User manual SWISHER ZMAX ZT2560

ZT2560 ZT2560 25 HP ­ 60" CUT CELEBRATING OVER 60 YEARS OF INNOVATION 1945 - 2006 1602 CORPORATE DRIVE, P.O. BOX 67, WARRENSBURG, MISSOURI 64093 PHONE 660-747-8183 FAX 660-747-8650 Made In The Manufacturing quality lawn care equipment since 1945 USA Rev. 06-046 OWNER'S MANUAL STARTING SERIAL # L506-017001 11849 LIMITED WARRANTY The manufacturer's warranty to the original consumer purchaser is: This product is free from defects in materials and workmanship for a period of two (2) years from the date of purchase by the original consumer purchaser. We will repair or replace, at our discretion, parts found to be defective due to materials or workmanship. This warranty is subject to the following limitations and exclusions: 1) Engine Warranty All engines utilized on our products have a separate warranty extended to them by the individual engine manufacturer. Any engine service difficulty is the responsibility of the engine manufacturer and in no way is Swisher Mower Co., Inc. or its agents responsible for the engine warranty. The Briggs & Stratton Engine Service Hot-Line is 1-800-233-3723. The Tecumseh Engine Service Hot-Line is 1-800-558-5402. This product is not intended for commercial use and carries no commercial warranty. This warranty applies only to products which have been properly assembled, adjusted, and operated in accordance with the instructions contained within this manual. This warranty does not apply to any product of Swisher Mower Co., Inc., that has been subject to alteration, misuse, abuse, improper assembly or installation, shipping damage, or to normal wear of the product. Excluded from this warranty are normal wear, normal adjustments, and normal maintenance. 2) Commercial Use 3) Limitation 4) Exclusions In the event you have a claim under this warranty, you must return the product to an authorized service dealer. All transportation charges, damage, or loss incurred during transportation of parts submitted for replacement or repair under this warranty shall be borne by the purchaser. Should you have any questions concerning this warranty, please contact us toll-free at 1-800-222-8183. The model number, serial number, date of purchase, and the name of the authorized Swisher dealer from whom you purchased the mower will be needed before any warranty claim can be processed. THIS WARRANTY DOES NOT APPLY TO ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR ALL EXPRESSED WARRANTIES. Some states do not allow the limitation of consequential damages or limitations on how long an implied warranty may last, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may have other rights, which vary from state-to-state. This is a limited warranty as defined by the Magnuson-Moss Act of 1975. 2 CONTENTS 2 LIMITED WARRANTY............ 16 OPERATION.............................. Features.......................................... 16 Starting............................................. 19 Grass Height of Cut.................. 19 Controls.......................................... 20 21 SERVICE & ADJUSTMENTS.. Adjusting Deck Height.............. 21 Deck Level..................................... 21 Deck Belt Replacement............ 22 Hydro Belt Replacement............ 23 Seat Adjustment.............................. 24 Parking Brakes.............................. 25 26 WIRING SCHEMATIC.............. Operator Presence................... 12 27 PARTS BREAKDOWN.............. Tires................................................... 12 34 TROUBLESHOOTING............... Blade Maintenance....................... 13 37 MOWER IDENTIFICATION........ Battery............................................. 13 38 REPLACEMENT PARTS........... V-belts............................................ 14 39 MAINTENANCE LOG................. Engine............................................... 14 40 SWISHER HISTORY................. Overall Unit Care........................ 14 Transporting Safety................... 14 INTRODUCTION..................4 General............................................ 4 Before Operating........................ 4 Uncrating & Assembly............... 5 6 SYMBOLS & DECALS.......... 8 SAFETY INSTRUCTIONS....... General use and safety rules...8 Slope Operation......................... 10 Children Safety............................ 10 11 SPECIFICATIONS................. CUSTOMER RESPONSIBILITY............... 12 3 INTRODUCTION Congratulations Thank you for purchasing a Swisher Zero Turn mower. This machine is built for the greatest efficiency and rapid mowing of large areas. Conveniently located controls and dual commercial grade hydrostatic transmissions regulated by steering levers, contribute to the machine's performance. This manual is a valuable document. Following the instructions for use, service, maintenance, etc. can greatly increase the life-span of your machine . General In this operator's manual, left and right, backward and forward are used in relation to the normal operators position. NOTE: Read Before Operating If you have never used a Zero Turn mower before, refer to the Operation Controls section of this manual before attempting to operate one for the first time. This machine is constructed only for mowing grass on lawns and other free and even ground without obstacles. This machine is not intended for commercial use. The manufacturer's directions concerning operation, maintenance, and repairs must be carefully followed. This machine must only be operated, maintained, and repaired by persons that are familiar with the machine's special characteristics and who are well versed in safety instructions. Accident prevention regulations, other general safety regulations, occupational safety rules, and traffic regulations must be followed without fail. Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any resulting personal injury or property damage. Read engine manufacturer's operating and maintenance instructions. Read and observe all safety instructions on your mower and in the manual Check engine oil. Check fuel caps to sure that they are in place. 4 Set control handles outward ­ setting parking brake Be sure mower blades are turned off ­ PTO switch pushed down. Know how to stop the engine ­ Turn key to off Know how to stop the unit ­ Return control handles to neutral INTRODUCTION Uncrating & Assembly TOOLS REQUIRED: 2 - ½" Wrenches or ½" Socket with drive ratchet Tire pressure gauge Nail bar or claw hammer Wire snips To Remove The Mower From The Crate Dispose of top and side panels of the crate. Remove loose parts and packing material Cut any banding or strapping that may be holding the mower to the crate. Disengage spark plug wire and place where it cannot make a connection. Raise the mower deck to its highest position.. Disengage the parking brakes by placing the handle controls in the upright position. Open the transmission valves at the rear of the unit by pulling the release rods and locking them in place. SEE INSTRUCTION DECAL AT THE REAR OF THE UNIT. Carefully push the mower off the crate to a safe and level area. Check engine oil. All engines are filled with oil and tested at the factory. Verify oil level and add if necessary before starting engine. SEE ENGINE OWNER'S MANUAL Check the battery. If the battery is put into service after the "month & year" of the date on the battery, then it may need to be charged with a 12 volt charger for a minimum of 1 hour, but no more than 2 hours at a rate of 6 to 10 amps. Attach battery cables to battery. Always attach the positive terminal first. Install steering levers. Remove the bolts from the control arms on the mower. Align the holes in the lever with the holes in the control arms and attach with the bolts provided. Make sure both bolts on both handles are tight. Close the transmission valves at the rear of the unit. SEE INSTRUCTION DECAL AT THE REAR OF THE UNIT. Reconnect spark plug wire. Check tire pressure on all four wheels. REFER TO UNIT SPECIFICATIONS TABLE 5 SYMBOLS & DECALS OD45- Warning Decal Swisher Flag U.S.A.­ OD39 Notice Do Not Alter Wiring Decal­ OD74 Flying Debris Decal ­ OD43 Operator Must Be Seated Decal­ OD73 Triangle Danger Decal ­ OD55 No Step Decal ­ OD11 6 SYMBOLS & DECALS cont. Parking Brake Decal Key/PTO Decal - 10273 Left - 10270 Hydro Release - 10280 Parking Brake Decal Throttle/Choke Decal - 10271 Right - 10279 Danger/Warning Decal - 10276 Decals Not Shown 10275 10281 OD9128 XZT60 Decal Small Height Adjustment Decal 60" Deck White Decal 10542 10274 OD99125 Replacement Parts Decal Z-Max Decal Medium Swisher Decal 7 SAFETY INSTRUCTIONS These instructions are for your safety. Read them carefully. This Safety Alert Symbol indicates important messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury. General Use Read all instructions in this operator's manual and on the machine before starting it. Ensure that you understand them and then abide by them. Learn how to use the machine and its controls safely and learn how to stop quickly. Also learn to recognize the safety decals. Only allow the machine to be used by adults who are familiar with its use. Make sure nobody else is in the area of the machine when you start the engine, engage the drive, or run the machine. Stop the machine if someone enters the work area. Clear the area of objects such as stones, toys, steel wire, etc. that may become caught in the blades and thrown out. Do Not Use this machine without the Discharge Chute in place. Stop the engine and disconnect the spark plug before cleaning the discharge deck. Never take passengers. The machine is only intended for use by one person. NOTE: If you have never used a Zero Turn mower before, refer to the Operation Controls section of this manual before attempting to operate one for the first time. 8 SAFETY INSTRUCTIONS General Use Continued Remember Always look around before and during reversing maneuvers. Slow down before turning. Shut down the mower deck when not mowing. Be careful when rounding fixed objects, so that the blades do not hit them. Only operate the machine in daylight or other well-lit conditions. Keep the machine a safe distance from holes or other irregularities in the ground. Never use the machine if you are tired, if you have consumed alcohol, or if you are taking other drugs or medications that can affect your vision, judgment, or coordination. Beware of traffic when working near or crossing a road. Never leave the machine unsupervised with the engine running. Always shut down the blades, engage the parking brakes, stop the engine, and remove the ignition key before leaving the machine. Never allow children or other persons not trained in the use of the machine to use or service it. Local laws may regulate the age of the user. Make sure that you have first aid equipment close at hand when using the machine. Never use the machine when barefoot. Always wear protective shoes or boots. Always wear approved protective glasses or a full visor when assembling or driving. Ear Protection is recommended Never wear loose clothing that can get caught in moving parts. 9 The operator is responsible for avoiding dangers or accidents. WARNING When using the machine, approved personal protective equipment shall be used. Personal protective equipment cannot eliminate the risk of injury, but it will reduce the degree of injury if an accident does occur. Ask your retailer for help in choosing the right equipment. SAFETY INSTRUCTIONS Slope Operation Remove obstacles such as stones, tree branches, etc. Mow up and down, not side to side. Never drive the rider on terrain that slopes more than 10 degrees. Avoid starting or stopping on a slope. If the tires begin to slip, shut down the blades and drive slowly down the slope. Always drive evenly and slowly on slopes. Make no sudden changes in speed or direction. Avoid unnecessary turns on slopes, and if it proves necessary, turn slowly and gradually downward, if possible. Watch for holes, ruts, or bumps. On uneven terrain, the machine can tip more easily. Long grass can hide obstacles. Drive slowly and use small movements of the steering controls. Do not mow wet grass. It is slippery, and the tires can loose their grip, so that the machine slides. Do not try to stabilize the machine by putting a foot on the ground. Remember The operator is responsible for avoiding dangers or accidents. Children Serious accidents may occur if you fail to be on guard for children in the area of the machine. Children are often attracted to the machine and mowing work. Never assume that children will stay put where you last saw them. Keep children away from the mowing area and under close supervision by another adult. Shut off the machine if children enter the work area. Never allow a child to ride with you. Never allow children to operate the machine. Be extra cautious near corners, bushes, trees, or other objects that block your view. 10 SPECIFICATIONS GASOLINE CAPACITY AND TYPE OIL TYPE (SPI-SF-SJ): SPARK PLUG GROUND SPEED TIRE SIZE DUAL 2.0 GAL TANKS UNLEADED REGULAR SEE ENGINE MANUAL SEE ENGINE MANUAL 0 ­ 6 mph FRONT: 4.10x3.5-5 5/8 Bearing REAR: 20 X 10 X 8 FRONT: 50 psi Max REAR: 22 psi Max 12V / Heavy Duty 275 CCA Type U1L 27 + - 3 ft. lbs 35 ft. lbs 1.5" ­ 5" 60" ­ 3 Mulching Blade System Automatic - On Steering Handles Pivoting Deluxe 18" Back w/ Arm Rest 6" Adjustable Slide Commercial Grade Eaton Hydrostatic Spring Assisted LENGTH: WIDTH: Including Deck WEIGHT: 70" 60 ¼" " 680 lbs TIRE PRESSURE BATTERY HYDRO Bolt Torque BLADE BOLT TORQUE CUTTING HEIGHT CUTTING WIDTH PARKING BRAKE FRONT AXLE SEAT TRANSMISSION DECK LIFT UNIT MEASUREMENTS 11 CUSTOMER RESPONSIBILITIES Operator Presence System Be sure the operator presence and interlock systems are working properly. If your mower does not function as described, repair the problem immediately. The engine should not start unless the parking brakes (handle controls) are engaged (rotated outward), the PTO (Blade Engagement ­ See OPERATION FEATURES section of this manual) switch is disengaged (pressed down), and the operator is on the seat. When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake should shut off the engine. When the engine is running and the PTO switch is engaged, any attempt by the operator to leave the seat without first disengaging the PTO switch, should shut off the engine. When the engine is running and the control levers are rotated in, any attempt by the operator to leave the seat without rotating the control levers out, should shut off the engine. The PTO switch should never engage without the operator on the seat. Tires Maintain proper air pressure in all tires ( SEE SPECIFICATIONS section) Keep tires free of gasoline, oil, or insect control chemicals which can harm rubber. Avoid stumps, stones, deep ruts, sharp objects and other hazards that may cause tire damage. 12 CUSTOMER RESPONSIBILITIES Blade Maintenance CAUTION Stop engine and remove ignition key for safety. Disconnect spark plug wire. Wear heavy, thick gloves when holding onto blade. Avoid the sharp edge of the blade. For best results, mower blades must be kept sharp. Replace bent or damage blades. Safely raise front of mower. SEE WARNING Hold or block blade from turning. Loosen blade nut and remove blade. Replace blade, (SEE SPECIFICATIONS). WARNING When it is necessary to raise the mower for any repair or service, use jackstands to provide adequate support. DO NOT rely on hydraulic or mechanical jacks Battery WARNING The battery contains sulfuric acid and electrolytes which are poisonous and corrosive. The battery is a maintenance-free battery and the fluid level cannot be checked. Charge battery if needed. To clean battery and terminals Remove terminal guard. Disconnect the BLACK battery cable first, then the RED battery cable and remove the battery. Rinse the battery with plain water and dry. Clean terminals and battery cable ends with wire brush until shiny. Coat terminals with grease or petroleum jelly Reinstall battery Reconnect the battery cables 13 CUSTOMER RESPONSIBILITIES V-Belts Check V-belts for deterioration and wear after 100 hours of operation and replace if necessary. Replace belts if they begin to slip from wear. SEE SPECIFICATION for belt part numbers and SERVICE section of this manual for instructions on how to replace the belt. Engine REFER TO YOUR ENGINE OWNERS MANUAL Overall Unit Care Reduce the risk of fire by removing grass, leaves, and other debris that may have accumulated on the machine. Allow the machine time to cool before cleaning or putting it in storage. Wash mower periodically. Clean above and below deck. Keep all electrical connections clean and tight. Driving and Transport on Public Roads Check applicable road traffic regulations before driving and transporting on public roads. If the machine is transported, you should always use approved fastening equipment and ensure that the machine is well anchored. The cutting deck should also be lowered to the lowest position and the steering levers should be in the outward position, so that the parking brake is engaged. 14 CUSTOMER RESPONSIBILITIES MAINTENANCE SCHEDULE Before Each Use Check Brake Operation Check Tire Pressure Check Operator Presence Parking Brake Check for Loose Fasteners Sharpen/Replace Mower Blades Check Battery Clean Battery & Terminals Check Belts Check Engine Oil Change Engine Oil w/ filter Change Engine Oil w/o filter Replace Oil Filter 8 Hours 25 Hours 50 Hours 100 Hours Season Before Storage X X X X X X X X X3 X X X X X X X X X1,2 X1,2 X1,2 X2 X X2 X X X Clean Air Filter Inspect Muffler Clean Engine Cooling Fins Replace Spark Plug Replace Fuel Filter 1 ­ Change more often when operating under a heavy load or in high ambient temperatures 2 ­ Service more often when operating in dirty or dusty conditions 3 ­ Replace blades more often when mowing in sandy soil 15 OPERATION FEATURES 9 7 10 6 1. 2. 3. 4. 5. 6. Throttle Control ­ Used to control Engine Speed Hour Meter ­ Indicates hours of operation Choke Control ­ Used when starting a cold engine PTO Switch ­ Used to engage or disengage the deck blades Ignition Switch ­ Used to start or stop the engine Deck Lift Handle ­ Used to raise and lower the cutting deck 8. 7. 12 Control Levers / Parking Brake ­ Sets the speed of the mower in both the forward and reverse directions and also turns the mower / Engages and disengages the Automatic Parking Brake system Hydro Bypass ­ Engages transmissions for normal operation and disengages transmissions for pushing or pulling the unit Fuel Tanks ­ Dual 2.0 gal fuel tanks Seat Slide Battery Pivoting Front Axle Discharge Chute 9. 10. 11. 12. 13. SEE DETAILS PAGE 16 OPERATION FEATURES 9 7 13 1. 2. 3. 4. 5. 6. Throttle Control ­ Used to control Engine Speed Hour Meter ­ Indicates hours of operation Choke Control ­ Used when starting a cold engine PTO Switch ­ Used to engage or disengage the deck blades Ignition Switch ­ Used to start or stop the engine Deck Lift Handle ­ Used to raise and lower the cutting deck 8. 7. Control Levers / Parking Brake ­ Sets the speed of the mower in both the forward and reverse directions and also turns the mower / Engages and disengages the Automatic Parking Brake system Hydro Bypass ­ Engages transmissions for normal operation and disengages transmissions for pushing or pulling the unit Fuel Tanks ­ Dual 2.0 gal fuel tanks Seat Slide Battery Pivoting Front Axle Discharge Chute 9. 10. 11. 12. 13. SEE DETAILS PAGE 17 OPERATION FEATURES Left Control Panel Right Control Panel 3 1 2 4 6 5 11 1. 2. 3. 4. 5. 6. Throttle Control ­ Used to control Engine Speed Hour Meter ­ Indicates hours of operation Choke Control ­ Used when starting a cold engine PTO Switch ­ Used to engage or disengage the deck blades Ignition Switch ­ Used to start or stop the engine Deck Lift Handle ­ Used to raise and lower the cutting deck 8 Rear of Unit 7. Control Levers / Parking Brake ­ Sets the speed of the mower in both the forward and reverse directions and also turns the mower / Engages and disengages the Automatic Parking Brake system Hydro Bypass ­ Engages transmissions for normal operation and disengages transmissions for pushing or pulling the unit Fuel Tanks ­ Dual 2.0 gal fuel tanks Seat Slide Battery Pivoting Front Axle Discharge Chute 8. 9. 10. 11. 12. 13. 18 OPERATION Starting Operator must be sitting in the seat. Control handles must be in the neutral (outward) position (which sets the parking brakes). PTO must be in the disengage position (pushed down). Set choke (if needed), turn key and release as soon as engine starts. Adjust throttle to half and shut choke off. Close motion control levers (move inward), releasing the Parking Brakes Be sure all people are clear of the area. Engage blades and set RPM to maximum. NOTE: If you have never used a Zero Turn mower before, refer to the Operation Controls section of this manual before attempting to operate one for the first time. Grass Height & Cutting Suggestions Do not attempt to cut wet grass The average lawn should be cut to 2 ½" during the cool season and to over 3" during the hot months. For healthier and better looking lawns, mow often and after moderate growth. As a rule , never cut more than 1/3 of the total grass blade length. Correct mowing height can reduce weeds and lawn disease. For best performance, grass over 6 inches in height should be mowed twice. The first cut should be set relatively high and the second set to the desired height. 19 OPERATION Controls Be familiar with all controls, their functions and how to operate them before starting the machine. Motion control levers on each side of the console control the direction of movement. SEE FIGURE BELOW Control Handles Neutral Position Slow Forward Fast Forward 90 Degree Right Turn 90 Degree Left Turn Slow Reverse NOTE: If you have never used a Zero Turn mower before, refer to the Operation Controls section of this manual before attempting to operate one for the first time. 360 Degree Right Turn 360 Degree Left Turn Note: The pressure required to operate the mower is very slight 20