Swisher ZT2560 User Manual

REPAIR MANUAL

ZT2560

Swisher Mower Co Warrensburg, MO

TABLE OF CONTENTS

1. If engine won’t crank

2. If engine won’t crank – continued

3. If engine cranks but won’t start If engine stalls when PTO is engaged

4. If PTO clutch will not engage Hour meter not operating

5. Wire identification at switches

6. Wire identification at switches – continued

7. Drive control adjustment

8. Drive control adjustment – continued Drive control overview

9. Electrical components

10. Parking brake and neutral switch operation

11. Deck lifting system

12. Deck belt replacement

13. Repairing or replacing blade driver

14. Replacement Parts – Quick reference

IF ENGINE WON’T CRANK

ALWAYS CHECK FUSE FIRST

TEST #1

Using a remote starter switch or suitable device, make a connection between the large terminals on the solenoid. If engine does not crank!!!

•Battery may be weak or dead

•Starter may be bad

•Battery cables may have bad connections

•Do not go to Test #2 until this test gives results

TEST #2

If engine did crank in test #1, disconnect green wire at spade connector and apply positive voltage from the battery to the primary wire on the solenoid. Make sure the one with the eyelet is grounded. If engine doesn’t crank now, replace the solenoid. Remember, all other

tests are useless unless these two tests make the engine turn over.

TEST #3

If engine did crank in the first part of test #2, reconnect green wire to solenoid. Make sure the drive controls are out in neutral position. Using a jumper wire attached to the positive terminal of the battery, apply 12 volts to the red wire on terminal B of the ignition switch. Try to crank, using the ignition switch. If engine cranks, the fuse or the fuse holder, or related wiring is defective somewhere back to the solenoid.

TEST #4

If engine did not crank in test #3, make sure the drive controls are in neutral position. This time move the jumper wire attached to the positive terminal of the battery, to the green wire on S switch. If all components in the circuit are working, the engine should crank. If it doesn’t, move on to next test.

terminal of the ignition

A neutral switch is located on the lower end of both drive control handles and is activated when the handles are outward in the neutral position. Check that the plunger buttons on both switches are depressed at least 3/8”. Meter should go to zero when checking continuity across switch terminals with plungers depressed.

If any of the switches in this circuit tested bad, install a new one and perform Test #4 again. If all switches are good, a connecting wire must be at fault. Don’t move past Test #4 until it assures a good circuit. When you do get good results, hook all wires back to original position and try the ignition switch again. If no results, you will need to replace the ignition switch.

With PTO switch in the off position, meter should go to zero when checking continuity across these two terminals.

ENGINE CRANKS BUT WON’T START

Checks for electrical problems

•While turning ignition switch to its first position, listen for the fuel solenoid on the carburetor to click. It must click to supply fuel to the carburetor.

•Try a new spark plug.

•Check for spark at plug when it is removed and the threaded end is grounded.

•Unplug the six-position socket that connects engine wiring to mower wiring harness.

Engine will still crank. If plug doesn’t have a spark now, ignition module is probably defective.

Checks for mechanical problems

•Make sure the tank gas valve is turned on.

•Remove air filter element to check for signs of gas in the throat of the carburetor.

•If no gas, check to see if choke is working properly.

•If all above checks show positive, carburetor must have an internal problem. Remove and

clean the carburetor.

ENGINE STALLS WHEN PTO IS ENGAGED

The seat safety switch plug not being properly inserted, or a defective plug can cause this problem. If the plug is not inserted or is defective, the spark plug is grounded out when the PTO is engage.

To check, remove plug from the PTO switch. Using an ohmmeter, place one probe on the terminal connected to the black wire going to the seat safety switch plug. Place the other probe on a good chassis ground. The meter should be on zero with no weight on the seat. Pulling the seat down should open the circuit.

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