REPAIR MANUAL ZT18542 ZT2350 Swisher Mower Co Warrensburg, MO
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. For additional assistance on service Contact Swisher Mower Co., Inc.
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.
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.
This panel is located right in front of the battery. It is accessible by removing the plate below the front edge of the seat. 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.
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.
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.
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 Green wire goes to PTO switch 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 engine plug One white wire goes to clutch and other one goes to ground. STARTER SOLENOID Heavy red cable goes to the starter. Heavy red cable goes to the positive post of the battery.
WIRE IDENTIFICATION ON ZT18542 WIRING HARNESS TO ENGINE PLUG CONNECTION 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 PLUG TO ENGINE Red wire goes to terminal on solenoid with the positive battery cable Black wire goes to the ig
WIRE IDENTIFICATION ON ZT2350 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.
CARBURETOR FUEL SOLENOID USED ON ZT2350 Black wire goes to engine ground. Gray wire goes to the engine plug, then on to the ignition switch where it receives power to activate the fuel shut off valve. Fuel shut off solenoid is a Briggs part and is available through them only. USED ON ZT18542 Fuel shut off solenoid is a Briggs part and is available through them only. Gray wire goes to the engine plug, then on to the ignition switch where it receives power to activate the fuel shut off valve.
BATTERY CHARGING SYSTEMS USED ON THE ZT2350 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.
ADJUSTING THE DRIVE CONTROLS Remove left and right instrument covers for access Once the tracking adjustments have been made on the previous page, the handles can now adjusted straight across from each other by loosening both nuts that mount handles and rotate them forward or backwards.This adjustment can also be used to bring both handles closer or farther forward for the comfort of the operator. Adjusting this screw and its locking nut can move the handles left or right to avoid contact between them.
TRACKING ADJUSTMENTS Adjustments to the unit may need to be made if the unit does not track in a straight line. The primary reason for the unit not tracking straight is incorrect or unbalanced tire pressure. Before making any adjustments first check and adjust the tire pressure. DO NOT EXCEED MAXIMUM RECOMMENDED TIRE PRESSUE. ADJUST LINKAGE: Place steering levers outward locking them in the neutral position. Turn off engine and raise seat. Under the seat are (4) adjustment bolts.
REPLACEMENT OF THE HYDRO UNIT Prepare to replace the unit by jacking the mower up on the side where the defective unit is located. Use a jack stand to support the mower while you are working. Remove the wheel on the defective unit. Remove the rear cover behind the clutch and remove the deck belt. Remove the transmission idler spring from its mounting bolt on the transmission plate allowing the transmission belt to be removed from the defective unit.
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 the shaft. Make sure the outer lip is down to best contact the pulley. 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.
BELT REPLACEMENT ROUTING •Clutch drive belt replacement •Remove belt covers •Disconnect tension idler from tension bracket •Remove belt from mower pulley and electric clutch Part # 3816 •Install new belt onto electric clutch and mower pulley and check for proper routing and clearance. •Reconnect idler tension bolt to tension bracket Hydrostats belt replacement •Remove clutch drive belt. See clutch belt replacement. •Disconnect wiring from electric clutch. •Disconnect idler spring from tension bracket.
REPLACEMENT PARTS Quick Reference Swisher Part# Description •66LR Hydro belt •3752 Deck belt for 42” •3816 Deck belt for 50” •9004 and 9005 Blades for 42” (1 of each) •10099 Set of Blades for 50” •9018 Blade driver assembly •B98 Blade driver bearing •9076 Blade shaft •3785 Blade pulley for 42”deck •B4104TK Blade pulley for 50”deck •3623 Ignition switch •9043 Starter solenoid •3605 PTO switch •6102NC Gas cap •TZ2S Deck idler spring 16
“Z” SERIES swisherinc.com ZERO TURN HYDROSTATIC DRIVE 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.
