Print Instructions for Print Vendors (Paper Manuals) OPERATOR’S 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 cover stock (NOTE: If total order quantity is less than 100 pieces, use uncoated cover stock) Press: • Body - 1-color, 2-sided • Cover - 1-color, 2-sided Bindery: • Staple (2X), Face Trim TOTAL PAGE COUNT: 80 or greater Paper Size: • 8-1/2 x 11 • Body - 50 lbs brilliant white offset or equivalent.
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OPERATOR’S MANUAL TM Stallion Zero-Turn Riding Mower with 4-Wheel Independent Suspension Model Number: ZT2561F ZT2761F Description: STALLION, 4W-IS, w/ 25 HP Kohler & 61” Mower Deck STALLION, 4W-IS, w/ 27 HP Kohler & 61” Mower Deck mowers are built by Ferris Industries, a Simplicity company. TM Ferris Industries 5375 North Main Street Munnsville, NY 13409 800-933-6175 22987 Revision 04 Rev.
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.
Table of Contents Troubleshooting, Adjustments & Service .......20 Safety Rules & Information ................................2 Identification Numbers .......................................7 Features & Controls ............................................8 Troubleshooting the Tractor...................................20 Troubleshooting the Mower ...................................21 Seat Adjustment....................................................22 Ground Speed Control Lever Adjustment .............
Safety Rules & Information 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 property or equipment. This mowing deck is capable of amputating hands and feet and throwing objects. The triangle in text signifies important cautions or warnings which must be followed.
Safety Rules & Information SLOPE OPERATION Operation - Con’t. • Turn off the PTO switch to disengage the blades when not mowing. • Never operate with guards not securely in place. Be sure all interlocks are attached, adjusted properly and functioning properly. • Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher. • Do not change the engine governor setting or overspeed the engine.
Safety Rules & Information CHILDREN EMISSIONS 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 turn unit off if children enter the area. • Before and during reverse operation, look behind and down for small children.
Safety Rules & Information WARNING WARNING STORED ENERGY DEVICE: Improper release of springs can result in serious personal injury. Spring should be removed by an authorized dealer only. Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
Safety Rules & Information 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. The safety decals below are on your rider and mower.
Identification Numbers Identification Numbers Identification Tag S A M P LE PRODUCT When contacting your authorized dealer for replacement parts, service, or information you MUST have these numbers. Record your model/serial number and engine serial numbers on the space provided for easy access. These numbers can be found in the locations shown.
Features & Controls of the Zero Turn Rider 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. A. B. C. D. E. F. G. H. I. J. K. L.
Features & Controls 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. 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. Check their operation regularly. E.
Operating the Zero Turn Rider GENERAL OPERATING SAFETY CHECKS BEFORE STARTING Before first time operation: • 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.
Operating the Zero Turn Rider WARNING 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 Lawn Care Section for tips on mowing patterns, lawn care, and trouble shooting information. 7.
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.
Operating the Zero Turn Rider Practice Turning Around a Corner Practice Turning In Place While traveling forward allow one handle to gradually return back toward neutral. Repeat several times. To turn in place, “Zero Turn,” gradually move one ground speed control lever forward from neutral and one lever back from neutral simultaneously. Repeat several times. NOTE: To prevent pivoting directly on the tire tread, it is best to keep both wheels going at least slightly forward.
Operating the Zero Turn Rider STORAGE WARNING Temporary Storage (30 Days Or Less) Never store the unit, with gasoline in engine or fuel tank, in a heated shelter or in enclosed, poorly ventilated enclosures. Gasoline fumes may reach an open flame, spark or pilot light (such as a furnace, water heater, clothes dryer, etc.) and cause an explosion. Handle gasoline carefully. It is highly flammable and careless use could result in serious fire damage to your person or property.
Notes 00 15
Regular Maintenance MAINTENANCE SCHEDULE & PROCEDURES The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by observing the elapsed time recorded by the hour meter.
Regular Maintenance CHECKING / ADDING FUEL WARNING To add fuel: 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. Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. DO NOT spread hose clamps further than necessary. Ensure clamps grip hoses firmly over filter after installation. 1.
Regular Maintenance LUBRICATION Lubricate the unit at the following lubrication points. Grease: • • • • • • • • Oil: front caster wheel axles motion control pivot bearings suspension a-arms mower deck pusher bars deck lift pivots deck lift foot pedal mower deck idler arm mower deck caster pivots • control handle pivots • floor plate hinge • discharge chute hinge Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys.
Regular Maintenance SERVICING THE MOWER BLADES 1. Blades should be sharp and free of nicks and dents. If not, sharpen blades as described in following steps. 2. To remove blade for sharpening, use a 1” wrench on the flats of the spindle shaft while removing the blade mounting bolt with a 15/16” wrench (Figure 13). 3. Use a file to sharpen blade to fine edge. Remove all nicks and dents in blade edge. If blade is severely damaged, it should be replaced. 4. Balance the blade as shown in Figure 14.
Troubleshooting Adjustments & Service TROUBLESHOOTING WARNING While normal care and regular maintenance will extend the life of your equipment, prolonged or constant use may eventually require that service be performed to allow it to continue operating properly. To avoid serious injury, perform maintenance on the tractor or mower only when the engine is stopped and the parking brake engaged.
Troubleshooting, Adjustment & Service Rider Troubleshooting Continued. PROBLEM CAUSE REMEDY Engine runs, but rider will not drive. 1. 1. Turn valve(s) clockwise to close. Rider drive belt slips. Brake will not hold. Rider steers or handles poorly. 2. 3. 4. 1. 2. 1. 2. 1. 2. Hydraulic release valve(s) in “open” position. Belt is broken. Drive belt slips. Brake is not fully released. Pulleys or belt greasy or oily. Belt stretched or worn. Brake is incorrectly adjusted. Brake caliper pads worn.
Troubleshooting, Adjustment & Service SEAT ADJUSTMENT See Figure 16. 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 into position. Seat Adjustment Lever GROUND SPEED CONTROL LEVER ADJUSTMENT The control levers can be adjusted in two ways. The alignment of the control levers can be adjusted along with the placement of the levers (how close the ends are to one another) can be adjusted. Figure 16.
Troubleshooting, Adjustment & Service NEUTRAL ADJUSTMENT If the tractor “creeps” while the ground speed control levers are locked in NEUTRAL, than it may be necessary to adjust the linkage rod. NOTE: Perform this adjustment on a hard, level surface such as a concrete floor. 1. Disengage the PTO, engage the parking brake and turn off the engine. 2. There are three (3) nuts on the linkage rod.
Troubleshooting, Adjustment & Service PARKING BRAKE ADJUSTMENT 1. Disengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. 2. Locate the upper brake spring (A, Figure 21). 3. With the parking brake engaged, measure the compressed spring length. The spring should be 2” to 21/8” (5,0 - 5,4cm) when compressed. 4. If the spring is not within this range, jack up the rear of the machine and secure with jackstands. Remove both drive tires. 5.
Troubleshooting, Adjustment & Service FRONT SUSPENSION ADJUSTMENT INCREASE The shock assembly can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to customize the ride according to operator’s weight and/or operating conditions.
Troubleshooting, Adjustment & Service A B B B C Figure 26. Adjust PTO Clutch B A. B. C. A Window Adjustment Nut .016”-.018” (0,40-0,45mm) Feeler Gauge Figure 25. PTO Clutch Adjustment A. B. Adjustment Window (Qty. 3, one shown) Adjustment Nut WARNING PTO CLUTCH ADJUSTMENT Check the PTO clutch adjustment after the initial 50 hour break-in period and then after every 250 hours of operation.
Troubleshooting, Adjustment & Service CUTTING HEIGHT ADJUSTMENT B WARNING Before checking mower, shut off PTO and engine. Allow all moving parts to stop. Remove ignition key, then disconnect the spark plug wire and fasten it away from the spark plug. The cutting height adjustment pin (A, Figure 27) controls the mower cutting height. The cutting height is adjustable between 1-3/4” (4,4cm) and 5” (12,7cm) in 1/4” (0,64cm) increments.
Troubleshooting, Adjustment & Service 5. See Figure 30. Measure the distance between the rear lift pivots and the suspension-mounted lift pivots. Add or remove 5/8” SAE washers from in between the deck lift rod and the lift link until measurements are equal. 6. Adjust 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 31. 7. Loosen the nuts and allow the rear of the deck to rest on the 2 x 4’s and 1/4” spacers.
Troubleshooting, Adjustment & Service MOWER BELT REPLACEMENT To avoid damaging belts, DO NOT PRY BELTS OVER PULLEYS. A B 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the hardware fastening the PTO clutch to the rubber anchor pad. 3. See Figure 33. Remove the hairpin clip and clevis pin and remove the deck lift foot pedal.
Troubleshooting, Adjustment & Service BATTERY SERVICE 6. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60° F). The best method of making certain a battery is fully charged, but not over charged, is to measure the specific gravity of a cell once per hour. The battery is fully charged when the cells are gassing freely at low charging rate and less than 0.
Troubleshooting, Adjustment & Service THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES To Starter Switch To Starter Switch Jumper Cable Starting Vehicle Battery Discharged Vehicle Battery Jumper Cable To Ground Engine Block MAKE CERTAIN VEHICLES DO NOT TOUCH Figure 36.
Lawn Care & Mowing Information GENERAL INFORMATION • • • • • • • Proper mowing is an important part of maintaining your lawn in the best possible condition. A healthy and well maintained lawn is better able to resist drought, weeds, and other stresses. But too much maintenance is as detrimental to your lawn as neglect. Proper care for your lawn involves more than just “cutting the grass.
Lawn Care & Mowing Information HOW HIGH TO MOW THE GRASS Cut less than 1/3 Often cutting height is a matter of personal preference. Typically, you should mow the grass when it is is between three and five inches high. The proper cutting height range for a specific lawn will depend upon several factors, including the type of grass, the amount of rainfall, the prevailing temperature, and the lawn’s overall condition.
Lawn Care & Mowing Information WHEN AND HOW OFTEN TO MOW The time of day and condition of the grass greatly affect the results you’ll get when mowing. For the best results, follow these guidelines: l Mow when the grass is between three and five inches high. l Mow with sharp blades. Short clippings of grass one inch or shorter decompose more quickly than longer blades. Sharp mower blades cut grass cleanly and efficiently, preventing frayed edges which harm the grass.
Lawn Care & Mowing Information MOWING METHODS Proper Broadcast Mowing Broadcasting, or side-discharging, disperses fine clippings evenly over the entire lawn. Many golf courses use this method. Your mower has a deep dish deck to allow freer circulation of clippings so they are broadcast evenly over the lawn. ENGINE SPEED & GROUND SPEED FOR BROADCASTING Always operate the engine at full throttle when mowing.
Lawn Care & Mowing Information TIPS On Dealing With Clippings Clippings are beneficial to your lawn. A common misconception about clippings is that they automatically lead to thatch—this is untrue.
Lawn Care & Mowing Information SOLUTIONS FOR COMMON MOWING PROBLEMS Streaking Streaking Streaking is when thin strips of uncut grass are left behind the mower. Streaking is usually caused by operator error or poor blade maintenance.
Lawn Care & Mowing Information Uneven Cutting Uneven Cutting Uneven cutting is waviness or smooth troughs in the lawn surface. Uneven cutting is usually caused by mower deck damage or misadjustment.
Common International Symbols PTO Clutch Choke Fast (Throttle) Parking Brake Slow (Throttle) Brake Throttle Mower Cutting Height Adjustment Fuel Headlights Technical Manuals Additional Technical Literature Available Operators Manuals Additional copies of this manual are available, (and as part of our product support commitment, we maintain a stock of printed operators manuals going back many years!) Parts Manuals Fully illustrated parts manuals are also available — these manuals show all of the produc
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