Swisher ZT2560 Zero Turn Riding Mower Owner's Manual

ZT2560

25 HP – 60” CUT

CELEBRATING OVER 65 YEARS OF INNOVATION SINCE 1945

1602 CORPORATE DRIVE, P.O. BOX 67, WARRENSBURG, MISSOURI 64093 PHONE 660-747-8183 FAX 660-747-8650

Manufacturing quality lawn care equipment since 1945

OWNER’S MANUAL

STARTING SERIAL # L507-009001 11849

Made In The USA

Rev. 07-009

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.

2) Commercial Use

3) Limitation

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.

4) Exclusions 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.

CONTENTS

INT RODUCT ION………………

4 General use and safety rules…8

CUST OM ER RESPONSIBILIT Y……………

12

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.

Set 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.

AT

Close the transmission valves at the rear of the unit.

SEE INSTRUCTION DECAL THE REAR OF THE UNIT

.

Reconnect spark plug wire.

Check tire pressure on all four wheels.

REFER TO UNIT SPECIFICATIONS TABLE

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

SYMBOLS & DECALS cont.

Key/PTO Decal - 10273 Throttle/Choke Decal - 10271 Hydro Release 10280 10275 11839 OD9128 Danger/Warning Decal - 10276

Decals Not Shown

XZT60 Decal Small Height Adjustment Decal 60” Deck White Decal 13072 10274 OD99125 Replacement Parts Decal Z-Max Decal Medium Swisher Decal

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.

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.

Remember The operator is responsible for avoiding dangers or accidents.

Only operate the machine in daylight or other well-lit conditions.

WARNING

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.

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.

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.

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.

Remember

Always drive evenly and slowly on slopes.

The operator is

Make no sudden changes in speed or direction.

responsible for

Avoid unnecessary turns on slopes, and if it proves

avoiding dangers or

necessary, turn slowly and gradually downward, if possible.

accidents.

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.

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.

SPECIFICATIONS

GASOLINE CAPACITY AND TYPE OIL TYPE (SPI-SF-SJ): SPARK PLUG GROUND SPEED TIRE SIZE TIRE PRESSURE BATTERY HYDRO Bolt Torque BLADE BOLT TORQUE CUTTING HEIGHT CUTTING WIDTH PARKING BRAKE FRONT AXLE SEAT TRANSMISSION DECK LIFT UNIT MEASUREMENTS 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: 70” WIDTH: 60 ¼” “ Including Deck WEIGHT: 680 lbs

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.


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).

Battery

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

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


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.

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


MAINTENANCE SCHEDULE

Before Each Use

X

8 Hours 25 Hours 50 Hours 100 Hours Season

X X X X X X X X X 3 X X X 1,2 X 1,2 X X X 1,2

Before Storage

X X X

Clean Air Filter Inspect Muffler Clean Engine Cooling Fins Replace Spark Plug Replace Fuel Filter

X 2 X X X 2 X X

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

FEATURES

9

OPERATION

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 12 7.

8.

9.

10.

11.

12.

13.

Control Levers – Sets the speed of the mower in both the forward and reverse directions and also turns the mower .

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

SEE DETAILS PAGE

9

FEATURES

OPERATION

7 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 13 7.

8.

9.

10.

11.

12.

13.

Control Levers – Sets the speed of the mower in both the forward and reverse directions and also turns the mower.


SEE DETAILS PAGE

FEATURES

Left Control Panel 3 1

OPERATION

2 4 Right Control Panel 6 5 1.

2.

3.

4.

5.

6.

8 11 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 Rear of Unit 7.

8.

9.

10.

11.

12.

13.

Control Levers – Sets the speed of the mower in both the forward and reverse directions and also turns the mower.


OPERATION

Starting

Operator must be sitting in the seat. Control handles must be in the neutral (outward) position. Parking brake must be on. 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. Set engine RPM to maximum and then engage the blades.

Grass Height & Cutting Suggestions

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. 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.

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

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


Deck Belt Routing & Replacement

Removal

Disconnect spark plug wire Apply parking brake

Replacement

Install new belt by placing it around the deck pulleys. Refer to routing diagram below.

Lower the deck to its lowest position Remove the belt covers The belt will be loose at this time Disconnect tension idler Roll the belt over the top of the deck pulleys Tightly secure the belt tension back to its original position Reinstall the belt covers Remove belt Reconnect spark plug wire Front of Unit For replacement belt part number refer to Replacement Parts Quick Reference Chart in this manual


Hydro Belt Routing & Replacement

Removal

Disconnect spark plug wire Apply parking brake Disconnect wiring from electric clutch

Replacement

Install new belt by placing it around the engine pulley and the hydro pulleys. Refer to routing diagram below.

Remove clutch stop weldment (9973TK) The belt will be loose at this time Remove t he engine to deck belt Tightly secure the belt tension back to its original position Disconnect idler spring Disconnect tension idler Reinstall the belt from the engine to the deck Remove belt from the engine pulley and from the Hydro pulleys 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

Engine to Deck Belt

SERVICE & ADJUSTMENTS 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.


Parking Brakes

The Swisher ZT2560 is equipped with a Parking Brake system activated by pulling the brake knob (10) up.

Adjustment for the system is located on the ends of the brake weldment rod (18).

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 25

ITEM #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

DESCRIPTION

Weldment ; Rod Mount - ZTR Brake Plat e; Clasp - ZTR Brake Weldment ; Rod Piv ot Weldment ; ZTR Brake Linkage - Left Weldment ; ZTR Brake Linkage - Right Spacer 5/16-18 x 3/4 FLA NGE BOLT 5/16-18 SERR FLA NGE NUT Weldment ; Push Rod, ZTR Brake SHIFT KNOB 3/32 X 1 Cot t er Pin 1/4-20 Flange Nut 5/16-18 Jam Nut 1/4-20 X 3/4 Flange (Self Cut t ing) Two Speed Spring (A Z32 1998) 1/4 SAE Washer 1/4-20 Nylok Nut Link - Clut ch Chain

PART #

13190 13191 13195 13202 13198 B99S NB596 NB170 13207 B19 NB708 NB524 NB173 NB690 TZ2S NB274 NB180 T2L

WIRING HARNESS

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

Item #

1 2 3 4 5 6 7 8 9 10 11 PARTS BREAKDOWN

Description

Frame Pan Lift Support Plate (right) Lift Support Plate (left) Lock Plate Bolt - Self Tapping, 5/16-18 9" X 1.25" Steering Linkage Txt Blk Spacer 5/16-18 X 1 1/4 Serrated Flange Bolt Linkage Tab 5/16-18 Serrated Flange Nut Solenoid Bracket Painted

Part #

9999 9937 9936 9922 26x249 10898 B99S NB253 9958 NB170 9913

Item #

12 13 14 15 16 17 18 19 20 21 22 23

Description

Height Adjust Handle Deck Lift Handle Spring 5/16-18 X 2 1/2 GR5 Bolt 5/16 SAE Washer Nut - Nyloc 5/16-18 ZY Front Handle Cover 5/16-18 X 3 GR2 Bolt Bolt - 5/16-18 X 1 1/4 HCC GR5 ZY Bushing - Latch Pin Height Adjust Handle Grip Deck Lift Weldment Bolt - 5/16-18 X 1 1/2 HCC GR5 ZY

Part #

9952 10535 NB138 NB275 NB181 9941 NB563 NB504 7839Z 7826 12838 NB505

PARTS BREAKDOWN

Item #

1 2 3 4 5 6 7 8 9 10 11 12

Description Part #

25 HP B&S Engine 5/16-18 Serrated Flange Nut Spacer Engine Pulley Motor Pulley 3.25" 1/4 X 1/2 Key Stock N/A NB170 BB105SL 9993 4258 Engine Pulley Spacer Short .687

Electric Clutch Washer Belleville Engine Pulley 7/16-20 X 3.25 HCF GR5 ZP 689S 3813 699 NB705 5/16-18 X 1 1/4 Serrated Flange Bolt NB253 Oil Drain Valve AS122 Oil Drain Valve Cap AS123

Not Shown

Description

Solenoid Assembly Wiring Harness

Part #

9043 10264

ENGINE ASSEMBLY

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

Not Shown

Bracket - Gas Tank Mounting 9978TK

GAS TANK ASSEMBLY

PARTS BREAKDOWN

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

Description

Deck - Lift Linkage Assembly 5/16-18 Serrated Flange Nut Bolt - Carriage 5/16-18 X 3/4 GR5 ZY Bolt - 5/16-18 X 1 1/4 HCC GR5 ZY Washer - SAE 5/16 ZY Bushing - Latch Pin 5/16-18 Nyloc Nut Strap - Linkage, Painted Tension Bracket 5/16-18 X 3 1/2 eye bolt Deck - Belt, Idler Assy Idler Pulley OD-2.16", ID-3/8" Bolt - HCC 3/8-16 X 1 1/2 GR5 ZY Idler Spacer Idler Bushing Bolt - Serr Flange, 5/16-18 X 1 1/2 Travel Reduction Brkt Txt Blk Sping Assist Bracket Spring - Clutch Rod; T60 Bolt - HTC, 3/8-16 X 2 GR5 ZY Nut - 1/2-13 GR2 ZY Arm - Lower Belt Idler Nut - HNC, 3/8-16 GR2 ZY Pulley - Idler OD-2.75", ID-3/8" Washer - SAE Flat 3/8 ZY Nut - 2 Way Lock 3/8-16 ZY Bolt - HCC 1/2-13 X 3 GR5 ZY

Part #

12777 NB170 10216 NB504 NB275 7839Z NB181 12878 9918 NB315 10534 B27 NB107 6040 6037 NB254 11176 9926 682S NB231 NB213Z 3691 NB212 7509 NB272 NB280 NB131

Item #

28 29 30 31 32 33 34 35 36 37

Description

Chain - Deck Hanger Two Links Chain - Deck Hanger 8 Links Bolt - Serr Flange, 5/16-18 X 3/4 Gr 5 Belt to Deck Idler Bracket 3/8-16 Nyloc Nut Idler Bracket Painted Bolt - HCC 3/8-16 X 2 GR5 ZY Shackel - Anchor 1/4" Pulley - Idler V OD-3.54", ID-3/8" Nut - Nyloc 1/2-13 ZY

Part #

12825 12826 NB596 9957 NB182 9944 NB198 12957 3622 NB281

PARTS BREAKDOWN

LIFT DETAIL 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 29 30 31 32

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 Eyebolt - 5/16-18 X 2 Eyebolt - 5/16-18 x 2 3/4" ZY (FRONT) Nut - 5/16-18 HNC GR2 ZY Washer - Fender, 5/16 X 1 1/4 Bushing - Latch Pin

Part #

NB575 NB182 6037 NB693 6041TK 6040 NB107 B527 NB280 NB174 NB207 TZ2S 10775 NB315 10198 2046 NB210Z NB579 7839Z

Center Driver

1 2 3 4 5

6 7

8 9 10 11 12 13 14 15 16 17 18 PARTS BREAKDOWN 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 6" Blade Driver Shaft 5" Blade Driver Shaft Blade Driver Housing 3/8-24 X 1 Engine Bolt Locktite NB175 AS155 B4104 12823 NB179 12824 10540 B98W 9008 NB216 3293 NB238 NB607 B98 9078 9077 10539TK NB238N

Outside Driver

PARTS BREAKDOWN

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

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 Screw - 3/8 - 16 Rolok 1.5 x .761 x .098 x .134 Belv washer 5/64 x 3/4 cotter pin Wheel Hub Lug Nut 1/2-20 Support - Hydro Connector - Hydro Support Screw - .312 - 18 X .75

WASHER .37 SQ 16 GA FLAT 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) Battery Clutch Stop Weldment

Part #

9935 10268 10269 3756 9920 13044 AS155 NB519 2203LN 13082 13083 26X249 17X148 9919 9929 9928 NB620 NB274 NB275 NB125 78392 NB263 9973

Item #

25 26 27 28 29 30 31 32 33 34

Description

5/16-18 X 3/4 Serr Flng Bolt 5/16-18 Serrated Flng Nut ZY Rear Stabilizer Hydro Release Handle Spring for Idler Arm Hydro Release Plate 5/16-18 X 1 Rolock Screw ZY 5/16 SAE Washer ZY 5/16 X 7/10 X .006 Sp Wave Washer Washer - 3/8 lock, External Tooth; ZT

NOT SHOWN

Battery Hold Down 1/4-20 X 1 1/2 HTC GR2 ZY 1/4-20 Nylok Nut 1/4 SAE Washer 1/4-20 Kep Nut ZY Battery Cable 10" Red Battery Cable 10" Black

Part #

NB596 NB170 9946 9923 BRS6 9924 10543 NB275 10544 13045 BHOLD NB162 NB180 NB274 NB203 BCSR BCSR

PARTS BREAKDOWN

Item #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 24 25 26 27 28 16 17 18 19 20 21 22 23

Description

Seat Base Control Panel Hour Meter Throttle Control 35" Handle Pivot 1" Dir. Handle Weldment, Right Txt Blk 5/16-18 X 1 Serrated Flange GR5 Bolt Storage Compartment 5.5" Neutral Bracket Txt Blk 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 Height - Selector, Deck, Txt Blk Arm - Control, Painted Txt Blk 1" Dir. Wldmnt, Left Txt Blk Control Panel Right Key Switch PTO Switch Side Plate 5/16-18 Serrated Flange Nut Return to Neutral Switch 8-32 Kep Nut Safety Switch Rocker Arm

Part #

9998 9991 3803 3788 9985 11768 10548 690424 10899 3609 9927 NB693 NB212 NB174 NB272 NB280 NB507 9940 9986 11769 9990 3623 3605 9996 NB170 3695 NB201 9925 29 30 31 32 33 34 35 36 37 38 39 40 49 50 51 52 53 41 42 43 44 45 46 47 48 5/16-18 Nyloc Nut 5/16 SAE Washer Spacer 1/2-13 GR2 Nut 8-32X 1/2 Phil Truss Screw 5/16-18 X 1 1/4 Serrated Flange Bolt ZT Seat 15" 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 Bracket - Height Indicator Txt Blk Washer - Axle,Textured Black NB181 NB275 B99S NB213Z NB197 NB253 10569 9984 3807 9995 9954 9950 9951 9949 9994 B98 665 3010 NB624 NB178 3395 NB595 NB195 NB122 11770 9915

NOT SHOW N

Arm Rest Kit Mat for Pan Mat for Foot Plate Seat Grommet 1/4-20 X 1 1/2 HCCGR2ZP 1/4 SAE W asher 1/4-20 Nylok Nut 60" Choke Cable 10571 10729 10549 9931 NB104Z NB274 NB180 9914

TROUBLESHOOTING

PROBLEM CAUSE CORRECTION Engine Will Not Start

1.

2.

3.

Out of fuel Engine not “choked” properly Engine flooded 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 8.

9.

10.

11.

12.

1.

2.

3.

4.

5.

6.

7.

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 Hard To Start Engine Will Not Turn Over Engine Clicks but Will Not 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 1.

2.

3.

4.

6.

7.

8.

9.

1.

2.

3.

4.

5.

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 6.

7.

8.

9.

1.

2.

3.

4.

5.

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 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

TROUBLESHOOTING Continued

PROBLEM CAUSE CORRECTION Loss of Power

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

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.

6.

7.

8.

9.

1.

2.

3.

4.

5.

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.

TROUBLESHOOTING Continued

PROBLEM CAUSE CORRECTION Poor cut uneven Battery will not charge

1.

2.

3.

1.

2.

3.

4.

5.

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 1.

2.

3.

Replace blade. Tighten blade bolt Level deck. See section in this manual Clean underside of mower deck 4.

5.

1.

2.

3.

Replace deck Replace blade driver assembly Replace battery Check/clean all connections. See section in this manual Replace solenoid

Loss of drive

1.

2.

3.

Bypass linkages in the bypass position Hydro belt worn, damaged, or broken Idler spring loose or broken 1.

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

Mower Identification Unauthorized Replacement Parts

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. 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

[email protected]

Replacement Parts

Quick Reference

Swisher Part # Part Description 12777 AS069 6046 3756 5058 3293 10263 10540 12824 Deck Lift Linkage Assy Fuse 10 Amp 47” Hydro Belt 20 x 10 x 8 Rear Tire 122” Deck Belt 20.5 Mulching Blade 84” 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.

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 1-800-222-8183. 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.

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 20 th century’s top household inventions. Swisher offers value and function in its products to meet your grounds maintenance needs.

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