Swisher ZT18542 Operating instructions

REPAIR MANUAL

ZT18542

ZT2350

Swisher Mower Co

Warrensburg, MO

For additional assistance on service

Contact Swisher Mower Co., Inc.

Phone 1-800-222-8183

Fax 1-660-747-8650

E-mail [email protected]

This manual was produced at the beginning of

our 2006 production. It was specifically

written for those models built after January,

2006. For those models built before that time

refer to the owners manuals for specific parts or

call the Swisher Mower factory for assistance.

For warranty issues or ordering parts for

the engines or the hydro units, contact the

authorized dealer in your area.

TABLE OF CONTENTS

1. If engine won’t crank

2. If engine won’t crank - continued

Battery ground connection at engine

3. Engine cranks but won’t start

Engine stalls when PTO is engaged

4. If PTO clutch will not engage

5. Wiring diagram

Hour meter not operating

6. Wire identification at switches

7. Wire identification on ZT18542

8. Wire identification on ZT2350

9. Carburetor fuel solenoid

10. Battery charging systems

11. Adjusting the drive controls

12. Tracking adjustments

13. Replacement of the hydro unit

14. Repairing or replacing the blade driver

15. Belt replacement routing

IF ENGINE WON’T CRANK

ALWAYS CHECK FUSE FIRST

TEST #1

Using a remote starter switch or a 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 terminal of the ignition

switch. If all components in the circuit are working, the

engine should crank. If it doesn’t, move on to next test.

A neutral switch is located at 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 inch. Loosening the two mounting screws and

sliding the switch to the side can adjust these.

Ohmmeter should go to zero when checking continuity

across switch terminals with plungers depressed.

With PTO switch in the

off position, meter should

go to zero when checking

continuity across these

two terminals.

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.

This panel is located

right in front of the

battery. It is accessible

by removing the plate

below the front edge of

the seat.

Negative battery ground on ZT2350Negative battery ground on ZT18542

BATTERY GROUND CONNECTION AT ENGINE

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.

IF PTO CLUTCH WILL NOT ENGAGE

Apply a negative ground to this terminal

Apply 12Volts to this terminal. Clutch should

activate, if it doesn’t, clutch is defective.

If clutch checks OK, use a voltmeter to measure for

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

measured, move on to next test.

The problem may 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. 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.

Used on

ZT2350

Used on

ZT18542

WIRING DIAGRAM

HOUR METER USED ONLY ON ZT2350

HOUR METER NOT OPERATING

Hour meter has a positive and a

negative post. Gray wire should go on

the positive. Power is supplied from the

ignition switch.

Green wire from hour meter is

grounded by the oil pressure switch,

therefore only has a ground when the

engine is running.

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

Heavy red cable

goes to the starter.

Red wire goes through

fuse and onto ignition

switch.

Green wire goes to

neutral switches and

on to the ignition

switch.

Heavy red cable

goes to the

positive post of the

battery.

Red wire goes to

engine plug.

Green wire with

orange stripe goes

to the ground.

PTO SWITCH PLUG

Black wire goes to the

ignition switch.

Green wire goes to the

ignition switch.

Gray wire goes to the

ignition switch.

Black wire goes to the seat

switch.

Green wire goes to the

neutral switches.

Brown wire goes to the

clutch.

WIRE IDENTIFICATION ON ZT18542

Gray wire goes to ignition switch

Black wire goes to ignition switch

Red wire goes to terminal on

solenoid with the positive battery

cable

Red wire goes to engine charging

system

Orange wire is not used on this

application

Black wire goes to engine ignition

module

Gray wire goes to carburetor fuel

solenoid

WIRING HARNESS TO ENGINE PLUG CONNECTION

WIRING HARNESS PLUG TO ENGINE

Red wire goes to terminal on solenoid

with the positive battery cable

Black wire goes to the ignition switch

Gray wire to the ignition switch

This manual suits for next models

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