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REPAIR MANUAL
ZT2560
Swisher Mower Co
Warrensburg, MO
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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 repla
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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 solenoi
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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 With PTO switch in one and perform Test #4 again. If all switches are good, a the off position, meter co
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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 defe
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IF PTO CLUTCH WILL NOT ENGAGE Apply a negative ground to this terminal Apply 12 volts to this terminal. Clutch should activate, if it doesn’t, clutch is defective. If clutch checks OK, use a voltmeter to measure if there is 12 volts at the brown wire’s terminal. First turn ignition switch to the ON position but don’t start the engine. Now engage the PTO switch. For the first test put the negative probe on a good ground, not on the white wire’s terminal in the plug. If no voltage is measur
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WIRE IDENTIFICATION AT SWITCHES 3623 IGNITION SWITCH One gray wire goes to the Green wire goes to PTO switch PTO switch and the other goes to the hour meter Red wire goes to fuse and on to battery positive at the solenoid terminal. One black wire goes to PTO switch and the other goes to the One white wire goes to clutch engine plug and other one goes to ground. STARTER SOLENOID Green wire goes to Heavy red cable neutral switches goes to the starter. and on to the ignition switch. Red
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WIRING HARNESS TO ENGINE PLUG CONNECTION Gray wire goes to carburetor fuel solenoid Green wire goes to oil pressure switch Black wire goes to engine ignition module Red wire goes to engine charging system Green wire goes to hour meter Red wire goes to terminal on solenoid with the positive battery cable. Black wire goes to the ignition switch. Gray wire goes to hour meter WIRING HARNESS PLUG TO ENGINE Gray wire goes to hour meter Red wire goes to terminal on solenoid with the positive batter
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BATTERY CHARGING SYSTEM Red wire goes to the engine plug and then on to the positive terminal of the solenoid to keep the battery charged. Easiest way to check if the charging is taking place is to measure the DC voltage of the battery before you start the Voltage engine. Then start the engine. Measure Regulator the voltage at the battery with the engine running. The voltage should be at least one volt higher right after the engine is started. This voltage will drop a little as the b
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DRIVE CONTROL ADJUSTMENTS LEFT SIDE SHOWN Control plate shown Start your adjustments by putting the in neutral position drive control arms in the neutral position. Remove the linkage from the control plate at the Eaton hydro by removing the cotter pin and washer on the under side. By moving the control plate forward and backwards by hand you can easily find the neutral position on the hydro. Hydro linkage With the drive control handles in the neutral position, this linkage pivot should
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DRIVE CONTROL ADJUSTMENTS (CONTINUED) LEFT SIDE SHOWN Once both hydro units are pulling equally, make your final control handle adjustment with this ball linkage. Whichever handle is going the farther forward, lengthen the linkage on that side until the handles are straight across when mower is traveling in a straight line. If a lot of adjustment is needed, shorten the linkage on the opposite side for half of the adjusting. OVERVIEW OF DRIVE CONTROL LINKAGE RIGHT SIDE SHOWN Right side c
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PARKING BRAKE AND NEUTRAL SWITCH OPERATION Right side drive control handle. Parking brake cable attaches here. Right side is shown. Control panel has been removed for better view. Parking brake is activated by this bolt as the drive control handle is swung outward in the neutral position. Tension on brake cable can be adjusted by raising or lowering this bolt, but the main adjustment is performed on the other end of the cable down by the rear wheels. Safety switch rocker arm pivots on
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DECK LIFTING SYSTEM Three rocker arms are activated by the deck lift handle. This is the right side control. Note the routing of the cable. It drops straight below to the deck. This center rocker arm lifts the front center of the deck. It also drops through the lower frame but is directed by two pulleys under the mower frame to the front of the deck. The deck lift system has two springs to assist in raising the deck. The ease of lifting the deck can be adjusted by tightening this nut
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DECK BELT REPLACEMENT ENGINE TO DECK BELT •Lower the deck to lowest setting •Loosen tension on tension idler •Remove worn or damaged belt •Using part# 10263 belt, route it around the engine pulley as shown in the diagram. •Retighten the tension idler and check the operation Belt coming from the electric clutch will be routed around this idler pulley on the outside. As belt leaves the previous idler pulley it will be routed around this flat idler pulley to the inside and then forward to th
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REPAIRING OR REPLACING BLADE DRIVER Torque top nut to 90 ft/lbs Since there are no hubs on Replacing this nut each our pulleys, this Belleville time is recommended. washer is important to apply friction to the pulley to turn the shaft. Make sure the Machine washers are used outer lip is down to best to keep the pulley from contact the pulley. contacting the outer race of the bearing. When applying torque to the top nut the pressure is to the Pulley does not have a hub. inner race on
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For additional assistance on service Contact Swisher Mower Co., Inc. Phone 1-800-222-8183 Fax 1-660-747-3160 E-mail cust.serv@swisherinc.com 14
