Simplicity ZT2761F 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

22989

Revision 09

Rev. Date: 4/2004

TP 400-7087-09-SL-D

Model Number: Description:

ZT2561F STALLION, 4W-IS, w/ 25 HP Kohler & 61” Mower Deck ZT2761F STALLION, 4W-IS, w/ 27 HP Kohler & 61” 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

Stallion

Zero-Turn Riding Mower

with 4-Wheel Independent Suspension

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 400-7087-03-SL-D

Table of Contents

RIDER COMPONENTS

Main Frame & Front Suspension Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

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

Fuel Supply Hose 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-Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Motion Control Group-Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Neutral Return Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Hydraulic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Reservoir Mount & Battery Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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

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

Rear Suspension Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Wheels & Tires Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Deck Lift Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Electrical Service Schematics (S/N: 278 & below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-51

Electrical Service Schematics (S/N: 279 - 1026) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52-55

Electrical Service Schematics (S/N: 1027 & above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56-59

Decals - Brand, Model, Safety & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

MOWER DECK COMPONENTS

61” Mower Deck - Housing, Covers, Spindles & Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

61” Mower Deck - Belt, Pulleys & Idler Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

61” Mower Deck - Rollers & Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

61” Mower Deck - Rear Mount Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

REFERENCE INFORMATION:

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

2

TP 400-7087-02-SL-D

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

ZT2561F ZT2761F

Main Frame & Front Suspension Group

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

17

18

20

19

17

21

16

22

12

1

13

14

11

3

4

5

2

15

4

5

10

2

9

7

8

6

11

6

7

13

14

See Wheels & Tires Group

12

3

TP 400-7087-06-SL-D

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

ZT2561F ZT2761F

REF NO. PART NO. QTY. DESCRIPTION

Main Frame & Front Suspension Group

Footnotes: * S/N: 1026 & below - If main frame is replaced, all components for the neutral return system on page 32 must be ordered.

1 3847952 * 1 MAIN FRAME 2 25284 4 NUT, Hex, Nylon Lock, 3/4-16 3 46092 2 SPACER, .76 x 1.00 x .50 4 22039 4 BALL JOINT, 3/4-16 5 47461 4 SPACER, .76 x 1.00 x .25 6 25265-28 4 CAPSCREW, Hex Hd, 3/4-16 x 3-1/2 7 25093 4 NUT, Hex, Jam, 3/4-16 8 3847743 1 SUSPENSION ARM - LH

9 22853 1 SPANNER WRENCH 10 22842 2 SHOCK & SPRING ASSEMBLY 11 25096 4 NUT, Hex, Nylon Lock, 3/8-16 12 3847049 2 CASTER TIRE MOUNT 13 25156 4 WASHER, 3/8 14 25013-18 2 CAPSCREW, Hex Hd, 3/8-16 x 2-1/4 15 46093 2 SPACER, .75 x 1.50 x 1.00 16 21072 2 GREASE SEAL 17 20884 4 BEARING, Tapered Roller 18 3847742 1 SUSPENSION ARM - RH 19 25160 2 WASHER, 3/4 20 25104 2 NUT, Hex, Slotted, 3/4-16 21 21073 2 CAP 22 25203-10 2 PIN, Cotter

4

TP 400-7087-02-SL-D

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

ZT2561F ZT2761F

Floor & Brake Cover Group

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

1

2

13

3

12

6

10

8

11

4

9

8

5

7

6

5

TP 400-7087-02-SL-D

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

ZT2561F ZT2761F

REF NO. PART NO. QTY. DESCRIPTION

Floor & Brake Cover Group

Footnotes:

1 25013-8 4 CAPSCREW, Hex Hd, 3/8-16 x 1

2 25156 8 WASHER, 3/8

3 21003 1 HOLE PLUG

4 25128 4 NUT, Hex, Serrated Flange, 3/8-16

5 22308 2 BODY CLIP, 5/16-18

6 25011-6 4 CAPSCREW, Hex Hd, 5/16-18 x 3/4

7 25057 2 NUT, Hex, Nylon Lock, 5/16-18

8 45915 2 SAFETY WALK

9 3847773 1 FLOOR PAN 10 44873 1 SAFETY WALK 11 21877 2 RUBBER PAD 12 25155 2 WASHER, 5/16 13 3845634 1 BRAKE COVER PANEL

6

TP 400-7087-02-SL-D

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

ZT2561F ZT2761F

Seat & Mount Group

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

1

5

3

2

4

6

8

7

9

16

10

11

15

12

6

7

14

13

7

TP 400-7087-04-SL-D

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

ZT2561F ZT2761F

REF NO. PART NO. QTY. DESCRIPTION

Seat & Mount Group

Footnotes:

* - See Electrical Schematic for switch part number

1A 22973 1 SEAT, Derby (complete)

* 20930-3 1 SEAT ADJUSTER RAILS (set of 2) 2 3847744 1 SEAT MOUNT 3 46470 1 SEAT STOP ROD 4 20047 1 COLLAR, 5/16 Set 5 25013-32 2 CAPSCREW, Hex Hd, 3/8-16 x 4 6 25057 6 NUT, Hex, Nylon Lock, 5/16-18 7 25096 3 NUT, Hex, Nylon Lock, 3/8-16 8 25013-48 1 CAPSCREW, Hex Hd, 3/8-16 x 6 9 25156 1 WASHER, 3/8

10 46586 1 SPACER, .38 x .50 x 5.06 11 22798 1 SPRING, Compression 12 25326 1 WASHER, 3/8 x 2 13 * 1 SWITCH (see electrical schematic) 14 25270 2 SCREW, #10-24 x 1 15 25029 2 NUT, Hex, #10-24 16 22612 2 RUBBER BUMPER

8

TP 400-7087-02-SL-D

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

ZT2561F (S/N: 138 & below)

Fuel Tank, Mount & Bumper Group

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

3

2

1

4

5

19

18

2

8

3

6

7

9

10

6

20

6

13

11

12

6

14

8

15

14

9

10

11

9

12

13

8

14

9

14

17

16

9

8

9

TP 400-7087-02-SL-D

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

ZT2561F (S/N: 138 & 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 3846491 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 3846489 1 TIE BAR MOUNT-RH 6 25011-6 4 CAPSCREW, Hex Hd, 5/16-18 x 3/4 7 25126 4 NUT, Hex, Nylon Lock, 1/4-20 8 25013-10 8 CAPSCREW, Hex Hd, 3/8-16 x 1 9 25156 8 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 8 NUT, Hex, Serrated Flange, 3/8-16 15 3847937 1 TANK MOUNT-RH 16 3847852 1 BUMPER 17 3847936 1 TANK MOUNT-LH 18 45495 1 FUEL TANK-LH, Complete (see footnote) 19 22395 4 RUBBER ISOLATOR 20 3846490 1 TIE BAR MOUNT-LH

10

TP 400-7087-02-SL-D

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

ZT2561F (S/N: 139 & above) ZT2761F

Fuel Tank, Mount & Bumper Group

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

3

2

1

4

5

2

18

17

3

6

7

6

8

19

6

9

11

10

12

11

13

8

13

14

13

9

10

16

15

14

13

11

TP 400-7087-02-SL-D

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

ZT2561F (S/N: 139 & above) ZT2761F

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 3846491 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 3846489 1 TIE BAR MOUNT-RH 6 25011-6 4 CAPSCREW, Hex Hd, 5/16-18 x 3/4 7 25126 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 8 NUT, Hex, Serrated Flange, 3/8-16 12 3847981 1 TANK MOUNT-RH 13 25156 8 WASHER, 3/8 14 25013-10 8 CAPSCREW, Hex Hd, 3/8-16 x 1 15 3847852 1 BUMPER 16 3847980 1 TANK MOUNT-LH 17 47903 1 FUEL TANK-LH, Complete (see footnote) 18 22395 4 RUBBER ISOLATOR 19 3846490 1 TIE BAR MOUNT-LH

12

TP 400-7087-02-SL-D

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

ZT2561F (S/N: 138 & 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 400-7087-09-SL-D

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

ZT2561F (S/N: 138 & 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 50831-60 1 HOSE, 60” 4 50831-39 1 HOSE, 39” 5 50831-29 1 HOSE, 29” 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 400-7087-02-SL-D

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

ZT2561F (S/N: 139 & above) ZT2761F

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 400-7087-09-SL-D

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

ZT2561F (S/N: 139 & above) ZT2761F

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 50831-60 1 HOSE, 60” 4 50831-39 1 HOSE, 39” 5 50831-29 1 HOSE, 29” 6 50833-51 1 WIRE LOOM, 51” 7 50833-33 1 WIRE LOOM, 33” 8 50833-24 1 WIRE LOOM, 24” 9 23061 2 ELBOWFITTING

10 1726400 2 RUBBER BUSHING 11 23069 4 CLAMP, Hose 12 50925-20 2 HOSE, 20” 13 23067 2 FITTING, Screen

16

TP 400-7087-03-SL-D

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

ZT2561F ZT2761F

Control Cover & Mount Group

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

2

3

4

3

1

See Fuel Tank

& Mount Group

5

See Instrument

Panel Group

4

9

6

5

8

3

15

4

16

4

3

7

22

See Fuel Tank

13

4

14

3

19

20

15

16

5

21

& Mount Group

23

5

14

18

11

10

17

5

14

5

7

12

4

13

3

17

TP 400-7087-03-SL-D

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

ZT2561F ZT2761F

REF NO. PART NO. QTY. DESCRIPTION

Control Cover & Mount Group

Footnotes:

1 3847849 1 CONTROL COVER-RH 2 1719392 1 CUP HOLDER 3 25011-8 10 CAPSCREW, Hex Hd, 5/16-18 x 1 4 25155 10 WASHER, 5/16 5 22308 10 BODY CLIP, 5/16-18 6 3847941 1 CONTROL COVER MOUNT-RH 7 3845890 2 TANK MOUNT BAR 8 22030 1 FUEL SHUT OFF VALVE 9 3847848 1 CONTROL COVER-LH

10 3847940 1 CONTROL COVER MOUNT-LH 11 21379 1 GROMMET 12 25127 4 NUT, Hex, Serrated Flange, 5/16-18 13 3847942 2 DEBRIS GUARD 14 25128 12 NUT, Hex, Serrated Flange, 3/8-16 15 25013-6 12 CAPSCREW, Hex Hd, 3/8-16 x 3/4 16 25156 12 WASHER, 3/8 17 3846417 1 COVER MOUNT-LH 18 3846472 2 FAN SHIELD 19 25010-8 4 CAPSCREW, Hex Hd, 1/4-20 x 1 20 25154 4 WASHER, 1/4 21 22665 4 BODY CLIP, 1/4-20 22 3846426 1 COVER MOUNT-RH 23 21077 1 GROMMET