ZT2560 Repair Manual

 

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REPAIR MANUAL ZT2560

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Swisher Mower Co Warrensburg, MO

 

TABLE OF CONTENTS

1.

If engine won’t crank 

2.

If een ngine won’t ccrrank – continued 

3.

If een ngine ccrranks b bu ut w wo on’t ssttart If engine stalls when PTO is engaged 

4.

If P PT TO clutch will n no ot een ngage Hour meter not operating

5.

Wire iid dentification at ssw witches

6.

Wire ire iid dentif tificatio tion aatt ssw witc tch hes – contin inu ued 

7.

Drive control adjustment

8.

Drive cco ontrol aad djustment – continued  Drive control overview

9.

Electrical components

10.. 10

Pa Park rkin ing g bra brake ke an and dn neu eutra trall sw switc itch ho ope pera ratio tion n

11.

Deck lifting system

12.

Deck belt repla laccement

13.. 13

Re Repa pair irin ing go orr rrep epla laci cing ng bl blad adee dri drive ver  r 

14.

Rep epla lace cem men entt P Par arts ts – Quic ick k rreefe fere renc ncee

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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 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 This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

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

1  

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.

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

2

 

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 carbur etor to click. It must click to supply fuel to the carburet carburetor. or. 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. This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

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

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on zero with no weight on the seat. Pulling the seat down should open the circuit. Accept All

3  

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 ON position the engine. Now engage the PTO switch. For the first test put the negative probe on a good ground,not ground, not on the white wire’s terminal in the plug. If no voltage is measured, move on to next test.

With the PTO switch ON there should be continuity  between these two connectors, if not, replace switch. If switch tested good, check wires and connectors back to ignition switch and back to clutch plug.

 

If all checked good in the two previous tests, the  problem may now be a poor ground on the white wire in the clutch plug. Check by testing for continuity to ground or check for voltage between the two terminals This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings. Hour

HOUR METER NOT OPERATING

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meter has a positive and a  post. Gray wire should go on negative post. negative the positive. Power is supplied from the ignition switch.

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Green wire from hour meter is grounded by the oil pressure switch, therefore only has a ground when the Accept All engine is running.

4  

WIRE IDENTIFICATION AT SWITCHES 3623 IGNITION SWITCH One gray wire goes to the PTO switch and the other goes to the hour meter 

One black wire goes to PTO switch and the other goes to the engine plug

Green wire goes to PTO switch

Red wire goes to fuse and on to battery positive at the solenoid terminal. One white wire goes to clutch and other one goes to ground.

STARTER SOLENOID Green goes to neutralwire switches and on to the ignition switch.

Heavy red cable goes to the starter. Red wire goes to engine plug.

Green wire with orange stripe goes to the ground.

Heavy red cable goes to the  positive post of the  battery.

Red wire goes to ignition switch. This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You Black wire goesat to may change your settings anythe time or accept the default settings. ignition switch. Privacy Policy

Green wire goes to the Marketing ignition switch.

PTO SWITCH PLUG Black wire goes to the seat switch.

Green wire goes to the neutral switches.

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Gray wire goes to the Accept All switch.

Save ignition

Brown wire goes to the clutch.

5  

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

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Red wire goes to terminal on solenoid with the positive  battery cable.

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Green Save

wire goes toAll hour meter  Accept

Black wire goes to the ignition switch.

6  

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 engine. Then start the engine. Measure 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 battery gets recharged.

Voltage Regulator

To test alternator before it goes to the regulator, unplug the yellow connector and measure the AC voltage across the the two gray wires inside this connector.There should be at least 20 volts AC.

CARBURETOR FUEL SOLENOID

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ground.

Gray wire goes to the engine plug, then on to the ignition switch where it Privacyreceives Policy power to activate the fuel shut off valve. Marketing Personalization Analytics

Fuel shut off solenoid is a Briggs part Accept All and is available through them only.

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7  

DRIVE CONTROL ADJUSTMENTS LEFT SIDE SHOWN

Control plate shown in neutral position

Hydro linkage

Start your adjustments by putting the 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. With the drive control handles in the neutral position, this linkage pivot should  be close to straight up and down.

With control plate on hydro still in the neutral position, try to put hydro linkage  back into the hole on the th e plate. If it won’t go in without forcing one way or the other, adjust threads here to make an easy hookup. With the control linkage once again removed, move the control plate forward as far as it will go.

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Move the control handle forward until this linkage contacts the adjusting bolt in front of it.Again try to put the control linkage in to the control plate. Do not adjust the control linkage to make this happen, adjust the bolt in front instead.

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This adjusting bolt will now be used to set both drive wheels to pull equally. With the control handles fully forward,

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observe which side is turning the fastest. Extend the bolt rear ward to slow the travel of that side until they are pulling the same on both sides.

8  

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 control handle

Pivot point for control handle movement

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Adjustment threads on control rod  Accept All

Pivot point

Forward and reverse control on hydrostat

9  

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 a bolt at this point. p oint.

This is the neutral safety switch that  prevents the engine from cranking unless the drive controls are both swung outward in neutral position. The switch This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

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The parking brake can be adjusted by moving the nuts on this cable. A nut is located on each side of this frame. As the outer cable moves forward, the brake will become tighter.

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has a slotted mount bracket so the travel of the push button can be adjusted to depress about 3/8” to activate. Further information about checking this switch is found in the electrical diagnosing section

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10  

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 equally on each spring.

The guide pulley for the front center deck lift cable. This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

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Front guide pulley for the center lift cable.

To level the deck, start by lowering the deck lift handle to its lowest position. If the deck is not setting on the ground, turn the nuts under these three brackets until it does. The left and right cables in the rear should then be tightened until the back end of the deck is level across and rides about 1\4 inch higher than the front end.

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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 10263 belt,  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 the deck.

DECK CROSS BELT •Remove the belt covers This website stores data such as cookies to enable essential site functionality, as well as marketing, personalization, and analytics. You may change your settings at any time or accept the default settings.

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Tension on belt can be adjusted by tightening or loosening this nut. Accept All

•Remove the engine to deck belt from deck pulley •Loosen the tension to the tension idler  •Remove the worn or damaged belt and replace with part# 5058  belt 5058 belt •Reinstall the engine to deck belt and retighten both tension idlers

12  

REPAIRING OR REPLACING BLADE DRIVER Torque top nut to 90 ft/lbs Replacing this nut each time is recommended.

Since there are no hubs on our pulleys, this Belleville washer is important to apply friction to the pulley to turn

Machine washers are used to keep the pulley from contacting the outer race of the bearing. When applying torque to the top nut the pressure is to the inner race only and onto the shank on the inner shaft.

the shaft. the outer lip isMake downsure to best contact the pulley.

Bottom end of the shaft has the same ¾ in. SAE threads as the top end. This washer is wide enough to to cover the full  bottom of the housing and is used as a protector for the seal in the bearing.

Machine washer used as a spacer just like

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Pulley does not have a hub. When removing, just lift it off like a washer, no puller is needed.

Bearings are sealed. They can be driven out and new ones pressed in for repairing the spindle assembly. It can also be purchased as a unit for easier repair.

This adaptor block is right hand threaded onto the ¾ in. shaft. Torque this block to 90 ft/lbs just like the nut at the top of the shaft.

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Install the blade adaptor block to the bottom of the shaft. Before applying torque, install the  blade to the block using only the th e outer two bolts. Leave the center bolt out for now. no w. Block Personalization the blade to outer deck edge by using a 4x4 or similar stop. Using a torque wrench on the Marketing

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top nut above the pulley, apply The andbolt the adaptor block receive the tightening. Now put 90 theft/lbs. washer ontop thenut center and install intowill the equally shaft. Save Accept All Torque the three bolts to 35 ft/lbs. The center bolt will lock the block so it won’t come off.

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For additional assistance on service

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Contact Swisher Mower Co., Inc.

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Phone 1-800-222-8183

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Fax 1-660-747-3160 E-mail [email protected]