User manual SWISHER ZT2460 Z-MAX

ZT2460 ZT2460 24 HP ­ 60" CUT CELEBRATING 60 YEARS OF INNOVATION 1945 - 2005 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 1 OWNER'S MANUAL STARTING SERIAL # L505-040001 10277 Rev 05-010 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. 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 2) Commercial Use 3) Limitation 4) Exclusions CONTENTS LIMITED WARRANTY.......... INTRODUCTION.................. General.............................. Before Operating..................... Uncrating & Assembly.......... 2 4 4 4 5 6 8 8 10 10 11 OPERATION............................. 16 Features........................... Starting............................ Grass Height of Cut............. Controls............................. 16 19 19 20 21 21 21 22 23 24 25 26 27 34 37 38 39 40 SYMBOLS & DECALS.......... SAFETY INSTRUCTIONS.... General use and safety rules... Slope Operation.................. Children Safety.................. SERVICE & ADJUSTMENTS.. Adjusting Deck Height....... Deck Level..................... Deck Belt Replacement.... Hydro Belt Replacement.... Seat Adjustment.............. Parking Brakes............... SPECIFICATIONS.............. CUSTOMER RESPONSIABLITY............ Operator Presence.......... Tires................................ Blade Maintenance............ Battery.............................. V-belts............................ Engine............................ Overall Unit Care................ Transporting Safety............ Maintenance...................... 12 WIRING SCHEMATIC......... 12 PARTS BREAKDOWN......... 12 TROUBLESHOOTING.......... 13 MOWER IDENTIFICATION.... 13 REPLACEMENT PARTS...... 14 MAINTENCE LOG............... 14 SWISHER HISTORY........... 14 14 15 3 INTRODUCTION 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: 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. Read Before Operating 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. 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 4 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 Operator Must Be Seated Decal­ OD73 Flying Debris Decal ­ OD43 No Step Decal ­ OD11 Triangle Danger Decal ­ OD55 6 SYMBOLS & DECALS cont. Parking Brake Decal Left - 10270 Key/PTO Decal - 10273 Parking Brake Decal Right - 10279 Throttle/Choke Decal - 10271 Hydro Release - 10280 Danger/Warning Decal - 10276 Decals Not Shown OD99128 10275 10281 10542 10274 OD99125 60" Deck White Decal ZT2460 Decal Small Height Adjust Decal Replacement Parts Decal Z-Max Decal Medium Swisher Decal 7 SAFETY INSTRUCTIONS 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 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. Remember 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. 9 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: TIRE PRESSURE BATTERY HYDRO Bolt Torque BLADE BOLT TORQUE CUTTING HEIGHT CUTTING WIDTH PARKING BRAKE FRONT AXLE SEAT TRANSMISSION DECK LIFT UNIT MEASUREMENTS 70" 60 ¼" " 680 lbs 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 Before Storage 8 Hours 25 Hours 50 Hours 100 Hours Season 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 12 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 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. 16 SEE DETAILS PAGE 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. 17 SEE DETAILS PAGE OPERATION FEATURES Left Control Panel Right Control Panel 3 1 2 4 6 5 11 8 Rear of Unit 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 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 Right Turn Note: The pressure required to operate the mower is very slight 20 SERVICE & ADJUSTMENTS Adjusting The Cutting Height Push out on the Deck Lift Handle and raise or lower the deck to the desired position. Position 1 is the lowest setting and Position 8 is the highest position The cutting range is from approximately 1 ½" to approximately 5" Deck Leveling TOOLS REQUIRED: 2 - ½" Wrenches or ½" Socket with drive ratchet Lower the cutting deck down to the lowest position (position 1) Loosen the nuts on the top side of the deck hanger brackets (3 places) where the lift cables attach to. With all three loose on top of the brackets the deck should now set on the ground resting on the roller wheels. Tighten the nuts on the top of the lift brackets making sure that all three lift cables are pulled tight. Lift deck using the deck lift handle to the desired position 21 SERVICE & ADJUSTMENTS Deck Belt Routing & Replacement Removal Disconnect spark plug wire Apply parking brake Lower the deck to its lowest position Remove the belt covers Disconnect tension idler Roll the belt over the top of the deck pulleys Remove belt Replacement Install new belt by placing it around the deck pulleys. Refer to routing diagram below. The belt will be loose at this time Tightly secure the belt tension back to its original position Reinstall the belt covers Reconnect spark plug wire Front of Unit For replacement belt part number refer to Replacement Parts Quick Reference Chart in this manual 22 SERVICE & ADJUSTMENTS Hydro Belt Routing & Replacement Removal Disconnect spark plug wire Apply parking brake Disconnect wiring from electric clutch Remove clutch stop weldment (9973TK) Remove the engine to deck belt Disconnect idler spring Disconnect tension idler Remove belt from the engine pulley and from the Hydro pulleys Replacement Install new belt by placing it around the engine pulley and the hydro pulleys. Refer to routing diagram below. The belt will be loose at this time Tightly secure the belt tension back to its original position Reinstall the belt from the engine to the deck Reconnect wiring to the electric clutch Reconnect spark plug wire Idler Pulley Engine Pulley For replacement belt part number refer to Replacement Parts Quick Reference Chart in this manual 23 SERVICE & ADJUSTMENTS Engine to Deck Belt Removal Apply parking brake Lower the deck to its lowest position Disconnect tension idler Remove belt from the mower deck and the electric clutch Replacement Install new belt by placing it around the electric clutch and route it through the idler and around the deck pulley. Refer to routing diagram below. The belt will be loose at this time Tightly secure the belt tension back to its original position Seat Adjustment The Swisher ZT2460 is equipped with a 6" range sliding seat. Release the tension on the seat adjustment lever by pushing the yellow tip lever to the left. See features section in this manual Using your own weight, slide the seat to the desired position Release the lever 24 SERVICE & ADJUSTMENTS Parking Brakes The Swisher ZT2460 is equipped with an Automatic Parking Brake system on each control handle. When the control handles are in the out most position the parking brakes are on. Adjustment for the system is located on the ends of the brake cable at the hydro pan & frame Raise the rear wheel off the ground. Disengage the hydro to be adjusted with the hydro release handle at the rear of the unit Adjust so that the brake is not on when the handles are in the operator position. The wheel should turn freely. The wheel should not turn when the handle is move to the engaged or outward position. To tighten the brake, turn the adjustment nuts towards the end of the cable. Recheck adjustment with control handle Lower unit back to the ground Reengage the hydro at the rear of the unit 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 25 WIRING HARNESS 26 Item # Description Part # 1 24HP B&S Engine N/A 2 Frame Pan 9999TK 3 Lift Support Plate (right) 9937TK 4 Lift Support Plate (left) 9936TK 5 1/3-13 X 2 GR5 Bolt NB509 6 2 1/2 Cable Pulley 10211 7 1 1/2 Cable Pulley 5542 8 1/2-13 Nut NB213Z 9 1/2-13 Nyloc Nut NB281 10 Lock Plate 9922TK 11 5/16-18 X 3/4 Serrated Flg Bolt NB596 12 5/16-18 Jam Nut NB173 13 5/16-18 X 1 1/4 Serrated Flange Bolt NB253 14 Rear Deck Lift Cable 9947 15 Linkage Tab 9958TK 16 Deck Lift Weldment 9933TK 17 5/16-18 Nyloc Nut NB181 PARTS BREAKDOWN Item # Description Part # 18 Front Deck Lift Cable 9948 19 Height Adjust Handle 9952TK 20 Height Adjust Handle Grip 7826 21 Front Handle Cover 9941TK 22 5/16-18 X 2 1/2 GR5 Bolt NB138 23 5/16-18 X 3 GR2 Bolt NB563 24 5/16 SAE Washer NB275 25 Deck Lift Handle Spring 10535 26 5/16-18 Serrated Flange Nut NB170 27 5/16-18 X 1 1/2 Serrated Flange Bolt NB252 28 Solenoid Bracket Painted 9913TK 1 23 24 14 22 15 25 18 16 27 28 1312 14 17 5 8 21 20 19 2 3 10 6 26 4 11 9 7 27 Item # Description Part # PARTS 1 24 HP B&S Engine N/A 2 5/16-18 Serrated Flange Nut NB170 1 3 Spacer Engine Pulley BB105SL 4 Motor Pulley 3.25" 3753 5 1/4 X 1/2 Key Stock 4258 6 Engine Pulley Spacer Short .687 689S 7 Electric Clutch 3813 8 Washer Belleville Engine Pulley 699 9 7/16-20 X 3.25 HCF GR5 ZP NB705 10 5/16-18 X 1 1/4 Serrated Flange Bolt NB253 11 Oil Drain Valve AS122 10 12 Oil Drain Valve Cap AS123 2 BREAKDOWN 12 11 5 Not Shown Description Solenoid Assembly Wiring Harness Part # 9043 10264 3 4 6 7 8 9 14 ENGINE ASSEMBLY 13 15 16 17 Item # 13 14 15 16 17 18 19 19 Description Fuel Tank Cap Grommet Fuel Shut Off Valve Fuel Line Clamp 1/4" Fuel Line Check Valve 1/4" Part # AS100 6102NC AS119 AS120 6FLC AS140 10265 GAS TANK ASSEMBLY 28 18 PARTS BREAKDOWN 1 2 3 36 30 35 37 31 30 28 34 34 29 38 32 I te m # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4 5 10 17 39 6 7 8 9 11 12 13 24 14 14 15 23 5 21 16 25 19 18 20 26 27 22 31 33 31 De scription 1/ 4- 20 X 3/ 4 Carriage Bolt 1 1/ 2" Block Pulley 1/ 4- 20 Serrated Flg Nut Sping Assist Bracket 5/ 16- 18 X 3/ 4 Serrated Flange Bolt Pulley Mount Tab 1/ 2- 13 X 2 GR5 Bolt Cable Pulley 1/ 3- 13 GR2 Nut 1/ 2- 13 Nyloc Nut 5/ 16- 18 Serrated Flange Nut 1/ 4- 20 X 1 1/ 2 GR2 Bolt Tension Bracket Pa rt # 10547 10728 NB524 9926TK NB596 9963TK NB509 5542 NB213Z NB281 NB170 NB162 9918TK NB315 NB181 9957TK NB281 6040 5/ 16- 18 X 3 1/ 2 center of eye eye bolt 5/ 16- 18 Nyloc Nut Belt to Deck Idler Bracket 1/ 2- 13 Nyloc Nut Idler Spacer 15 16 17 18 Item # 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Description Idler Bushing Idler Bracket Painted Idler Pulley OD-2.16", ID-3/8" 3/8-16 X 1 1/2 HCC GR5 ZP Clutch Rod Spring T60 1/4-20 Flange Nut 5/16 Nylon Bushing 3/8-16 2-Way Lock Nut 3/8-16 Nyloc Nut Lower Belt Idler Arm 1/2-13 X 3 HCC GR5 Bolt ZP 3/8-16 X 2 HTC GR2 ZP 3/8 SAE Washer 3/8-16 2-Way Lock Nut Idler Pulley OD-2.75", ID-3/8" 3/8-16 HNC GR2 ZP 1/2-13 Nut GR2 ZP 5/16-18 X 1 HCC GR5 ZP 5/16-18 Serrated Flng Nut Idler Pulley V OD-3.54", ID-3/8" Clutch Rod Spring T60 Part # 6037 9944TK B27 NB107 682S NB524 NB198 NB280 NB182 3691TK NB131 NB231 NB272 NB280 7509 NB212 NB213Z NB501 NB170 3622 682S 29 PARTS BREAKDOWN 5 12 24 23 22 19 18 17 20 2 16 8 9 7 6 2 12 9 16 7 6 14 6 12 Item # Description Part # 1 60 ZT Deck weldment - painted 9901 TK 2 5/16-18 x 3/4 Serr flange bolt NB596 3 Belt Cover - painted 6025TK 4 3/8 SAE washer NB272 5 3/8-16 nyloc nut NB182 6 Anti-scalp roller 3/8 ID AS001 7 5/16-18 serrated flange nut NB101 8 Deck Hanger - painted 9938TK 9 5/16-18 serrated flange nut NB170 10 Chute mount-painted 6030TK 11 5/16-18 x 8 1/2 HCC GR2 ZP NB136 12 5/16-18 nyloc nut NB181 13 Torsion spring- bent leg 9100 14 Discharge Chute Weldment-painted 9902TK 15 3/8-16 x 5 1/2 GR5 ZP NB575 16 3/8-16 nyloc nut NB182 17 Idler Bushing 6037 18 3/8-16 x 2 1/4 HTC GR5 ZP NB693 19 Idler Arm -painted 6141TK 20 Idler Spacer 6040 21 3/8-16 x 1 1/2 HCC GR5 ZP NB107 22 Idler Pulley OD 3.25, ID 3/8 B527 26 25 4 4 3 21 7 6 5 4 3 2 2 10 11 12 13 15 28 1 6 30 1 2 PARTS BREAKDOWN Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description 3/4-16 Nut Belleville Washer Pulley 4 1/2" Spacer 3/4 ID X 1 1/4 OD 18 GA Washer Center Blade Driver Outer Blade Driver 3/4 ID X 1 3/4 OD Flat Washer Blade Mount Plate 3/8-24 Two Way Lock Nut Blade 3/8-24 X 1 1/2 Bolt Belleville Washer Blade Bearing 7" Blade Driver Shaft 5" Blade Driver Shaft Blade Driver Housing Part # NB175 AS155 B4104TK 6065PM NB179 10541 10540 B98W 9008 NB216 3293 NB167 NB607 B98 9075 9077 10539 3 4 5 14 15 6 17 14 1 5 9 11 13 12 16 7 17 10 8 3 5 14 2 Center Driver 14 5 9 10 11 13 8 12 Outside Driver 31 23 3 15 22 11 14 12 PARTS BREAKDOWN 16 2 17 24 26 27 25 8 25 32 29 31 33 28 1 30 26 10 13 18 21 14 19 4 5 20 6 9 Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Description Part # Item # 23 Hydro Pan Weldment 9935TK 24 Eaton Hydro w/ Resv & Tank 10268 25 Eaton Hydro w/ Resv & Tank & Ext 10269 26 Tire & Wheel 20 x 10 x 8 3756 27 Wheel Hub Assembly 9920 28 3/8-16x 3/4 serr flange rolok serr 10545 29 1.5 x .761 x .098 x .134 Belv washer AS155 30 5/64 x 3/4 cotter pin NB519 31 Wheel Hub Lug Nut 1/2-20 2203LN 32 Parking Brake Cable Assembly 9976 33 1/4-20 x3/4 GR5 ZP NB250 Clutch cable clevis T44ch 9023MOD 1/4-20 nylok nut NB180 Shift linkage- Painted 9919TK Hydro linkage Right Weldment 9929 Hydro linkage Left Weldment 9928 1/4-28 x 3/4 GR5 ZP NB620 1/4 SAE Washer NB274 5/16 SAE Washer NB275 1/8 x 2 Cotter Pin NB633 Latch Pin Bushing 78392 Ball Linkage right (silver) NB263 Description Battery Part # 9973TK NB596 NB170 9946TK 9923 BRS6 9924TK 10543 NB275 10544 Clutch stop weldment - painted 5/16-18 x3/4 serr flange bolt 5/16-18 serrated flange nut Rear Stabilizer-Painted Hydro release handle Spring for Idler Arm Hydro release plate - Painted 5/16-18x1 Rolock screw 5/16 sae washer 5/16-7/10 x .006 waste water NOT SHOWN Battery Hold Down 1/4-20 X 1 1/2 atc gr2 zp 1/4-20 Nylok nut 1/4 SAE Washer 1/4-20 kep nut Battery Cable 10" Red Battery Cable 10" Black Battery Cable Boot BHOLD NB162 NB180 NB274 NB203 BCSR BCSR BCBT 32 PARTS BREAKDOWN 36 22 23 33 21 6 24 25 5 5 17 5 13 11 12 19 8 20 34 37 29 28 26 27 10 9 9 15 52 45 54 46 53 57 38 39 4 2 1 56 55 47 50 40 44 41 42 3 48 43 49 Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 51 Part # 9998TK 9991TK 3803 3788 9985TK 9932TK 10548 9956TK 9992TK 3609 9927 NB699 NB212 NB174 NB272 NB280 NB507 NB275 NB181 9930TK 9990TK 3623 3605 3669 9996TK NB170 3695 NB201 9925TK 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 5/16-18 Nyloc Nut 5/16 SAE Washer Spacer 1/2-13 GR2 Nut 8-32X 1/2 Phil Truss Screw Control Panel Right 5/16-18 X 1 1/4 Serrated Flange Bolt ZT Seat 18" Seat Mount Seat Bracket Foot Plate Pivot Plate Housing Weldment Deck Stabilizer-Left Deck Stabilizer-Right Deck Stabilizing Bar Pivot Axle Weldment-Painted Blade Bearing Textured Black Caster T50 Tire/Wheel Slick 4.10x3.5-5 5/8 Bearing 5/8-11 X 7 HCC GR5 ZP 5/8 ID X 1 OD 10 GA Washer Wheel Spacer 1" 5/8-11 2 Way Lock Jam Nut 13/16 X 1 1/4 X 1/8 Washer 3/4-16 Jam Nylok Nut 5/16-18 X 1 Serrated Flange GR5 2P Axle Washer-Painted Spacer 5/16-18 Serrated Flng Nut NOT SHOWN Arm Rest Kit Mat for Pan Mat for Foot Plate 60" Choke Cable NB181 NB275 B99S NB213Z NB197 9990TK NB253 10570 9984TK 3807TK 9995TK 9954TK 9950TK 9949 9994TK B98 665TK 3010 nb624 nb178 3395 nb595 nb195 nb122 10548 9915tk B99S NB170 10571 10729 105549 9914 Description Seat Base Control Panel Hour Meter Throttle Control 35" Handle Pivot Handle Weldment 5/16-18 X 1 Serrated Flange GR5 Bolt Tool Box Neutral Bracket Tapered Spring Steering Linkage Control Arm 3/8-16 X 2 1/4 GR5 Bolt 3/8-16 GR2 3/8-16 Jam Nut 3/8 SAE Washer 3/8-16 2-Way Lock Nut 5/16-18X2 GR5 Bolt 5/16 SAE Washer 5/16-18 Nyloc Nut Handle Weldment Control Panel Right Key Switch PTO Switch Tinnerman Clips 5/16-18 Heavy Duty Side Plate 5/16-18 Serrated Flange Nut Return to Neutral Switch 8-32 Kep Nut Safety Switch Rocker Arm 33 TROUBLESHOOTING PROBLEM CAUSE 1. 2. 3. 4. 4. 5. 6. 7. Bad spark plug Dirty air filter Dirty fuel filter Water in fuel 5. 6. 7. CORRECTION Fill fuel tank Choked engine and attempt to restart Wait several minutes before attempting to restart. Replace spark plug Clean or replace air filter Replace fuel filter Drain fuel tank & carburetor, refill tank with fresh gas and replace fuel filter 1. Out of fuel Engine not "choked" properly Engine flooded Engine Will Not Start 2. 3. 8. 9. 10. 11. Loose or damaged wiring Carburetor out of adjustment Engine valves out of adjustment Extreme cold conditions 8. 9. 10. 11. Check all wiring See Engine Manual Contact an authorized service center See Engine Manual Engine Hard To Start 1. 2. 3. 4. 5. 6. 7. 8. Bad spark plug Dirty air filter Dirty fuel filter Weak or dead battery Carburetor out of adjustment Engine valves out of adjustment Loose or damaged wiring Stale or dirty fuel 1. 2. 3. 4. 5. 6. 7. 8. Replace spark plug Clean or replace air filter Replace fuel filter Recharge or replace battery See Engine Manual Contact an authorized service center Check all wiring Drain fuel tank & refill with fresh gasoline Engine Will Not Turn Over 1. 2. 3. 4. 5. 6. 7. 8. 9. Directional handles not in correct position PTO engaged Weak or dead battery Blown fuse Corroded battery terminals Loose or damaged wiring Faulty ignition switch Faulty solenoid Faulty operator presence switch/switches 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. Place handles in the out most position Push PTO switch down Recharge or replace battery Replace fusel Clean battery terminals ­ See battery section of this manual Check all wiring Check/replace ignition switch Check/replace solenoid Contact an authorized service center Recharge or replace battery Clean battery terminals ­ See battery section of this manual Check all wiring Check/replace solenoid Engine Clicks but Will Not Start 1. 2. 3. 4. Weak or dead battery Corroded battery terminals Loose or damaged wiring Faulty solenoid 34 TROUBLESHOOTING Continued PROBLEM 1. CAUSE Cutting too much grass/ too fast "Choke" position Buildup of grass, leaves and trash under deck. Dirty air filter Low oil level/dirty oil Faulty spark plug Dirty fuel filter Stale or dirty fuel Water in fuel Spark plug wire loose Dirty engine air screen/fins Dirty/clogged muffler Loose or damaged wiring Carburetor out of adjustment Engine valves out of adjustment Loose drive belt 10. 11. 12. 13. 14. 15. 16. 1. 2. 3. 4. 5. 6. 7. 8. 9. CORRECTION Set in High Cut (position 8)/reduce speed Push choke control in Clean underside of mower deck Clean or replace air filter Check oil level/change oil Clean and re-gap or change plug Replace fuel filter Drain fuel tank & refill tank with fresh gas Drain fuel tank & carburetor, refill tank with fresh gas and replace fuel filter Connect and tighten spark plug wire Clean engine air screen/fins Clean/replace muffler Check all wiring See Engine Manual Contact an authorized service center Adjust idler/replace belt Loss of Power 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Excessive Vibration 1. 2. 3. 4. Worn, bent or loose blade Bent blade driver Loose/damage part or parts Faulty blade driver assembly 1. 2. 3. 4. Replace blade. Tighten blade bolt. Replace blade driver Tighten loose part or parts. Replace damaged parts. Replace blade driver assembly Engine backfires when turning engine OFF 1. Engine throttle control not set at "SLOW" position for 30 seconds before stopping engine. 1. Move throttle control to "SLOW" position and allow to idle for 30 seconds before stopping engine 1. Incorrect tire pressure 1. Unit Does not Travel in a straight line Check tire pressure (See Specifications) 35 TROUBLESHOOTING Continued PROBLEM 1. CAUSE Worn, bent or loose blade Mower deck not level Buildup of grass, leaves and trash under deck. Bent deck Faulty Blade driver assembly 1. Bad battery Poor cable connections Faulty solenoid 3. 1. 2. 3. CORRECTION Replace blade. Tighten blade bolt Level deck. See section in this manual Clean underside of mower deck Poor cut uneven 2. 3. 4. 5. 4. 5. 1. 2. Replace deck Replace blade driver assembly Replace battery Check/clean all connections. See section in this manual Replace solenoid Battery will not charge 2. 3. 1. Bypass linkages in the bypass position Hydro belt worn, damaged, or broken Idler spring loose or broken 1. Loss of drive 2. 3. Make sure that the bypass linkages are in the drive or engaged position. Located at the rear of the machine. Refer to decal on the rear of the unit. Replace Hydro belt. Replace Idler spring 2. 3. 36 Mower Identification Each mower has its own model number. Each engine has its own model number. The model number for the mower will be found under the seat. The model number for the engine will be found on the top of the blower fan housing. All mower parts listed herein may be ordered directly from Swisher Mower & Machine Co. Inc. or your nearest Swisher dealer. All engine parts may be ordered from the nearest dealer of the engine supplied with your mower.