed Control Levers

These levers control the ground speed of the rider.The left lever controls the left rear drive wheel and the right controls the right rear drive wheel.

Moving a lever forward increases the FORWARD speed of the associated wheel, and pulling back on a lever increases the REVERSE speed.

Note:The further a lever is moved away from the neutral position the faster the drive wheel will turn.

See the Operating the Zero Turn Rider section for steering instructions.

B. Seat Adjustment Lever

The seat can be adjusted forward and back.Move the lever forward, position the seat as desired, and release the lever to lock the seat in position.

C. Ignition Switch

The ignition switch starts and stops the engine, it has three positions:

OFF Stops the engine and shuts off the

electrical system.

RUN Allows the engine to run and powers the

electrical system.

START Cranks the engine for starting.

NOTE: Never leave the ignition switch in the RUN position with the engine stopped–this drains the battery.

Please take a moment and familiarize yourself with the name, location, and function of these controls so that you will

better understand the safety and operating instructions provided in this manual.

Figure 1. Control Locations

Features & Controls

SAFETY INTERLOCK SYSTEM

This unit is equipped with safety interlock switches and other safety devices. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with safety devices. Check their operation regularly.

Operational SAFETY Checks

Your unit is equipped with a seat switch safety system. Check the seat switch operation every fall and spring with the following tests.

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 NEUTRAL

position, OR

• Operator is not on the seat.

Test 2 — Engine SHOULD crank if:

• PTO switch is NOT engaged, AND

• Parking brake is engaged, AND

• Motion control handles are locked in the NEUTRAL

position, AND

• 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 disen-

gaged.

Test 4 — Blade Brake Check

Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned off (or operator rises off seat). If mower drive belt does not stop within five 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 NEUTRAL position after the operator returns to the seat in order to start the engine.

WARNING

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.

D. Parking Brake Handle

The parking brake is applied by pulling UP on the parking brake handle until it locks over-center.To release the parking brake, push the handle DOWN.

E. PTO (Power Take Off) Switch

The PTO switch engages and disengages the mower. Pull UP on the switch to engage, and push DOWN to disengage.

F & G. Deck Lift Pedal & Cutting Height Adjustment Pin

These control the cutting height of the mower deck. Depress the pedal until it locks into the TRANSPORT

position. Place the adjustment pin in the desired cutting height and release the lift pedal.

H & I.Throttle / Choke Control

Pulling the round choke control knob (I) out fully chokes the engine for cold starts. (A warm engine may not require choking.) Moving the throttle control (H) fully forward is FULL throttle position. Always operate the unit at FULL throttle when mowing.

J. Headlight Switch

Turn the switch ON to light the front headlight.

K. Hour Meter

Measures the time of the PTO being engaged.

L. Fuel Shut Off Valve

Turning the handle to the desired position determines which tank will be supplying fuel. With the handle pointing forward, it will draw fuel from the left-hand tank. With the handle pointed towards the rear, it will draw fuel from the right-hand fuel tank. With the handle pointing towards the right, it will shut off fuel flow to the engine.

Operating the Zero Turn Rider

GENERAL OPERATING SAFETY

Before first time operation:

• Be sure to read all information in the Safety and Operation sections before attempting to operate this tractor and mower.

• Become familiar with all of the controls and how to stop the unit.

• Drive in an open area without mowing to become accustomed to the unit.brake pedal or set the parking brake.

CHECKS BEFORE STARTING

• Check that crankcase is filled to full mark on dipstick. See the engine Operator’s Manual for instructions and oil recommendations.

• Make sure all nuts, bolts, screws and pins are in place and tight.

• Adjust the seat position, and make certain you can reach all controls from operator’s position.

• Fill the fuel tank with fresh fuel. Refer to engine manual for fuel recommendations.

WARNING

Never allow passengers to ride on the unit. Before leaving the operator’s position for any

reason, engage the parking brake, disengage the PTO, stop the engine and remove the key.

To reduce fire hazard, keep the engine, tractor and mower free of grass, leaves and excess grease. Do not stop or park tractor over dry leaves, grass or combustible materials.

Gasoline is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills.

DANGER

OPERATING ON SLOPES CAN BE DANGEROUS

Never operate on slopes greater than 30 percent (16.7°) which is a rise of three feet vertically in 10 feet horizontally.

Operate the unit at a slow ground speed when driving onto slope.

Use extra caution when operating on slopes with rear-mounted grass catcher. Mow UP and DOWN the slope, never across the face, use caution when changing directions and DO NOT START OR STOP ON SLOPE.

Figure 2. Pre-start Checks

A. Fuel Tank Filler Neck B. Crankcase Oil Fill C. Seat Adjustment Lever

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.

ST ARTING THE ENGINE

1. While sitting in the operator’s seat, engage the parking brake and make sure the PTO switch is disengaged and the motion control handles are locked in the NEUTRAL position.

NOTE: A warm engine may not require choking.

Set the engine throttle control (H, Figure 1) to FAST throttle position. Then fully close the choke (I, Figure

1) by pulling the knob OUT fully.

3. Insert the key into the ignition switch (K, Figure 1) and turn it to START.

4. After the engine starts, gradually open the choke (push knob down fully).

Warm up the engine by running it for at least 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.

STOPPING THE RIDER

1.Returning the ground speed control levers (A, Figure

1) to the middle position will stop tractor movement. Pivot the levers outward and lock them in NEUTRAL.

2.Disengage the PTO by pushing down on the PTO switch (E, Figure 1).

3.Engage the parking brake by pulling the handle (D, Figure 1) up until it locks into position.

4.Move the throttle control (H, Figure 1) to mid-throttle position and turn the ignition key to OFF Remove the key.

MOWING

1. Engage the parking brake. Make sure the PTO switch is disengaged, the motion control handles are locked in the NEUTRAL position and the operator is on the seat.

2. Start the engine (see STARTING THE ENGINE).

3. Set the mower cutting height.

4. Set the throttle to FULL.

5. Engage the PTO by pulling up on the PTO switch (E, Figure 1).

6. Begin mowing. See Section C for tips on mowing patterns, lawn care, and trouble shooting information.

7. When finished, shut off the PTO.

8. Stop the engine (see STOPPING THE TRACTOR AND ENGINE).

PUSHING THE RIDER BY HAND

1. Disengage the PTO, engage the parking brake, turn the ignition OFF, and remove the key.

2. Lift the seat plate to gain access to the battery compartment and hydraulic pumps.

3. To disengage the pumps (free-wheel position), turn the hydraulic release valves (A, Figure 3) located on the pumps COUNTER-CLOCKWISE a maxim

um of

2 full turns.

4. Disengage the parking brake. The tractor can now be pushed by hand.

5. After moving the tractor, re-engage the pumps (drive position) by turning the release valves CLOCKWISE and tighten to 80-120 in. lbs. of torque.

DO NOT TOW RIDER

Towing the unit will cause hydraulic pump and wheel motor damage. Do not use another vehicle to push or pull this unit.

Operating the Zero Turn Rider

Figure 3. Hydraulic System By-Pass

A. Hydraulic Release Valve (right-hand pump shown)

Operating the Zero Turn Rider

ZERO TURN DRIVING PRACTICE

The lever controls of the Zero Turn rider are

responsive

and learning to gain a

smooth

and

efficient

control of the rider’s forward, reverse, and turning movements will take some practice.

Spending some time going through the maneuvers shown and becoming familiar with how the unit accelerates, travels, and steers — before you begin mowing — is absolutely essential to getting the most out of the Zero Turn rider.

Locate a smooth, flat area of your lawn — one with plenty of room to maneuver. (Clear the area of

objects, people and animals before you begin.) Operate the unit at mid-throttle during this practice session (ALWAYS operate at full throttle when mowing), and turn slowly to prevent tire slippage and damage to your lawn.

We suggest you begin with the Smooth T ra vel procedure to the right, and then advance through the forward, reverse, and tur ning maneuvers.

You must release the parking brake prior to moving the control levers inward.

BASIC DRIVING

Forward T ravel Practice

Gradually move both ground speed control levers — evenly FORWARD from neutral.Slow down and repeat.

NOTE: Straight forward travel takes practice. If necessary, top speed can be balance-adjusted — see the Speed Balancing Adjustment in the Adjustments section near the back of this manual.

Reverse T ravel Practice

LOOK DOWN & BEHIND, then gradually move both ground speed control levers evenly BACK from neutral. Slow down and repeat.

NOTE:Practice backing up for several minutes before attempting to do so near objects.The rider turns sharply in reverse as well as forward, and backing up straight takes practice.

Figure 5. Forward Travel

Forward Travel

Figure 6. Forward Travel

Reverse Travel

Smooth T ravel

The lever controls of the Zero Turn rider are

RESPONSIVE

The BEST method of handling the ground speed control levers is in three steps — as shown in Figure 4.

FIRST place your hands onto the levers as shown.

SECOND, to go forward gradually push the levers forward with your palms.

THIRD, to speed up move the levers farther forward. To slow down smoothly, slowly move the levers toward neutral.

Figure 4. Move Control

Levers Gradually

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