User manual SWISHER ZT2560 Z-MAX

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 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 t he 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 ZT2560 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 Travel Reduction Adjustment (Ref. Page 29) To improve the tracking of the Swisher ZT2560 the speed of one of the rear wheels needs to be decreased. If the ZT2560 pulls to the right the left wheel will need to decrease speed and if pulling to the left the right wheel will need to decrease speed. To decrease the speed in one of the rear wheels turn the bolt (item 40) counter clockwise. This will limit travel of the handle. Ensure after the bolt has been moved that the nuts holding the bolt in place are securely tightened. 24 SERVICE & ADJUSTMENTS Parking Brakes The Swisher ZT2560 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 PARTS BREAKDOWN Item # Description Part # 1 25HP 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 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 24 23 22 14 15 25 18 16 21 27 28 13 12 14 17 20 19 2 3 5 8 10 6 26 4 7 11 9 27 PARTS BREAKDOWN 1 Item # Description Part # 1 25 HP B&S Engine N/A 2 5/16-18 Serrated Flange Nut NB170 3 Spacer Engine Pulley BB105SL 4 Motor Pulley 3.25" 9993 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 10 5/16-18 X 1 1/4 Serrated Flange Bolt NB253 2 11 Oil Drain Valve AS122 3 12 Oil Drain Valve Cap AS123 12 11 5 4 6 Not Shown Description Solenoid Assembly Wiring Harness Part # 9043 10264 7 8 9 14 ENGINE ASSEMBLY 13 15 16 17 19 Item # 13 14 15 16 17 18 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 18 GAS TANK ASSEMBLY 28 PARTS BREAKDOWN 1 2 3 36 30 35 11 31 30 28 34 34 29 Item # 19 31 20 21 Description Part # 22 23 1/4-20 X 3/4 Carriage Bolt 10547 24 1 1/2" Block Pulley 10728 25 1/4-20 Serrated Flg Nut NB524 26 Sping Assist Bracket 9926TK 27 5/16-18 X 3/4 Serrated Flange Bolt NB596 28 Pulley Mount Tab 9963TK 29 1/2-13 X 2 GR5 Bolt NB509 30 Cable Pulley 5542 31 1/2-13 Nut GR2 ZP NB213Z 32 1/2-13 Nyloc Nut NB281 5/16-18 Serrated Flange Nut NB170 33 1/4-20 X 1 1/2 GR2 Bolt NB162 34 Tension Bracket 9918TK 35 5/16-18 X 3 1/2 eye bolt NB315 36 38 5/16-18 Nyloc Nut NB181 39 Belt to Deck Idler Bracket 9957TK 40 1/2-13 Nyloc Nut NB281 41 Idler Spacer 6040 11 4 5 6 7 10 17 19 40 39 12 89 11 24 13 14 14 15 23 25 5 21 16 41 18 20 26 27 22 31 33 38 32 Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 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 3/8-16 X 2 HCC GR5 ZP 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 Idler Pulley V OD-3.54", ID-3/8" Clutch Rod Spring T60 5/16-18 X 1 1/2 Flge Serr. Bolt Travel Reduction Brkt Txt Blk Part # 6037 9944TK B27 NB107 682S NB524 NB198 NB280 NB182 3691TK NB131 NB231 NB272 NB280 7509 NB212 NB213Z NB501 3622 682S NB254 11176TK 29 PARTS BREAKDOWN IDLER DETAIL Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description 60 ZT Deck Weldment 5/16-18 x 3/4 Serr flange bolt Belt Cover 3/8 SAE washer 3/8-16 nyloc nut Anti-scalp roller 3/8 ID 3/8-16 X 4 Carriage Bolt Deck Hanger 5/16-18 serrated flange nut Chute mount 5/16-18 x 8 1/2 HCC GR2 ZP 3/8-16 Nyloc Nut ZY Torsion spring- bent leg Discharge Chute Part # 9901TK NB596 6025TK NB272 NB182 AS001 NB707 9938TK NB170 6030TK NB136 NB182 9100 9902TK Item # 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Description 3/8-16 x 5 1/2 GR5 ZP 3/8-16 nyloc nut Idler Bushing 3/8-16 x 2 1/4 HTC GR5 ZP Idler Arm -painted Idler Spacer 3/8-16 x 1 1/2 HCC GR5 ZP Idler Pulley OD 3.25, ID 3/8 3/8-16 2-way lock nut 3/8-16 Jam nut 3/8-16 Nylock nut Jam Two speed spring (A232 1998) Rear Roller Bracket 5/16-18 x 3 1/2 Center of Eye-5/8 Eye Part # NB575 NB182 6037 NB693 6041TK 6040 NB107 B527 NB280 NB174 NB207 TZ2S 10775 NB315 30 1 2 PARTS BREAKDOWN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 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 Bolt Belleville Washer Blade Bearing 7" Blade Driver Shaft 5" Blade Driver Shaft Blade Driver Housing 3/8-24 X 1 Engine Bolt Locktite NB175 AS155 B4104TK 6065PM NB179 10541 10540 B98W 9008 NB216 3293 NB238 NB607 B98 9075 9077 10539 NB238N 3 4 5 14 15 17 6 14 1 5 9 11 18 13 12 16 7 17 10 8 3 5 14 2 Center Driver 14 5 9 10 11 13 8 12 18 Outside Driver 31 23 3 PARTS BREAKDOWN 15 22 16 11 2 17 14 12 18 21 13 14 5 20 19 10 24 26 27 25 25 26 8 4 32 29 31 33 28 1 30 6 7 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 Hydro Pan Weldment Eaton Hydro w/ Resv & Tank Eaton Hydro w/ Resv & Tank & Ext Tire & Wheel 20 x 10 x 8 Wheel Hub Assembly Hex Flng Serr Screw ZP 3/8-16 1.5 x .761 x .098 x .134 Belv washer 5/64 x 3/4 cotter pin Wheel Hub Lug Nut 1/2-20 Parking Brake Cable Assembly 1/4-20 x3/4 GR5 ZP Clutch cable clevis T44ch 1/4-20 nylok nut Shift linkage- Painted Hydro linkage Right Weldment Hydro linkage Left Weldment 1/4-28 x 3/4 GR5 ZP 1/4 SAE Washer 5/16 SAE Washer 1/8 X 3/4 Cotter Pin Latch Pin Bushing Ball Linkage right (silver) Part # 9935TK 10268 10269 3756 9920TK NB780 AS155 NB519 2203LN 9976 NB250 9023MOD NB180 9919TK 9929 9928 NB620 NB274 NB275 NB125 78392 NB263 Item # 23 24 25 26 27 28 29 30 31 32 33 Description Battery 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 wave washer 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 Part # 9973TK NB596 NB170 9946TK 9923 BRS6 9924TK 10543 NB275 10544 BHOLD NB162 NB180 NB274 NB203 BCSR BCSR 32 PARTS BREAKDOWN Item # Description 1 Seat Base 2 Control Panel 3 Hour Meter 4 Throttle Control 35" 5 Handle Pivot 6 1" Dir. Handle Weldment, Right Txt Blk 7 5/16-18 X 1 Serrated Flange GR5 Bolt 8 Storage Compartment 9 5.5" Neutral Bracket Txt Blk 10 Tapered Spring 11 Steering Linkage Control Arm 12 3/8-16 X 2 1/4 GR5 Bolt 13 3/8-16 GR2 14 3/8-16 Jam Nut 15 3/8 SAE Washer 16 3/8-16 2-Way Lock Nut 17 5/16-18X2 GR5 Bolt 18 5/16 SAE Washer 19 5/16-18 Nyloc Nut 20 1" Dir. Wldmnt, Left Txt Blk 21 Control Panel Right 22 Key Switch 23 PTO Switch 24 Tinnerman Clips 5/16-18 Heavy Duty 25 Side Plate 26 5/16-18 Serrated Flange Nut 27 Return to Neutral Switch 28 8-32 Kep Nut 29 Safety Switch Rocker Arm Part # 9998TK 9991TK 3803 3788 9985TK 11768TK 10548 9956TK 10899TK 3609 9927 NB693 NB212 NB174 NB272 NB280 NB507 NB275 NB181 11769TK 9990TK 3623 3605 3669 9996TK NB170 3695 NB201 9925TK 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 5/16-18 Nyloc Nut NB181 5/16 SAE Washer NB275 Spacer B99S 1/2-13 GR2 Nut NB213Z 8-32X 1/2 Phil Truss Screw NB197 5/16-18 X 1 1/4 Serrated Flange Bolt NB253 ZT Seat 18" 10570 Seat Mount 9984TK Seat Bracket 3807TK Foot Plate 9995TK Pivot Plate Housing Weldment 9954TK Deck Stabilizer-Left 9950TK Deck Stabilizer-Right 9951TK Deck Stabilizing Bar 9949 Pivot Axle Weldment-Painted 9994TK Blade Bearing B98 Textured Black Caster T50 665TK Tire/Wheel Slick 4.10x3.5-5 5/8 Bearing 3010 5/8-11 X 7 HCC GR5 ZP NB624 5/8 ID X 1 OD 10 GA Washer NB178 Wheel Spacer 1" 3395 5/8-11 2 Way Lock Jam Nut NB595 13/16 X 1 1/4 X 1/8 Washer NB195 3/4-16 Jam Nylok Nut NB122 5/16-18 X 1 Serrated Flange GR5 2P 10548 Axle Washer-Painted 9915TK Spacer B99S 5/16-18 Serrated Flng Nut NB170 Height Indicator Bracket Txt Blk 11770TK NOT SHOWN Arm Rest Kit 10571 Mat for Pan 10729 Mat for Foot Plate 10549 NOT SHOWN Seat Grommet Seat Spring 1/4-20 X 1 1/2 HCCGR2ZP 1/4 SAE Washer 1/4-20 Nylok Nut 60" Choke Cable 9931 3609 NB104Z NB274 NB180 9914 33 TROUBLESHOOTING PROBLEM 1. CAUSE Out of fuel Engine not "choked" properly Engine flooded 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 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 Check all wiring See Engine Manual Contact an authorized service center See Engine Manual Open Engine Will Not Start 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Bad spark plug Dirty air filter Dirty fuel filter Water in fuel Loose or damaged wiring Carburetor out of adjustment Engine valves out of adjustment Extreme cold conditions Fuel shut off valves closed 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. 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 Engine Clicks but Will Not Start 1. 2. 3. 4. Weak or dead battery Corroded battery terminals Loose or damaged wiring Faulty solenoid 1. 2. 3. 4. Recharge or replace battery Clean battery terminals ­ See battery section of this manual Check all wiring Check/replace solenoid 34 TROUBLESHOOTING Continued PROBLEM Loss of Power 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 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 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 Unit Does not Travel in a straight line 1. 2. Incorrect tire pressure Rear wheels rotating at different speeds. 1. 2. Check tire pressure (See Specifications) Adjust travel reduction weldment. 35 TROUBLESHOOTING Continued PROBLEM Poor cut uneven 1. 2. 3. 4. 5. 1. 2. 3. CAUSE Worn, bent or loose blade Mower deck not level Buildup of grass, leaves and trash under deck. Bent deck Faulty Blade driver assembly 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 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 Loss of drive 1. 2. 3. Bypass linkages in the bypass position Hydro belt worn, damaged, or broken Idler spring loose or broken 1. 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. Unauthorized Replacement Parts Use only Swisher replacement parts. The replacement of any part on this unit with anything other than Swisher authorized replacement part may adversely affect the performance, durability and safety of this unit and may void the warranty. Swisher disclaims liability for any claims or damages, whether warranty, property damage, personal injury or death arising out of the use of unauthorized replacement parts. WHEN ORDERING PARTS, PLEASE HAVE THE FOLLOWING INORMATION AVAILABLE: ·Date Purchased ____________________ ·Purchased From____________________ ·PRODUCT ­ ZT2560 ·SERIAL NUMBER - _______________ ·MODEL NUMBER - _______________ ·ENGINE MODEL NUMBER - _______________ TYPE - _______________ ·PART NUMBER WITH PAINT CODE__________________ *PART DESCRIPTION______________________________ SWISHER MOWER & MACHINE CO. INC. 1602 CORPORATE DRIVE P.O. BOX 67 WARRENSBURG, MO 64093 Swisherinc.com TELEPHONE - 1-800-222-8183 FAX - 1-660-747-8650 Cust.serv@swisherinc.com 37 Replacement Parts Quick Reference Swisher Part # 9947 9948 AS069 6046 3756 5058 3293 10263 10540 10541 Part Description Rear Deck Lift Cable Front Deck Lift Cable Fuse 10 Amp 47" Hydro Belt 20 x 10 x 8 Rear Tire 122" Deck Belt 20.5 Mulching Blade 83" Engine to Deck Belt Blade Driver Assembly (outside) Blade Driver Assembly (center) CAUTION Use extreme care when working on machinery. Before performing any maintenance, turn off engine, allow the unit to cool & remove the key. Disconnect spark plug wire. Set Parking Brake by placing the control handles in the neutral or outward position. Do not wear watch or jewelry. Do not wear loose fitting clothes. Observe all common safety practices with tools. 38 WARRANTY RIGHTS AND OBLIGATIONS YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and Swisher Mower, is pleased to explain the evaporative emission control system (EECS) on your model year 2006 and later Swisher Product. In California, new Outdoor Power Equipment, must be designed, built and equipped to meet the State's stringent anti-smog standards. Swisher Mower must warrant the EECS on your Power Equipment, for the period of time listed below provided there has been no abuse, neglect, or improper maintenance. For model year 2006 the EECS on your mower includes the liquid fuel lines, fuel line connectors, and fuel line clamps. Where a warrantable condition exists, Swisher Mower will repair at no cost to you. Expenses covered under warranty include diagnosis, parts, and labor. MANUFACTURER'S WARRANTY COVERAGE: For a period of two years, any evaporative emission-related part included in the list of EECS parts for your mower is defective, the part will be repaired or replaced by Swisher Mower. OWNER'S WARRANTY RESPONSIBILITIES: As the owner of this Power Equipment, you are responsible for performance of the required maintenance listed in your owner's manual. Swisher Mower recommends that you retain all receipts covering maintenance on your Power Equipment, but Swisher Mower cannot deny warranty solely for the lack of receipts. As the Power Equipment owner, you should be aware that Swisher Mower, may deny you warranty coverage if your Power Equipment, or a covered part has failed due to abuse, neglect, or improper maintenance, unapproved modifications, or the use of parts not made or approved by the equipment manufacturer. You are responsible for presenting your Power Equipment to an authorized Swisher Service center as soon as the problem exists. Warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty rights and responsibilities, you should contact the Swisher Mower Service representative at 1-800-222-8183. WARRANTY COMMENCEMENT DATE: The warranty period begins on the date the Power Equipment Is purchased. LENGTH OF COVERAGE: This warranty shall be for a period of two (2) years from the initial date of purchase. WHAT IS COVERED: Warranted parts include the Liquid fuel line, fuel line connectors, and fuel line clamps. REPAIR OR REPLACEMENT OF PARTS: Repair or replacement of any evaporative warranted part will be performed at no charge to the owner at an authorized Swisher Mower Service Center. If you have a question regarding your warranty rights and responsibilities, you should contact your nearest authorized service center or call the Swisher Mower Service representative at 1800-222-8183. WARRANTY PERIOD: Any warranted part is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of "repair or replace as necessary" shall be warranted for two (2) years. Any warranted part that is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part. DIAGNOSIS: The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized Swisher Service Center. CONSEQUENTIAL DAMAGE: Swisher Mower, may be liable for damages to other engine or equipment components caused by the failure of a warranted part still under warranty. WHAT IS NOT COVERED: All failures caused by abuse, neglect, or improper maintenance is not covered. ADD-ON OR MODIFIED PARTS: The use of add-on or modified parts may be grounds for disallowing a warranty claim. Swisher Mower is not liable to cover failures of warranted parts caused by the use of an add-on or modified part. HOW TO FILE A CLAIM: If you have a question regarding your warranty rights and responsibilities, you should contact your nearest authorized service center or call Swisher Mower Service representative at 1-800-222-8183. 39 SWISHER HISTORY Back before electricity came to rural Missouri Max Swisher was producing lawn mowers from his mother's chicken house. Max never liked to mow grass. He installed a gearbox on his family's lawn mower creating a self-propelled unit. By tying one end of a rope to the mower and the other end to a tree in the center of the yard the mower circled the tree, shortening the rope and guiding the mower in concentric circles. Max enjoyed relaxing under a shade tree while his invention did all the work. Max had designed his first self-propelled rotary lawn mower to do his dirty work for him. Neighbors noticed his new invention and began asking him to make more. Today, 60 years later, Swisher Mower and Machine Company, Inc. is still producing innovative lawn and garden and ATV/UTV equipment designed to give us all more "relaxing in the shade" time. Swisher products have been featured nationally on television programs such as Regis and Kathie Lee and seen in publications like ATV Magazine, Country Journal, Popular Mechanics Magazine and others. In January 2000 Popular Mechanics Magazine named Max's zero turning radius riding mower one of the 20th century's top household inventions. Swisher offers value and function in its products to meet your grounds maintenance needs. CELEBRATING OVER 60 YEARS OF INNOVATION 1945 - 2006 40