Swisher ZT2460 Zero Turn Riding Mower Owner Manual

ZT2460
ZT2460
24 HP – 60” CUT
CELEBRATING OVER 65 YEARS OF INNOVATION
SINCE 1945
1602 CORPORATE DRIVE, WARRENSBURG MISSOURI 64093
PHONE 660-747-8183 FAX 660-747-8650
Made In The
Manufacturing quality lawn care equipment since 1945
USA
1
OWNER’S
MANUAL
STARTING SERIAL # L505-040001
10277 Rev 05-109
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
2) Commercial Use
3) Limitation
4) Exclusions
All engines utilized on our products have a separate warranty
extended to them by the individual engine manufacturer. Any
engine service difficulty is the responsibility of the engine
manufacturer and in no way is Swisher Mower Co., Inc. or its
agents responsible for the engine warranty. The Briggs &
Stratton Engine Service Hot-Line is 1-800-233-3723. The
Tecumseh Engine Service Hot-Line is 1-800-558-5402.
This product is not intended for commercial use and
carries no commercial warranty.
This warranty applies only to products which have been
properly assembled, adjusted, and operated in accordance
with the instructions contained within this manual. This
warranty does not apply to any product of Swisher Mower
Co., Inc., that has been subject to alteration, misuse, abuse,
improper assembly or installation, shipping damage, or to
normal wear of the product.
Excluded from this warranty are normal wear, normal
adjustments, and normal maintenance.
In the event you have a claim under this warranty, you must return the product to an
authorized service dealer. All transportation charges, damage, or loss incurred during
transportation of parts submitted for replacement or repair under this warranty shall be borne
by the purchaser. Should you have any questions concerning this warranty, please contact
us toll-free at 1-800-222-8183. The model number, serial number, date of purchase, and the
name of the authorized Swisher dealer from whom you purchased the mower will be needed
before any warranty claim can be processed.
THIS WARRANTY DOES NOT APPLY TO ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE SAME TIME
PERIODS STATED HEREIN FOR ALL EXPRESSED WARRANTIES. Some states do not
allow the limitation of consequential damages or limitations on how long an implied warranty
may last, so the above limitations or exclusions may not apply to you. This warranty gives
you specific legal rights and you may have other rights, which vary from state-to-state. This is
a limited warranty as defined by the Magnuson-Moss Act of 1975.
2
CONTENTS
OPERATION………………..………. 16
LIMITED WARRANTY……….
2
INTRODUCTION………………
4
Features………………………
16
General…………………………
4
Starting……………………….
19
Before Operating………………….
4
Grass Height of Cut………….
19
Uncrating & Assembly……….
5
Controls………...……..………
20
SYMBOLS & DECALS……….
6
SERVICE & ADJUSTMENTS..
21
SAFETY INSTRUCTIONS….
8
Adjusting Deck Height…….
21
General use and safety rules…
8
Deck Level…………………
21
Slope Operation………………
10
Deck Belt Replacement….
22
Children Safety………………
10
Hydro Belt Replacement….
23
11
Seat Adjustment…………..
24
Parking Brakes……………
25
SPECIFICATIONS…………..
CUSTOMER
RESPONSIABLITY…………
Operator Presence……….
Tires…………………………..
Blade Maintenance…………
Battery…………………………
V-belts……………………….
Engine……………………….
12
WIRING SCHEMATIC………
26
PARTS BREAKDOWN………
27
TROUBLESHOOTING……….
34
MOWER IDENTIFICATION….
37
REPLACEMENT PARTS……
38
MAINTENCE LOG……………
39
SWISHER HISTORY………..
40
12
12
13
13
14
14
Overall Unit Care…………....
14
Transporting Safety…………
14
Maintenance……….…………
15
3
INTRODUCTION
Introduction
Congratulations
Thank you for purchasing a Swisher Zero Turn mower. This machine is built for the greatest
efficiency and rapid mowing of large areas. Conveniently located controls and dual
commercial grade hydrostatic transmissions regulated by steering levers, contribute to the
machine’s performance.
This manual is a valuable document. Following the instructions for use, service,
maintenance, etc. can greatly increase the life-span of your machine .
General
In this operator’s manual, left and right, backward and forward are used in relation to the normal
operators position.
NOTE:
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 control handles outward – setting parking
brake
Be sure mower blades are turned off –
PTO switch pushed down.
Know how to stop the engine – Turn key to
off
Know how to stop the unit – Return control
handles to neutral
4
INTRODUCTION
Uncrating & Assembly
TOOLS REQUIRED:
2 - ½” Wrenches or ½” Socket with drive ratchet
Tire pressure gauge
Nail bar or claw hammer
Wire snips
To Remove The Mower From The Crate
Dispose of top and side panels of the crate.
Remove loose parts and packing material
Cut any banding or strapping that may be holding the mower to the crate.
Disengage spark plug wire and place where it cannot make a connection.
Raise the mower deck to its highest position..
Disengage the parking brakes by placing the handle controls in the upright position.
Open the transmission valves at the rear of the unit by pulling the release rods and
locking them in place. SEE INSTRUCTION DECAL AT THE REAR OF THE UNIT .
Carefully push the mower off the crate to a safe and level area.
Check engine oil. All engines are filled with oil and tested at the factory. Verify oil level
and add if necessary before starting engine. SEE ENGINE OWNER’S MANUAL
Check the battery. If the battery is put into service after the “month & year” of the date
on the battery, then it may need to be charged with a 12 volt charger for a minimum of 1
hour, but no more than 2 hours at a rate of 6 to 10 amps.
Attach battery cables to battery. Always attach the positive terminal first.
Install steering levers. Remove the bolts from the control arms on the mower. Align
the holes in the lever with the holes in the control arms and attach with the bolts provided.
Make sure both bolts on both handles are tight.
Close the transmission valves at the rear of the unit. SEE INSTRUCTION DECAL AT
THE REAR OF THE UNIT .
Reconnect spark plug wire.
Check tire pressure on all four wheels. REFER TO UNIT SPECIFICATIONS TABLE
5
SYMBOLS & DECALS
OD45- Warning Decal
Swisher Flag U.S.A.– OD39
Notice Do Not Alter Wiring Decal– OD74
Operator Must Be Seated Decal– OD73
No Step Decal – OD11
Flying Debris Decal – OD43
Triangle Danger Decal – OD55
6
SYMBOLS & DECALS cont.
Parking Brake Decal
Key/PTO Decal - 10273
Left - 10270
Parking Brake Decal
Hydro Release - 10280
Right - 10279
Throttle/Choke Decal - 10271
Danger/Warning Decal - 10276
Decals Not Shown
OD99128
60” Deck White Decal
10275
ZT2460 Decal Small
10281
Height Adjust Decal
10542
Replacement Parts Decal
10274
Z-Max Decal
OD99112
Medium Swisher Decal
7
SAFETY INSTRUCTIONS
Safety Instructions
These instructions are for your safety. Read them carefully.
This Safety Alert Symbol indicates important messages in
this manual. When you see this symbol, carefully read the
message that follows and be alert to the possibility of
personal injury.
General Use
Read all instructions in this operator’s manual
and on the machine before starting it. Ensure that
you understand them and then abide by them.
Learn how to use the machine and its controls
safely and learn how to stop quickly. Also learn to
recognize the safety decals.
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.
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.
8
SAFETY INSTRUCTIONS
General Use Continued
Always look around before and during reversing
maneuvers.
Slow down before turning.
Remember
The operator is
responsible for
avoiding dangers or
accidents.
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.
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.
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
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.
Remember
The operator is
responsible for
avoiding dangers or
accidents.
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.
10
SPECIFICATIONS
GASOLINE CAPACITY
AND TYPE
DUAL 2.0 GAL TANKS
UNLEADED REGULAR
OIL TYPE (SPI-SF-SJ):
SEE ENGINE MANUAL
SPARK PLUG
SEE ENGINE MANUAL
GROUND SPEED
0 – 6 mph
TIRE SIZE
FRONT: 4.10x3.5-5 5/8
Bearing
REAR: 20 X 10 X 8
TIRE PRESSURE
FRONT: 50 psi Max
REAR: 22 psi Max
BATTERY
12V / Heavy Duty 275 CCA
Type U1L
HYDRO Bolt Torque
27 + - 3 ft. lbs
BLADE BOLT
TORQUE
35 ft. lbs
CUTTING HEIGHT
1.5” – 5”
CUTTING WIDTH
60” – 3 Mulching Blade
System
PARKING BRAKE
Automatic - On Steering
Handles
FRONT AXLE
Pivoting
SEAT
Deluxe 18” Back w/ Arm
Rest
6” Adjustable Slide
TRANSMISSION
Commercial Grade Eaton
Hydrostatic
DECK LIFT
Spring Assisted
UNIT
MEASUREMENTS
LENGTH:
WIDTH:
70”
60 ¼” “
Including Deck
WEIGHT:
680 lbs
11
CUSTOMER RESPONSIBILITIES
Operator Presence System
Be sure the operator presence and interlock systems are working properly. If your
mower does not function as described, repair the problem immediately.
The engine should not start unless the parking brakes (handle controls) are
engaged (rotated outward), the PTO (Blade Engagement – See OPERATION
FEATURES section of this manual) switch is disengaged (pressed down), and
the operator is on the seat.
When the engine is running, any attempt by the operator to leave the seat
without first setting the parking brake should shut off the engine.
When the engine is running and the PTO switch is engaged, any attempt by
the operator to leave the seat without first disengaging the PTO switch, should
shut off the engine.
When the engine is running and the control levers are rotated in, any
attempt by the operator to leave the seat without rotating the control levers out,
should shut off the engine.
The PTO switch should never engage without the operator on the seat.
Tires
Maintain proper air pressure in all tires ( SEE SPECIFICATIONS section)
Keep tires free of gasoline, oil, or insect control chemicals which can harm
rubber.
Avoid stumps, stones, deep ruts, sharp objects and other hazards that may
cause tire damage.
12
CUSTOMER RESPONSIBILITIES
Blade Maintenance
CAUTION
Stop engine and remove ignition key for safety. Disconnect spark plug wire. Wear heavy,
thick gloves when holding onto blade. Avoid the sharp edge of the blade.
For best results, mower blades must be kept sharp. Replace bent or damage blades.
Safely raise front of mower. SEE WARNING
WARNING
Hold or block blade from turning.
Loosen blade nut and remove blade.
Replace blade, (SEE SPECIFICATIONS).
Battery
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
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
8 Hours
X
X
X
X
Check Operator
Presence
X
Parking Brake
x
Check for Loose
Fasteners
X
25 Hours
50 Hours
100 Hours
Season
X
Before
Storage
X
Sharpen/Replace
Mower Blades
X3
Check Battery
X
X
Clean Battery &
Terminals
X
X
Check Belts
Check Engine Oil
X
X
X
Change Engine Oil w/
filter
Change Engine Oil
w/o filter
X1,2
X1,2
Replace Oil Filter
Clean Air Filter
X1,2
X2
Inspect Muffler
X
Clean Engine Cooling
Fins
X2
Replace Spark Plug
X
Replace Fuel Filter
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
15
OPERATION
FEATURES
9
7
10
6
12
1.
Throttle Control – Used to control
Engine Speed
2.
Hour Meter – Indicates hours of
operation
3.
Choke Control – Used when starting a
cold engine
4.
PTO Switch – Used to engage or
disengage the deck blades
5.
Ignition Switch – Used to start or stop
the engine
6.
Deck Lift Handle – Used to raise and
lower the cutting deck
7.
Control Levers / Parking Brake – Sets the
speed of the mower in both the forward and
reverse directions and also turns the mower /
Engages and disengages the Automatic
Parking Brake system
8.
Hydro Bypass – Engages transmissions for
normal operation and disengages
transmissions for pushing or pulling the unit
9.
Fuel Tanks – Dual 2.0 gal fuel tanks
10.
Seat Slide
11.
Battery
12.
Pivoting Front Axle
13.
Discharge Chute
SEE DETAILS PAGE
16
OPERATION
FEATURES
9
7
13
1.
Throttle Control – Used to control
Engine Speed
2.
Hour Meter – Indicates hours of
operation
3.
Choke Control – Used when starting a
cold engine
4.
PTO Switch – Used to engage or
disengage the deck blades
5.
Ignition Switch – Used to start or stop
the engine
6.
Deck Lift Handle – Used to raise and
lower the cutting deck
7.
Control Levers / Parking Brake – Sets the
speed of the mower in both the forward and
reverse directions and also turns the mower /
Engages and disengages the Automatic
Parking Brake system
8.
Hydro Bypass – Engages transmissions for
normal operation and disengages
transmissions for pushing or pulling the unit
9.
Fuel Tanks – Dual 2.0 gal fuel tanks
10.
Seat Slide
11.
Battery
12.
Pivoting Front Axle
13.
Discharge Chute
SEE DETAILS PAGE
17
OPERATION
FEATURES
Left Control Panel
Right Control Panel
6
3
4
2
1
5
8
11
Rear of Unit
1.
Throttle Control – Used to control
Engine Speed
2.
Hour Meter – Indicates hours of
operation
3.
Choke Control – Used when starting a
cold engine
4.
PTO Switch – Used to engage or
disengage the deck blades
5.
Ignition Switch – Used to start or stop
the engine
6.
Deck Lift Handle – Used to raise and
lower the cutting deck
7.
Control Levers / Parking Brake – Sets the
speed of the mower in both the forward and
reverse directions and also turns the mower /
Engages and disengages the Automatic
Parking Brake system
8.
Hydro Bypass – Engages transmissions for
normal operation and disengages
transmissions for pushing or pulling the unit
9.
Fuel Tanks – Dual 2.0 gal fuel tanks
10.
Seat Slide
11.
Battery
12.
Pivoting Front Axle
13.
Discharge Chute
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. Set engine RPM to maximum and then
engage the blades.
NOTE:
Grass Height & Cutting Suggestions
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.
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
90 Degree Right Turn
Slow Forward
90 Degree Left Turn
Fast Forward
Slow Reverse
NOTE:
360 Degree Right Turn
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
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
Replacement
Removal
Apply parking brake
Install new belt by placing it around
the deck pulleys. Refer to routing
diagram below.
Lower the deck to its lowest position
The belt will be loose at this time
Remove the belt covers
Tightly secure the belt tension back
to its original position
Disconnect spark plug wire
Disconnect tension idler
Roll the belt over the top of the deck pulleys
Remove belt
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
Replacement
Removal
Apply parking brake
Install new belt by placing it around
the engine pulley and the hydro pulleys.
Refer to routing diagram below.
Disconnect wiring from electric clutch
The belt will be loose at this time
Remove clutch stop weldment (9973TK)
Tightly secure the belt tension back
to its original position
Disconnect spark plug wire
Remove the engine to deck belt
Reinstall the belt from the engine to
the deck
Disconnect idler spring
Disconnect tension idler
Reconnect wiring to the electric clutch
Remove belt from the engine pulley and from
the Hydro pulleys
Reconnect spark plug wire
Idler Pulley
Engine Pulley
For replacement belt part number refer to Replacement Parts
Quick Reference Chart in this manual
23
SERVICE & ADJUSTMENTS
Engine to Deck Belt
Removal
Apply parking brake
Lower the deck to its lowest position
Disconnect tension idler
Remove belt from the mower deck and the
electric clutch
Replacement
Install new belt by placing it around
the electric clutch and route it through
the idler and around the deck pulley.
Refer to routing diagram below.
The belt will be loose at this time
Tightly secure the belt tension back
to its original position
Seat Adjustment
The Swisher ZT2460 is equipped with a 6” range sliding seat.
Release the tension on the seat adjustment lever by pushing
the yellow tip lever to the left. See features section in this manual
Using your own weight, slide the seat to the desired position
Release the lever
24
SERVICE & ADJUSTMENTS
Parking Brakes
The Swisher ZT2460 is equipped with an Automatic Parking
Brake system on each control handle.
When the control handles are in the out most position the
parking brakes are on.
Adjustment for the system is located on the ends of the brake
cable at the hydro pan & frame
Raise the rear wheel off the ground.
Disengage the hydro to be adjusted with the hydro release
handle at the rear of the unit
Adjust so that the brake is not on when the handles are in the
operator position. The wheel should turn freely.
The wheel should not turn when the handle is move to the
engaged or outward position.
To tighten the brake, turn the adjustment nuts towards the end
of the cable.
Recheck adjustment with control handle
Lower unit back to the ground
Reengage the hydro at the rear of the unit
WARNING
When it is necessary to raise the mower for
any repair or service, use jackstands to
provide adequate support. DO NOT rely on
hydraulic or mechanical jacks
25
WIRING HARNESS
26
Item #
Description
Part #
1
24HP B&S Engine
N/A
2
Frame Pan
9999TK
3
Lift Support Plate (right)
9937TK
4
Lift Support Plate (left)
9936TK
5
1/3-13 X 2 GR5 Bolt
NB509
6
2 1/2 Cable Pulley
10211
7
1 1/2 Cable Pulley
5542
8
1/2-13 Nut
NB213Z
9
1/2-13 Nyloc Nut
NB281
10
Lock Plate
9922TK
11
5/16-18 X 3/4 Serrated Flg Bolt
NB596
12
5/16-18 Jam Nut
NB173
13 5/16-18 X 1 1/4 Serrated Flange Bolt NB253
14
Rear Deck Lift Cable
9947
15
Linkage Tab
9958TK
16
Deck Lift Weldment
9933TK
17
5/16-18 Nyloc Nut
NB181
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
14
24
23
PARTS BREAKDOWN
22
15
25
21
18
16
27
28
13
12 14 17
20
19
3
8
5
2
10
6
26
4
9
11
7
27
Item #
Description
Part #
PARTS
1
24 HP B&S Engine
N/A
2
5/16-18 Serrated Flange Nut
NB170
1
3
Spacer Engine Pulley
BB105SL
4
Motor Pulley 3.25"
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 5/16-18 X 1 1/4 Serrated Flange Bolt NB253
11
Oil Drain Valve
AS122 10
2
12
Oil Drain Valve Cap
AS123
BREAKDOWN
12
11
3
Not Shown
Part #
16915
10264
Description
Solenoid Assembly
Wiring Harness
5
4
6
7
8
9
ENGINE ASSEMBLY
14
13
15
17
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
11782
10265
19
16
GAS TANK ASSEMBLY
28
18
PARTS BREAKDOWN
1
2
4
5
3
17
6
7
36
39
8 9 11 12
13
24
14
30
35
37
30
31
33
10
28
15
23
31
16
14
25
5
21
19
18
20
26
27
22
34
34
29
38
32
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
31
Description
1/4-20 X 3/4 Carriage Bolt
1 1/2" Block Pulley
1/4-20 Serrated Flg Nut
Sping Assist Bracket
5/16-18 X 3/4 Serrated Flange Bolt
Pulley Mount Tab
1/2-13 X 2 GR5 Bolt
Cable Pulley
1/3-13 GR2 Nut
1/2-13 Nyloc Nut
5/16-18 Serrated Flange Nut
1/4-20 X 1 1/2 GR2 Bolt
Tension Bracket
5/16-18 X 3 1/2 eye bolt
5/16-18 Nyloc Nut
Belt to Deck Idler Bracket
1/2-13 Nyloc Nut
Idler Spacer
Part #
10547
10728
NB524
9926TK
NB596
9963TK
NB509
5542
NB213Z
NB281
NB170
NB162
9918TK
NB315
NB181
9957TK
NB281
6040Z
Item #
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Description
Idler Bushing
Idler Bracket Painted
Idler Pulley OD-2.16", ID-3/8"
3/8-16 X 1 1/2 HCC GR5 ZP
Clutch Rod Spring T60
1/4-20 Flange Nut
5/16 Nylon Bushing
3/8-16 2-Way Lock Nut
3/8-16 Nyloc Nut
Lower Belt Idler Arm
1/2-13 X 3 HCC GR5 Bolt ZP
3/8-16 X 2 HTC GR2 ZP
3/8 SAE Washer
3/8-16 2-Way Lock Nut
Idler Pulley OD-2.75", ID-3/8"
3/8-16 HNC GR2 ZP
1/2-13 Nut GR2 ZP
5/16-18 X 1 HCC GR5 ZP
5/16-18 Serrated Flng Nut
Idler Pulley V OD-3.54", ID-3/8"
Clutch Rod Spring T60
Part #
6037
9944TK
B27
NB107
682S
NB524
NB198
NB280
NB182
3691TK
NB131
NB231
NB272
NB280
7509
NB212
NB213Z
NB501
NB170 29
3622
682S
PARTS BREAKDOWN
5
12
26
4
3
24
23
28
25
4
5
7
4
6
21
22
1
2
19
10
20
18
2
16
3
2
8
17
12
11
9
7
13
6
2
12
9
16
7
15
6
14
6
6
12
Item #
Description
Part #
1
60 ZT Deck weldment - painted 9901 TK
2
5/16-18 x 3/4 Serr flange bolt
NB596
3
Belt Cover - painted
6025TK
4
3/8 SAE washer
NB272
5
3/8-16 nyloc nut
NB182
6
Anti-scalp roller 3/8 ID
AS001
7
5/16-18 serrated flange nut
NB101
8
Deck Hanger - painted
9938TK
9
5/16-18 serrated flange nut
NB170
10
Chute mount-painted
6030TK
11
5/16-18 x 8 1/2 HCC GR2 ZP
NB136
12
5/16-18 nyloc nut
NB181
13
Torsion spring- bent leg
9100
14
Discharge Chute Weldment-painted 9902TK
Item #
Description
15
3/8-16 x 5 1/2 GR5 ZP
16
3/8-16 nyloc nut
17
Idler Bushing
18
3/8-16 x 2 1/4 HTC GR5 ZP
19
Idler Arm -painted
20
Idler Spacer
21
3/8-16 x 1 1/2 HCC GR5 ZP
22
Idler Pulley OD 3.25, ID 3/8
23
3/8-16 2-way lock nut
24
3/8-16 Jam nut
25
3/8-16 Nylock nut Jam
26
Two speed spring (A232 1998)
27
Wire link for Idler Arm
28 5/16-18 x 3 1/2 Center of Eye-5/8 Eye
Part #
NB575
NB182
6037
NB693
6041TK
6040
NB107
14424
NB280
NB174
NB207
TZ2S
BRS6H
NB315
30
PARTS BREAKDOWN
1
2
3
4
5
14
15
6
17
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
3/4-16 Nut
Belleville Washer
Pulley 4 1/2"
Spacer
3/4 ID X 1 1/4 OD 18 GA Washer
Center Blade Driver
Outer Blade Driver
3/4 ID X 1 3/4 OD Flat Washer
Blade Mount Plate
3/8-24 Two Way Lock Nut
Blade
3/8-24 X 1 1/2 Bolt
Belleville Washer
Blade Bearing
7" Blade Driver Shaft
5" Blade Driver Shaft
Blade Driver Housing
Part #
NB175
AS155
B4104TK
6065PM
NB179
10541
10540
B98W
9008
NB216
3293
NB238
NB607
B98
9075
9077
10539TK
14
1
5
8
10
9
2
3
5
11
14
13
12
Center Driver
16
7
17
14
8
5
9
10
11
13
12
Outside Driver
31
23
PARTS BREAKDOWN
3
22
16 15
2 17
11
14 12
18
21
13
14
5
19
20
24
26
27
25
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
8
25
32
29 31 33
28
1
30
10
4
26
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
3/8-16x 3/4 serr flange rolok serr
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)
6
Part #
9935TK
10268
10269
3756
9920TK
10545
AS155
NB519
2203LN
9976
NB250
9023MOD
NB180
9919TK
9929
9928
NB620
NB274
NB275
NB125
7839Z
NB263
9
Item #
Description
23
Battery
24
Clutch stop weldment - painted
5/16-18 x3/4 serr flange bolt
5/16-18 serrated flange nut
Rear Stabilizer-Painted
Hydro release handle
Spring for Idler Arm
Hydro release plate - Painted
5/16-18x1 Rolock screw
5/16 sae washer
5/16-7/10 x .006 waste water
NOT SHOWN
Battery Hold Down
1/4-20 X 1 1/2 atc gr2 zp
1/4-20 Nylok nut
1/4 SAE Washer
1/4-20 kep nut
Battery Cable 10" Red
Battery Cable 10" Black
25
26
27
28
29
30
31
32
33
Part #
9973TK
NB596
NB170
9946TK
9923
BRS6
9924TK
10543
NB275
10544
BHOLD
NB162
NB180
NB274
NB203
BCSR
BCS
32
PARTS BREAKDOWN
21
22
23
36
6
24
19
33
25
5
34
5
37
20
8
17
13
11 12
29
28 26
27
10
38
52
9
15
39
53
4
45
57
38
2
1
54
46
3
56
55
47
41
40
42
44
50
48
43
49
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
51
Description
Seat Base
Control Panel
Hour Meter
Throttle Control 35"
Handle Pivot
Handle Weldment
5/16-18 X 1 Serrated Flange GR5 Bolt
Storage Compartment
Neutral Bracket
Tapered Spring
Steering Linkage Control Arm
3/8-16 X 2 1/4 GR5 Bolt
3/8-16 GR2
3/8-16 Jam Nut
3/8 SAE Washer
3/8-16 2-Way Lock Nut
5/16-18X2 GR5 Bolt
5/16 SAE Washer
5/16-18 Nyloc Nut
Handle Weldment
Control Panel Right
Key Switch
PTO Switch
Tinnerman Clips 5/16-18 Heavy Duty
Side Plate
5/16-18 Serrated Flange Nut
Return to Neutral Switch
8-32 Kep Nut
Safety Switch Rocker Arm
Part #
9998TK
9991TK
3803
3788
9985TK
9932TK
10548
9956TK
9992TK
3609
9927
NB693
NB212
NB174
NB272
NB280
NB507
NB275
NB181
9930TK
9990TK
3623
3605
3669
9996TK
NB170
3695
NB201
9925TK
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
5/16 SAE Washer
Spacer
1/2-13 GR2 Nut
8-32X 1/2 Phil Truss Screw
Control Panel Right
5/16-18 X 1 1/4 Serrated Flange Bolt
ZT Seat 18"
Seat Mount
Seat Bracket
Foot Plate
Pivot Plate Housing Weldment
Deck Stabilizer-Left
Deck Stabilizer-Right
Deck Stabilizing Bar
Pivot Axle Weldment-Painted
Blade Bearing
Textured Black Caster T50
Tire/Wheel Slick 4.10x3.5-5 5/8 Bearing
5/8-11 X 7 HCC GR5 ZP
5/8 ID X 1 OD 10 GA Washer
Wheel Spacer 1"
5/8-11 2 Way Lock Jam Nut
13/16 X 1 1/4 X 1/8 Washer
3/4-16 Jam Nylok Nut
5/16-18 X 1 Serrated Flange GR5 2P
Axle Washer-Painted
Spacer
5/16-18 Serrated Flng Nut
NOT SHOWN
Arm Rest Kit
Mat for Pan
Mat for Foot Plate
60" Choke Cable
NB275
B99S
NB213Z
NB197
9990TK
NB253
10570
9984TK
3807TK
9995TK
9954TK
9950TK
9951TK
9949
9994TK
B98
665TK
3010
NB624
NB178
3395
NB595
NB195
NB122
10548
9915TK
B99S
NB170
10571
10729
10549
9914
NOT SHOWN
Seat Grommet
Seat Spring
1/4-20 X 1 1/2 HCCGR2ZP
1/4 SAE Washer
1/4-20 Nylok Nut
33
9931
3609
NB104Z
NB274
NB180
TROUBLESHOOTING
PROBLEM
Engine Will
CAUSE
1.
Out of fuel
1.
Fill fuel tank
2.
Engine not “choked” properly
2.
Choked engine and attempt to restart
3.
Engine flooded
3.
Wait several minutes before attempting to
restart.
4.
Bad spark plug
4.
Replace spark plug
5.
Dirty air filter
5.
Clean or replace air filter
6.
Replace fuel filter
7.
Drain fuel tank & carburetor, refill tank
with fresh gas and replace fuel filter
Not Start
Engine Hard
To Start
6.
Dirty fuel filter
7.
Water in fuel
8.
Loose or damaged wiring
8.
Check all wiring
9.
Carburetor out of adjustment
9.
See Engine Manual
10.
Engine valves out of adjustment
10.
Contact an authorized service center
11.
Extreme cold conditions
11.
See Engine Manual
12.
Fuel shut off valves closed
12.
Open
1.
Bad spark plug
1.
Replace spark plug
2.
Dirty air filter
2.
Clean or replace air filter
3.
Dirty fuel filter
3.
Replace fuel filter
4.
Weak or dead battery
4.
Recharge or replace battery
5.
Carburetor out of adjustment
5.
See Engine Manual
6.
Engine valves out of adjustment
6.
Contact an authorized service center
7.
Loose or damaged wiring
7.
Check all wiring
Stale or dirty fuel
8.
Drain fuel tank & refill with fresh gasoline
8.
Engine Will
Not Turn
Over
Engine
Clicks but
Will Not
Start
CORRECTION
1.
Directional handles not in correct position
1.
Place handles in the out most position
2.
PTO engaged
2.
Push PTO switch down
3.
Weak or dead battery
3.
Recharge or replace battery
4.
Blown fuse
4.
Replace fusel
5.
Corroded battery terminals
5.
Clean battery terminals – See battery
section of this manual
6.
Loose or damaged wiring
6.
Check all wiring
7.
Faulty ignition switch
7.
Check/replace ignition switch
8.
Faulty solenoid
8.
Check/replace solenoid
9.
Faulty operator presence switch/switches
9.
Contact an authorized service center
1.
Weak or dead battery
1.
Recharge or replace battery
2.
Corroded battery terminals
2.
Clean battery terminals – See battery
section of this manual
3.
Loose or damaged wiring
3.
Check all wiring
4.
Faulty solenoid
4.
Check/replace solenoid
34
TROUBLESHOOTING Continued
PROBLEM
Loss of
Power
Excessive
Vibration
Engine
backfires
when turning
engine OFF
CAUSE
1.
Cutting too much grass/ too fast
1.
Set in High Cut (position 8)/reduce speed
2.
“Choke” position
2.
Push choke control in
3.
Buildup of grass, leaves and trash under
deck.
3.
Clean underside of mower deck
4.
Clean or replace air filter
5.
Check oil level/change oil
6.
Clean and re-gap or change plug
7.
Replace fuel filter
8.
Drain fuel tank & refill tank with fresh gas
9.
Drain fuel tank & carburetor, refill tank
with fresh gas and replace fuel filter
4.
Dirty air filter
5.
Low oil level/dirty oil
6.
Faulty spark plug
7.
Dirty fuel filter
8.
Stale or dirty fuel
9.
Water in fuel
10.
Spark plug wire loose
10.
Connect and tighten spark plug wire
11.
Dirty engine air screen/fins
11.
Clean engine air screen/fins
12.
Dirty/clogged muffler
12.
Clean/replace muffler
13.
Loose or damaged wiring
13.
Check all wiring
14.
Carburetor out of adjustment
14.
See Engine Manual
15.
Engine valves out of adjustment
15.
Contact an authorized service center
16.
Loose drive belt
16.
Adjust idler/replace belt
1.
Worn, bent or loose blade
1.
Replace blade. Tighten blade bolt.
2.
Replace blade driver
3.
Tighten loose part or parts. Replace
damaged parts.
2.
Bent blade driver
3.
Loose/damage part or parts
4.
Faulty blade driver assembly
4.
Replace blade driver assembly
1.
Engine throttle control not set at “SLOW”
position for 30 seconds before stopping
engine.
1.
Move throttle control to “SLOW” position
and allow to idle for 30 seconds before
stopping engine
1.
Unit Does
not
CORRECTION
Incorrect tire pressure
1.
Check tire pressure (See
Specifications)
Travel in a
straight line
35
TROUBLESHOOTING Continued
PROBLEM
Poor cut uneven
CAUSE
1.
Worn, bent or loose blade
1.
Replace blade. Tighten blade bolt
2.
Mower deck not level
2.
Level deck. See section in this manual
3.
Buildup of grass, leaves and trash under
deck.
3.
Clean underside of mower deck
4.
Bent deck
4.
Replace deck
5.
Faulty Blade driver assembly
5.
Replace blade driver assembly
Battery will
not charge
Loss of drive
CORRECTION
1.
Bad battery
1.
Replace battery
2.
Poor cable connections
2.
3.
Faulty solenoid
Check/clean all connections. See section
in this manual
3.
Replace solenoid
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.
2.
Replace Hydro belt.
3.
Replace Idler spring
1.
Bypass linkages in the bypass position
2.
Hydro belt worn, damaged, or broken
3.
Idler spring loose or broken
36
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 – ZT2460
•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
37
[email protected]
Replacement Parts
Quick Reference
Swisher Part #
Part Description
9947
Rear Deck Lift Cable
9948
Front Deck Lift Cable
AS069
Fuse 10 Amp
6046
47” Hydro Belt
3756
20 x 10 x 8 Rear Tire
5058
122” Deck Belt
3293
20.5 Mulching Blade
10263
84” Engine to Deck Belt
10540
Blade Driver Assembly
(outside)
10541
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
Maintenance Log
Date Oil
Changed
Date
Changed
Belts
Date Blades
Sharpen or
Changed
Notes
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 60 YEARS OF INNOVATION
1945 - 2005
40