Snapper ZF2200K, ZF2500K, ZF2500KH, ZF User manual

Parts Manual for
OUT FRONT Z-RIDER
ZERO TURNING HYDRO DRIVE
SERIES 0
POWER UNIT MODELS
ZF2200K
ZF2500K
ZF2500KH
MOWER UNIT MODELS
ZF6100M
ZF5200M
ZF7301M
COPYRIGHT © 2002
SNAPPER INC.
ALL RIGHTS RESERVED
(REV 4, 9/30/02) MANUAL No. 06106
T
M

2
CONTENTS
DESCRIPTION PAGE
FUEL TANK ASSEMBLY............................................................................................................. 3
ENGINE ASSEMBLY ................................................................................................................... 4
AIR INTAKE ASSEMBLY.............................................................................................................5
TANDEM HYDRO TRANSAXLE ASSEMBLY .......................................................................6 & 7
DRIVE TIRE/WHEEL ASSEMBLY............................................................................................... 8
FOOTREST ASSEMBLY ............................................................................................................. 9
HYDRO RESERVOIR ASSEMBLY............................................................................................ 10
UPPER CHASSIS AND SEAT LATCH ASSEMBLY.................................................................. 11
LOWER CHASSIS/CASTER WHEEL ASSEMBLY ...........................................................12 & 13
JOYSTICK CONTROL ASSEMBLY ..................................................................................14 & 15
PARKING BREAK ASSEMBLY.........................................................................................16 & 17
SEAT SUPPORT ASSEMBLY ................................................................................................... 18
FENDER/CONTROL CABLE ASSEMBLY ................................................................................ 19
UPPER DRIVE SHAFT ASSEMBLY..................................................................................20 & 21
DECK DRIVE SHAFT ASSEMBLY ....................................................................................22 & 23
CUTTER HOUSING ASSEMBLY............................................................................................... 24
TRACTION DRIVE IDLER ASSEMBLY..................................................................................... 25
DECALS .............................................................................................................................26 & 27
52” MOWER DECK ASSEMBLY.......................................................................................28 & 29
61” MOWER DECK ASSEMBLY.......................................................................................30 & 31
73” MOWER DECK SUB-ASSEMBLY ..............................................................................32 & 33
73” MOWER DECK ASSEMBLY.......................................................................................34 & 35
52 & 61” DECK IDLER ASSEMBLIES ..............................................................................36 & 37
73” DECK FRAME ASSEMBLY ........................................................................................38 & 39
73” DECK FRONT CASTER ASSEMBLY .........................................................................40 & 41
ELECTRICAL COMPONENTS ..........................................................................................42 & 43
SEAT ASSEMBLY .............................................................................................................44 & 45
WIRING SCHEMATIC ................................................................................................................46
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

3
FUEL TANK ASSEMBLY
ITEM PART NO. DESCRIPTION
1 1-3847 RETAINER, 3/8 Bolt (2)
2 5-4098 TANK, Fuel (Includes item 4)
3 3-5504 BRACKET, Fuel Tank Support
4 5-4119 ASSEMBLY, Cap/Gauge
5 9-1640 BOLT, 3/8-16 x 1” Carriage, Grade 5 (3)
6 9-1299 NUT, 3/8-16 Nyloc (3)
7 1-2222 CLAMP, Fuel Hose (4)
8 3-5853 HOSE, Fuel 1/4 x 4”
9 4-4777 FILTER, Fuel
10 4-5282 HOSE, Fuel 1/4 x 24”
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

4
ENGINE SUB-ASSEMBLY
ITEM PART NO. DESCRIPTION
1 --- ENGINE, 22 HP (Kohler Part No. CH22S PS-66536)
-- --- ENGINE, 25 HP (Kohler Part No. CH25S PS-68577)
2 1-2222 CLAMP, Fuel Hose (2)
3 2-2486 OIL DRAIN, Short
4 2-7972 ASSEMBLY, Oil Valve
5 3-5520 CLUTCH, Electric, Commercial Magstop
6 3-5675 SPACER, Clutch
7 3-5852 BRACKET, Anti-Rotation (5/16”)
8 3-5853 HOSE, Fuel 1/4 x 4”
9 9-1299 NUT, 3/8-16 Nycloc (4)
10 9-1301 WASHER, 7/16” Split Lock (2)
11 9-1304 SCREW, 3/8-16 x 1” Hex Head Cap, Grade 5
12 1-4359 FILTER, Fuel (in-line)
13 9-1553 SCREW, 3/8-16 x 1-3/4” Hex Head Cap, Grade 5 (4)
14 9-1806 SCREW, 7/16-20 x 1-1/2” Hex Head Cap Grade 5
15 9-1807 WASHER, 15/32 I.D. x 1-3/8 O.D. x 1/4 Flat
16 9-1808 SCREW, 7/16-14 x 1”, Grade 5
17 9-1840 SCREW, M5 x 10mm Pan Head Cap (2)
18 4-2707 GUARD, Muffler
19 9-1839 SCREW, M5 x 16mm Hex Head Self Tapping (2)
20 --- MUFFLER, 22 HP (Kohler Part No. A-24 068 00)
21 4-2708 BRACKET, Muffler
22 9-1838 SCREW, M6 x 12.5mm Hex Flange Cap (2)
23 4-6486 BRACKET, Muffler 25 HP Kohler
24 4-6487 SHIELD, Heat 25 HP Kohler
25 --- MUFFLER, 25 HP (Kohler Part No. A-24 068 17)
26 7-2256 SPACER, Muffler Guard
27 7-2155 GUARD, Muffler “Snapper”
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

5
AIR INTAKE ASSEMBLY
ITEM PART NO. DESCRIPTION
1 2-3295 U-NUT, 1/4-20 (3)
2 3-5767 SCREEN, Air Intake
3 3-5768 MOUNT, Air Intake
4 9-0361 SCREW, 5/16-18 x 5/8” Hex Fl. Self-Tap (2)
5 9-1787 SCREW, 1/4-20 Hex Flange Lock (3)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

6
TANDEM HYDRO TRANSAXLE ASSEMBLY
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

7
TANDEM HYDRO TRANSAXLE ASSEMBLY
ITEM PART NO. DESCRIPTION
1 1-0935 WASHER, 3/4 I.D. x 1-1/8” O.D. Flat (7)
2 1-2709 RETAINING RING, 1” External (2)
3 1-4264 WOODRUFF KEY, #404 (2)
4 1-5894 WOODRUFF KEY, #605 (2)
5 1-8978 FAN, 10 Blade 7” Dia. (2)
6 2-7175 BOLT, 5/16-18 x 2-1/2” Hex Head (2)
7 2-7223 WASHER, 1/4 Split Lock (4)
8 9-1814 SCREW, 1/4-20 x 1-1/4”, Hex Head Cap (3)
9 3-5522 ASSEMBLY, Transaxle 771B (R.H.) Side (shown)
-- 5-8190 same as above but with 25 PSI bypass filter
-- 3-5521 ASSEMBLY, Transaxle 771A (L.H.) Side
-- 5-8190 same as above but with 25 PSI bypass filter
10 3-5547 PULLEY, Transmission Input (2)
11 3-5634 SPACER, Transaxle (2)
12 3-5910 PLATE, Neutral Adjust (2)
13 3-5915 SPRING, Neutral Return Adjust (2)
14 3-5923 SPACER/ADAPTER, Fan
15 3-5925 ROD, Roll Release (2)
16 3-5927 SPRING, Neutral Return (2)
17 4-2612 SPACER, Fan (Weldment) (2)
18 4-2639 CAM, Neutral Return (Weldment) (2)
19 5-4293 PLATE, Neutral Return (Weldment) (2)
20 1-5753 BALL-JOINT (4)
21 9-0201 SET SCREW, 5/16-18 x 5/16” Hex Recess (4)
22 9-1299 NUT, 3/8-16, Hex Nyloc (4)
23 9-1514 WASHER, 13/32 I.D. x 13/16 O.D. Flat (4)
24 9-1603 NUT, 1/4-20 Hex Nyloc (8)
25 9-1627 WASHER, 1/4 I.D. x 1” O.D. (2)
26 9-1629 COTTER-PIN, 1/16 x 1/2” (2)
27 9-1786 BOLT, 3/8-16 x 4-3/4” Grade 5 (4)
28 9-1787 SCREW, 1/4-20 x 5/8”, Hex Flange Lock, Grade 5 (8)
29 9-1811 BOLT, 5/16-18 x 5/8”, Hex Flange Lock (4)
30 9-1812 NUT, 1/4-28, Hex Nyloc (4)
31 9-0505 SCREW, 1/4-20 x 2”, Hex Head Cap, Grade 5
32 3-5914 ROD, Threaded 1/4-28 x 5-3/8”
33 3-5916 ROD, Threaded 1/4-28 x 4-3/8”
34 9-1605 NUT, 1/4-28 Hex, Grade 5 or B (4)
35 4-2715 FILTER, Oil (EATON No. 103144)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

8
DRIVE TIRE/WHEEL ASSEMBLY
ITEM PART NO. DESCRIPTION
1 5-4109 ASSEMBLY, Rear Tire & Rim (Includes Item 2A, 3 & 4)
-- 5-4510 ASSEMBLY, Rear Tire & Rim (Includes 2B , 3 & 4)
2A 5-4110 TIRE, 20 x 10.00-8 4 ply “Multi-trac C/S”
2B 4-4707 TIRE, 21 x 11.00-8 “All Terrain 101”
3 5-4111 RIM, 8” Dia. X 7-3/4”
4 1-2234 VALVE, Air
5 2-7192 NUT, 1/2-20 Lug (5)
6 5-4461 ASSEMBLY, Wheel Hub
7 9-1793 PIN, Cotter, 9/64 x 1-1/2
8 9-1778 KEY, #808 Woodruff
-- 9-1978 KEY, #806 Woodruff
9 9-1828 NUT, 3/4-20 Slotted Hex
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

9
FOOTREST ASSEMBLY
ITEM PART NO. DESCRIPTION
1 2-2696 SPRING
2 2-8810 BUSHING, 5/16 I.D. x 7/16 O.D. x 3/16 (2)
3 3-5849 BOLT, 1/2-13, 3/4 Dia. X 1-1/16 Shoulder (2)
4 9-1602 BOLT, 5/16-18 x 1-1/2 Hex Flange Lock, Grade 5 (2)
5 3-5855 FOOT PAD, Rubber
6 3-5978 PLATE, Footrest Latch
7 3-5979 SPACER, Shoulder (Latch)
8 4-2630 FOOTREST (Weldment)
9 9-1296 WASHER, 11/32 I.D. x 11/16 O.D. x 1/16” Flat (2)
10 9-1298 NUT, 5/16-18 Nyloc (3)
11 9-1325 NUT, 1/2-13 Nyloc (2)
-- 9-1894 NUT, 1/2-13 Hex Center Lock, Grade 5 (2)
12 9-1331 WASHER, 13/32 I.D. x 1-1/2 O.D. x 1/8” Flat
13 9-1591 BOLT, 5/16-18 x 1 Hex Flange Lock, Grade 5
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

10
HYDRO RESERVOIR ASSEMBLY
ITEM PART NO. DESCRIPTION
1 1-6130 CLAMP, Hose 13/16” (8)
2 9-1298 NUT, 5/16-18 Nyloc (2)
3 3-5514 HOSE, Rubber R.H. Front (.625 I.D. x 13-1/2” Long)
4 3-5515 HOSE, Rubber R.H. Back (.625 I.D. x 16” Long)
5 3-5516 HOSE, Rubber L.H. Front (.625 I.D. x 24” Long)
-- 4-1834 HOSE, Rubber (.625 I.D. x 34” Long)
6 3-5517 HOSE, Rubber L.H. Back (.625 I.D. x 18” Long)
-- 4-1833 HOSE, Rubber (.625 I.D. x 6” Long)
7 3-5639 BRACKET, Reservoir (2)
8 5-4703 RESERVOIR, L.H. Hydro (includes cap, item 11)
9 5-4103 RESERVOIR, R.H. Hydro (includes cap, item 11)
10 9-1296 WASHER, 11/32 I.D. x 11/16” O.D. (2)
11 3-5512 CAP, Reservoir
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

11
UPPER CHASSIS AND SEAT LATCH ASSEMBLY
ITEM PART NO. DESCRIPTION
1 4-2601 UPPER CHASSIS
2 1-3874 BUSHING, 5/8” PM (2)
3 3-5993 LATCH, Seat Support
4 1-5761 BOLT, 5/16-18 Shoulder
5 2-6292 SPRING
6 9-1298 NUT, 5/16-18 Hex Nyoc
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

12
LOWER CHASSIS/CASTER WHEEL-ASSEMBLY
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

13
LOWER CHASSIS/CASTER WHEEL-ASSEMBLY
ITEM PART NO. DESCRIPTION
1 3-6406 BRACKET, Battery Support
2 1-4432 SPRING (2)
3 2-9074 PIN, Clevis 1/2 x 4” (2)
4 3-5468 SKID GUARD, R.H.
5 3-5469 SKID GUARD L.H.
6 3-5476 SLEEVE, Axle
7 3-5602 BEARING, 30mm x 62mm (2)
8 3-5638 J-CLIP, Open Cushoned (2)
9 3-5822 COUNTERWEIGHT, Large (3)
10 3-5823 COUNTERWEIGHT, Small
11 4-2589 CHASSIS, Lower
12 4-2590 SUPPORT, Caster
13 4-2591 YOKE, Caster
14 4-2628 PLATE, Hitch (2)
15 4-2629 PIN, Hitch (2)
16 5-4087 ASSEMBLY, Tire & Rim (includes Iitems 17 thru 21)
17 3-5474 TIRE, 13 x 5.00-6 4 Ply
18 3-5475 RIM
19 2-8722 BEARING (2)
20 1-2234 VALVE, Air
21 1-2700 FITTING, Lube
22 1-0965 RING, 1-3/16” External Retaining
23 9-1299 NUT, 3/8-16 Hex Nyloc (20)
24 9-1325 NUT, 1/2-13 Nyloc
25 9-1514 WASHER, 13/32 I.D. x 13/16 O.D., Flat (2)
26 9-1598 PIN, Cotter, 1/8 x 3/4” (4)
27 9-1773 SCREW, 1/2-13 x 7-1/4, Grade 5
28 9-1786 BOLT, 3/8-16 x 4-3/4”, Grade 5 (2)
29 9-1790 BOLT, 3/8-16 x 1-1/4”, Carriage, Grade 5 (8)
30 9-1795 WASHER, 1-1/4 I.D. x 1-7/8 O.D. Flat
31 9-1328 SCREW, 3/8-16 x 1-1/4”, Hex Hd. Cap, Gr. 5 (8)
32 9-1595 WASHER, 15/32 I.D. x 15/16” O.D., Flat (4)
33 9-1640 BOLT, 3/8-16 x 1” Carriage, Grade 5 (2)
34 3-6578 CAP, Caster Shaft
35 9-0361 SCREW, 5/16-18 x 5/8” Self Tapping
36 4-2777 SHIELD, Grass
37 9-1299 NUT, 3/8-16 Hex Nyloc (2)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

14
JOYSTICK CONTROL ASSEMBLY
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

15
JOYSTICK CONTROL ASSEMBLY
ITEM PART NO. DESCRIPTION
1 1-3072 ROLL PIN, 1/4 x 1” (8)
2 2-3656 HANDLE, Plastic
3 3-5532 BRACKET, Joystick Mounting
4 3-5533 BLOCK, Pivot J’Stick Control
5 3-5897 SHAFT, Upper Cross
6 3-5898 SHAFT, Lower Cross
7 4-2599 HANDLE, Joystick Control (Weldment)
8 4-2638 ARM/HUB Weldment (4)
9 5-4237 ASSEMBLY, Cross Shaft Support (includes
one 9A and two 9B)
9A 4-2623 SUPPORT, Cross Shaft (Weldment)
9B 1-3874 BUSHING (2)
10 3-5908 ROD, Threaded 1/4-28 x 2.71 long
11 3-5909 ROD, Threaded 1/4-28 x 3.85 long
12 9-0844 ROLL PIN 3/16 x 3/4”
13 9-1298 NUT, 5/16-18 Hex Nyloc (3)
14 9-1508 BOLT, 5/16-18 x 3/4” Sq.Nk. Carriage, Grade 5 (3)
15 9-1523 SCREW, 5/16-18 x 5/8” Hex Washer Self-Tap (2)
16 9-1628 WASHER, 41/64 I.D. x 1” O.D. Flat (4)
17 9-1800 BOLT, 5/16-18 Shoulder (4)
18 9-1812 NUT, 1/4-28 Hex Nyloc (4)
19 9-1816 ROLL PIN, 1/4 x 2-3/4”
20 9-1605 NUT, 1/4-28 Hex, Grade 5 or B (4)
21 1-5753 BALL-JOINT (4)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

16
PARKING BRAKE ASSEMBLY
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

17
PARKING BRAKE ASSEMBLY
ITEM PART NO. DESCRIPTION
1 1-2068 RING, Rear Lift Arm
2 2-6420 GRIP, Flat Bar
3 2-8200 SWIVEL, Adjustable (5/16-18 thread)
-- 4-6451 SWIVEL, Adjustable (3/8-24 thread)
4 3-4453 WASHER, 3/4 I.D. x 1-1/2 O.D. x 9/64” Flat
5 4-6456 ARM, Brake Lift (3/8-24 thread)
6 3-5888 ROD, Hydrostatic Brake (1/4-28 thread) (2)
7 3-6399 SLEEVE Bearing, 1/2 I.D. x .629 (2)
8 4-6469 ARM, Parking Brake
9 4-2635 SHAFT, Brake
10 4-2647 BRACKET, Joystick Lockout
11 4-2648 PLATE, Support
12 9-1313 COTTER PIN, 3/32 x 1” (6)
-- 9-1597 COTTER-PIN, 3/32 x 3/4” (6)
13 9-1514 WASHER, 13/32 I.D. x 13/16 O.D. x 5/64 Flat (3)
14 9-1523 SCREW, 5/16-18 x 5/8” Hex Washer Face Self-Tap (3)
15 9-1605 NUT, 1/4-28 Hex, Grade 5 (2)
16 9-1809 COTTER PIN, 1/8 x 1-1/4”
17 1-4001 PIN, Roll 1/8 x 3/4”
18 9-1812 NUT, 1/4-28 Hex Nyloc (2)
19 9-1832 SWIVEL, 1/4” Smooth (2)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

18
SEAT SUPPORT ASSEMBLY
ITEM PART NO. DESCRIPTION
1 9-1503 HAIRPIN, 3/32 x 1-1/2 (2)
2 1-7590 SWITCH, Seat (Normally Open)
3 1-9035 ROD, 5/16 x 13” Long
4 3-6492 SPRING, .106 Wire Dia., .68 I.D. x 1-1/2” (2)
5 2-2793 BUSHING, Molded Seat, 1/2 I.D., 5/8” O.D. (2)
6 2-2794 SPACER, .31 I.D., 1-3/8” Long (2)
7 2-3606 CAP, Vinyl, 1/4 I.D., 1/5 O.D. (2)
8 3-3362 HOLDER, Seat Switch
9 3-5827 PLATE, Seat Support
10 3-5828 BRACKET, Lower Seat Hinge
11 3-5839 BRACKET, Upper Seat Support Hinge
12 9-1046 SCREW, 5/16-18 x 2-1/2” Hex Head Cap, Grade 5 (2)
13 9-1296 WASHER, 5/16 x 11/16 O.D. Flat (2)
14 9-1298 NUT, 5/16-18 Hex Nyloc (16)
15 9-1508 BOLT, 5/16-18 x 3/4 Short Neck. Carriage, Grade 5 (6)
MANUAL No. 06106 OUT FRONT ZTR SERIES 0

19
FENDER/CONTROL CABLE ASSEMBLY
ITEM PART NO. DESCRIPTION
1 2-3655 LEVER, Throttle Control (2)
2 3-5548 HANDLE, 5/8” Tubing
3 3-5701 PANEL, Console
4 3-5940 PLATE, Joystick Control
5 4-2642 FENDER, R.H.
6 4-2643 FENDER, L.H.
7 3-5837 CABLE, Choke, Kohler
8 9-0913 SCREW, #10-24 Hex Washer Face Self-tap (8)
9 9-1017 SCREW, #8-32 x 3/8”Machine (2)
10 9-1523 SCREW, 5/16-18 x 5/8” Hex Washer Face Self-tap (15)
11 9-1787 SCREW, 1/4-20 x 5/8” Hex Flange Lock (3)
12 9-1018 NUT, #8-32 Hex (2)
13 3-5838 CABLE, Throttle, Kohler
14 9-1130 WASHER, 5/16 I.D. Flat (2)
OUT FRONT ZTR SERIES 0 MANUAL No. 06106

20
UPPER DRIVE SHAFT ASSEMBLY
MANUAL No. 06106 OUT FRONT ZTR SERIES 0