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WORKSHOP MANUAL

ZT 5132 T

Chapter

7 - ELECTRICAL SYSTEM

EDITION

2017

PAGE

39 /

7.1 TROUBLESHOOTING

7.1.1 Electrical system problem table

Below are some of the most common problems connected to the malfunctioning of the electrical

system are shown, with their probable cause and the remedial action to be taken.

Summary

7.1 TROUBLESHOOTING .........................................................................39

7.1.1 Electrical system problem table ....................................................39

7.1.2 Safety device intervention table ....................................................40

7.1.3 Equipment ....................................................................................40

7.1.4 Electrical measure gauges ...........................................................41

7.1.5 Electrical measurements ..............................................................42

7.2 SYSTEM AND COMPONENT DESCRIPTIONS .................................42

7.2.1 Wiring ...........................................................................................42

7.2.2 Battery ..........................................................................................43

7.2.3 Switches .......................................................................................45

7.2.4 Ignition switch ...............................................................................47

7.2.5 Relays and Solenoids ...................................................................47

7.2.6 Fuses ............................................................................................48

7.2.7 Diodes and Rectifiers ...................................................................49

7.2.8 Electromagnetic clutch .................................................................49

7.3 FUNCTIONAL CHECKS ......................................................................50

7.3.1 General system checks ................................................................50

7.4 ELECTRICAL WIRING DIAGRAMS ....................................................52

7.4.1 Wiring layout .................................................................................52

7.4.2 Operating layouts in user modes ..................................................53

7 - ELECTRICAL SYSTEM

PROBLEM

CAUSE

REMEDY

Engine does not start

The ignition consent conditions

have not been complied with

Comply with all consent conditions and test all the

microswitches

[

7.1.2]

[

7.2.3]

Low battery

Recharge the battery

[

7.2.2]

Uncertain battery cable con-

nections

Check and clean the terminals

[

7.2.2]

Uncertain spark plug

connections or faulty spark

plugs

Check and replace

Electromagnetic clutch

malfunction

The operator is absent

Comply with the consent conditions

[

7.1.2]

The operator present switch is

faulty

Check and replace

[

7.2.3]

Faulty switch, diode or clutch

Check the components

[

7.2.3]

[

7.2.7]

[

7.2.8]

and replace them

Summary of Contents for ZT 5132 T

Page 1: ...ZT 5132 T 2017 2019 WORKSHOP MANUAL ...

Page 2: ...use the correct equipment all the opera tions described with the objective of safeguarding machine performance and safety The Manufacturer is under no circumstances liable for any damage or injuries due to interventions performed by private individuals or inadequate facilities This manual does not contemplate interventions and repair work on the engine and transmission units as it is necessary to ...

Page 3: ... manual is divided into chapters paragraphs and sub paragraphs The front inside cover provides the table of contents indicating the various chapters Each chapter is dedicated to a specific topic and is preceded by an index that marks the various paragraphs contained therein Each paragraph is further divided into sub paragraphs relative to a single procedure Cross references to other parts of the m...

Page 4: ...al followed by the number of the relevant chapter paragraph or sub paragraph b Safety terminology and notes Some paragraphs are preceded by a definition that highlights their importance NOTE General reference for the correct maintenance execution and methods IMPORTANT Specific procedures or information necessary to avoid damage to the machine or equipment WARNING Non observance will result in the ...

Page 5: ... not entail particularly hazardous situations besides the normal hazard related to mechanical operations and that can be avoided by taking the neces sary care and attention normally required for this type of work As well as following the usual accident prevention regulations that apply to most repair shops we recommended you remove the ignition key before beginning any repair work protect hands wi...

Page 6: ... engine which results in a change in performance or use that is incorrect or different from the purpose for which it was designed and approved warn the Customer that failure to comply with the above points automatically voids the warranty and the responsibility of the Manufacturer 1 3 SERVICE CENTRE PROCEDURES 1 3 1 Machine registration The Warranty registration card must be completed signed and r...

Page 7: ...d parts in case of any subsequent disputes with Customers 1 3 5 Fault notification The Manufacturer welcomes any notifications of faults that recur with particular frequency It gives the opportunity for a careful inspection of the problem and the implementation of corrective action at production level Similarly the Manufacturer will report any faults discovered on the machines produced with rec om...

Page 8: ...facturer The engine has a serial number that clearly identifies the product and its specifications this number must al ways be quoted when requesting spare parts or any information from the Manufacturer Summary 2 1 IDENTIFICATION OF THE MACHINE AND COMPONENTS 8 2 1 1 Machine identification 8 2 1 2 Engine identification 8 2 1 3 Transmission Unit identification 9 2 2 EQUIPMENT REQUIRED 9 2 2 1 Basic...

Page 9: ...e makes it more practical to perform the interventions in the lower area of the machine 2 2 2 Special equipment No special tools or equipment are required to perform standard servicing operations However in order to facilitate checking the alignment of the blades it is recommended to use to use an in strument to measure the height from the ground 1 or extensible abutments 2 2 2 3 Screwing and torq...

Page 10: ...the footplate 2 and lift it enough to insert two stands 3 under the support arm 4 on the front wheels Release the jack and make sure the machine is stable before starting any work 2 3 3 Rear lifting Position two suitably sized wedges in front of the front wheels to prevent all uncontrolled movement of the machine Position a jack 1 in the centre of the rear beam of the chassis 2 and lift it enough ...

Page 11: ... the machine Clean the machine seat cutting deck etc removing all dirt and debris Do not use high pressure washers sol vents aggressive detergents or abrasive cleaners Re store damaged paint using STIGA paint Check the tyres See the technical specifications 3 1 Check and sharpen the cutting deck blades Check that the blades are not worn or damaged Sharpen and balance the blades 6 2 5 Check the bat...

Page 12: ...r over time conducting appropriate checks every time there is the chance to do so The machine safety system includes a Electric safety devices Always check the operation of the safety microswitches simulating various situations of use as indicated in the specific chapter 7 1 2 b Safety labels and symbols These labels are considered an integral part of the safety devices Always replace illegible an...

Page 13: ... 16 5 kw 3150 Tank capacity litres 10 5 Electrical system Voltage 12V Battery 12 Ah 190 CCA Transmission Transmission units brand and model N 2 Hydro Gear EZT 2200 1 Rh 1 Lh Maximum forward speed km h 11 3 Maximum reverse speed km h 4 8 Control belt Trapezoidal belt section HA unwrapped Wheels and Tyres Front Tubeless 11 x 4 5 Rear Tubeless 18 x 8 5 8 Front tyre pressure kPa 3 bar Front tyre press...

Page 14: ...WORKSHOP MANUAL ZT 5132 T Chapter 3 TECHNICAL DATA EDITION 2017 PAGE 14 58 3 2 OVERALL DIMENSIONS ...

Page 15: ...drive belt procedure 5 2 4 1 FIRST disconnect the black ground cable from the battery and THEN the red cable to prevent possible short circuits and dangerous situations 2 Disconnect the fuel delivery pipe taking care not to spill fuel 3 Remove all engine connections the accelerator cable the choke cable the cabling connector the starter motor connector the ground cables the venting tube 4 Measure ...

Page 16: ...lied To reassemble follow the operations described above in the reverse order taking care to make sure that the pin 8 is correctly inserted into the hole of the reaction arm 9 to start with manually tighten the engine fastening screws by 3 4 turns then fully tighten to a torque of 31 34 Nm tighten the clutch fastening screws to a torque of 43 64 Nm reinstate the tension of the tensioner spring 3 r...

Page 17: ...cing it and to do so requires the removal of certain elements of the unit beforehand 1 Unscrew the tank cap 1 disconnect the cap 1 clip 2 and fasten the wire 3 to the nozzle 4 to prevent it falling inside 2 Remove the left cover of the chassis 5 fixed by two screws 6 accessible from the front low er section one screw 7 fixing the rear section in place 1 2 6 5 6 7 5 1 4 2 3 ...

Page 18: ...f the fuel tank Completely empty the fuel taking care not to disperse it in the work area 1 Remove the clamp 1 disconnect the petrol pipe 2 and the venting tube 3 2 Grasp the tank 4 and extract it from its seat Complete the reassembly process following the steps described above in the reverse order Reconnect the fuel pipe 2 and the clamp 1 making sure there are no leaks 8 10 9 1 3 2 4 ...

Page 19: ...tion of travel to obtain a straight forward movement of the machine with the two levers aligned with each other 5 1 3 5 1 2 Ergonomic adjustment of the levers a Adjustment of the height and the longitu dinal position 1 Undo the two nuts 1 and move the lever 2 to the desired height using two of the three holes provided on the control arm 3 WARNING The lever must always be fixed by two screws Summar...

Page 20: ...s 1 and rotate the eccentric screw 2 until the desired distance between the levers is reached when returned to the working position 2 Fully tighten the nuts 1 5 1 3 Adjusting the direction of travel The stroke of the steering levers may require adjustment if the machine tends to deviate from its trajectory towards the right or left when both steering levers are pushed fully forward at maximum spee...

Page 21: ...affected side 3 Adjust the speed Turning the screw 2 clockwise to decrease the speed of the corresponding wheel Turning it counter clockwise to increase the speed of the corresponding wheel 4 Tighten the lock nut 1 If after this adjustment the lever handles are not aligned with each other proceed with the align ment adjustment 5 1 2a 5 2 TRANSMISSION 5 2 1 Adjusting the neutral system and parking ...

Page 22: ...d to Step 7 6 Stop the engine and reconnect the rod 7 and adjust the mechanical linkage of the machine 7 Observe the direction of the axle rotation Switch the engine off Loosen the adjuster screw 8 so that it is possible to rotate the con trol arm 9 Rotate the control arm in the op posite direction to the axle rotation with small 5 increases until the axle comes to a halt 8 Tighten the adjuster sc...

Page 23: ... instructions in the reverse or der When reassembling the parking brake rod 6 check that when the brake is engaged the toothed section 14 remains engaged with the cogwheel 9 with a spring 15 compression of 3 4 mm with respect to its free length The parking brake is adjusted correctly when it stops both the hydrostatic units and activates the safety microswitch c Adjusting the parking brake microsw...

Page 24: ...ng maximum operating speed NOTE The hydrostatic transmission units have a predetermined range of use given by the sum of the maximum speeds in forward and reverse gear Therefore any increase of either of the two pa rameters reduces the other and vice versa Maximum forward gear speed is given by the dis tance between the holes on the two rods 1 and 2 and has a factory default setting of 670 mm NOTE...

Page 25: ...ed with the piston crown facing the rear section of the machine 5 2 4 Replacing the transmission belt Follow steps 1 to 5 of the Blade control belt replacement procedure 6 3 1 1 Disconnect all electromagnetic clutch cables 2 Undo the two screws 1 and remove the heatproof baffle 2 to facilitate the next operations 3 Loosen the fixing screw 3 on the clutch 4 4 Hold the two parts of the blade control...

Page 26: ...reverse order to reas semble the clutch and blade control belt 6 3 1 5 2 5 Removing the transmission units Lift the rear part of the machine 2 3 3 Remove the rear wheel on the side required 5 3 1 1 Undo the two screws 1 and remove the heat proof baffle 2 to facilitate the next operations 2 Loosen the tension of the drive belt on the transmissions Measure the threaded project ing part of the pin 3 ...

Page 27: ...4 Undo the screw 8 fastening the connection rod 9 from the side of the transmission to be removed 5 Release the split pin 10 and disconnect the parking brake rod 11 6 Undo the screw 12 and disconnect the by pass lever 13 7 Unscrew the nut 14 and disconnect the rod joint head 15 from the drive control lever 9 8 13 12 10 11 15 14 6 7 ...

Page 28: ...s 24 Undo the nuts 22 and then carefully undo the two lower nuts 24 holding up the unit so that it does not fall When reassembling perform the operations described above in the reverse order Tighten the nuts 22 with a torque of 33 37 Nm Tighten the nuts 24 with a torque of 33 37 Nm NOTE After replacing a hydrostatic unit we rec ommend moving the by pass 25 lever 5 6 times in both directions so as ...

Page 29: ...eformed rims as they could impair the hold of the tyre On assembly it is advisable to spread grease on the shaft to facilitate the next wheel removal Tighten the screw 2 to a torque of 65 98 Nm 5 3 2 Replacing the front wheels Lift the front part of the machine 2 3 2 Undo the screw 1 and remove the wheel 2 from the support fork 3 NOTE The replacement wheel is available to gether with the tyre and ...

Page 30: ...tioned correctly Tighten the screw 2 to a torque of 124 Nm 5 3 4 Replacement and repair of tyres The tyres used on this machine are of the Tubeless type and so every repair of a hole in the tyre must be done by a tyre specialist according to the methods used for this type of tyre IMPORTANT The rear tyres can have different rolling diameters due to wear or after replacement of one of the two These ...

Page 31: ...the cutting deck to its highest position NOTE When measuring the blade heights it is recom mended to use to use a suitable measuring instrument 1 or extensible abutments 2 Summary 6 1 ADJUSTING THE CUTTING DECK 31 6 1 1 General information 31 6 1 2 Adjusting the blade height 31 6 2 BLADE MAINTENANCE 33 6 2 1 Access to the lower section of the cutting deck 33 6 2 2 Checking blade alignment 33 6 2 3...

Page 32: ...tation of each blade en gages the rotation of the other 4 Place the abutments 2 under the ends of the blades adjusted using the following values 114 mm below the front end 120 mm below the rear end or insert the measuring instrument 1 moving the feeler in line with the two ends of each blade 5 Adjust the lower nuts 5 on the two front rods 6 and the lower nuts 7 on the two rear rods 8 first on one ...

Page 33: ...dling the blades WARNING The three blades are connected to each other the rotation of each blade engages the rotation of the other two 1 Grasp two blades firmly together and rotate them so as to bring the cutting edges closer then check that the gap between the two ends does not exceed 4 5 mm 2 Repeat the operation approaching the cutting edges of the blades in the various different combinations H...

Page 34: ...rewdriver and a torque wrench 6 2 5 Sharpening and balancing the blades A badly sharpened blade causes grass to be come yellow and reduces grass collection capa bility if not balanced excessive vibration can be caused during use Always sharpen both cutting edges of the blade using a medium grade grinder Sharpening must only be performed from the side shown in the diagram removing as little materia...

Page 35: ...ment 1 Remove the left cover 1 fixed by three screws 2 2 Remove the right cover 3 fixed by three screws 4 3 Remove the centre cover 5 fixed by four screws 6 4 Release the spring 7 and rotate the tensioner arm 8 to loosen the belt 9 5 Hold the two parts of the belt 9 to release it from the clutch pulley 10 4 3 4 1 2 2 7 8 9 10 9 5 6 ...

Page 36: ...tions illustrated in the diagram Reassemble all removed parts fol lowing the above instructions in the reverse order 6 3 2 Replacement of the blade flanged supports Lift the front of the machine and stabilise it to al low required accessibility 6 2 1 Remove the blade to be replaced from the flang ed support 6 2 4 Follow steps 1 to 4 of the Blade control belt re placement procedure 6 3 1 Undo the f...

Page 37: ...OVAL OF THE CUTTING DECK 6 4 1 General information By removing the cutting deck you can carry out all servicing and replacement operations on the blade flanged supports and the drive systems more comfortably and easily With some practice and experience it is possible to do this job with the deck still in position 6 4 2 Removal and reassembly of the cutting deck 1 Place blocks under the edge of the...

Page 38: ...e nut 12 and remove the screw 13 being careful not to lose the connecting elements including the washer 14 the shorter internal spacer bar 15 and the bushing 16 8 Remove the cutting deck sliding it out from the right hand side Reassemble all removed parts following the above instructions in the reverse order paying attention to Correctly reposition the short spacer bars 15 in relation to the slot ...

Page 39: ... 6 Fuses 48 7 2 7 Diodes and Rectifiers 49 7 2 8 Electromagnetic clutch 49 7 3 FUNCTIONAL CHECKS 50 7 3 1 General system checks 50 7 4 ELECTRICAL WIRING DIAGRAMS 52 7 4 1 Wiring layout 52 7 4 2 Operating layouts in user modes 53 7 ELECTRICAL SYSTEM PROBLEM CAUSE REMEDY Engine does not start The ignition consent conditions have not been complied with Comply with all consent conditions and test all ...

Page 40: ...repair work A brief description of these follows Needle nose or long pliers Used to connect or bend wires and connectors in tight positions Diagonal cutters Used to cut wires or trim connections Wire stripper crimping tool Available separately or as a combined tool Used to strip insula tion from wires of various sizes crimp terminals and connector or wires Soldering iron and soldering gun Used to ...

Page 41: ... AC and DC Ammeter and an Ohmmeter Combination meters that do all of these things are available and called a Multimeter or Volt Ohm multitester VOM Meters of this kind are available in many forms and all change functions and ranges with switches or by plugging test leads into different jacks Multimeters are available in two basic types Analog and Digital Analog meters Analog meters have a needle t...

Page 42: ...esistance measurement An Ohmmeter is used to make resistance measurements and to check continuity through wires and electrical components There is one rule to keep in mind when using an ohm meter The ohmmeter has a self contained battery and requires no electrical power Using the ohmmeter on a circuit that has voltage applied may result in damage to the meter IMPORTANT Disconnect the battery from ...

Page 43: ...ccumulation of dirt corrosion cracks or loose or broken parts Keep the battery and its terminals clean Re place the battery if damaged Clean or service the battery after removing it from the machine Remove corrosion from battery terminals and cable connections with a wire brush then wash with a weak baking soda solution Scrub the exterior of the battery and cable terminals with a non metallic brus...

Page 44: ...bles Jump starting battery charging or replacement is required when the starter motor will not crank the engine IMPORTANT The machine used for jump starting should have a 12 volt battery with at least 500 cold cranking amperes and a negatively grounded system DANGER FROZEN BATTERIES CAN EXPLODE and result in death or serious in jury DO NOT charge a frozen battery Let the battery thaw out before pu...

Page 45: ...g current flow through it An example is an ignition switch that grounds the mag neto when in the OFF position completing the circuit but opens the circuit when in the ON po sition allowing the engine to operate The switches are selected with reference to their nominal current the contacts must be of sufficient size to carry the required current rated voltage and type of actuation pressure switches...

Page 46: ...es a defective switch The diagrams show the connections of the electrical components in different situations NOTE The continuous line indicates the electrical continuity of the circuit All switches are shown from the rear 3 9 4 7 1 3 9 4 7 1 B L M S A Y G B L M S A Y G B L M S A Y G 87 86 30 85 87A 87 86 30 85 87A 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 PTO Switch Seat switch Starter solenoid Relay Parkin...

Page 47: ...switch is function ing properly there will be no continuity between the contacts other than that described 7 2 5 Relays and Solenoids Solenoid and relays are both magnetically operated devices Both devices operate on the principle that passing a current of electricity through a coil of wire will create a magnetic field strong enough to attract a piece of iron or steel Each device uses this princip...

Page 48: ...eck across the coils with a voltmeter The voltage should read 12 volts with the ignition switch in the START position If no voltage appears the defect is in the start circuit If the voltage is correct turn off the power and check continuity of the coil with an ohmmeter If the coil is open the solenoid is faulty and must be replaced If the coil has the proper voltage applied and the continuity chec...

Page 49: ...eplaced IMPORTANT Diodes are marked to indicate polarity a band on one end an arrow on the side or they fit on a holder only one way to prevent inverting the polarity Rectifiers The battery is charged via an alternator on the engine A charging circuit contains a rectifier because alternators produce alternating current AC and batteries require direct current DC for charging The rectifier may be bu...

Page 50: ...ion and the fuse on the red wire Phase 3 With the ignition switch in the RUN position check if the battery voltage is transferred from terminal B to terminal A Terminal A on the ignition switch provides battery voltage to the rear of the PTO switch on the purple wire and to the neutral switches on the red purple wire to terminal S2 on the ignition switch and to terminal 85 on solenoid no 2 Termina...

Page 51: ...in the RUN posi tion test for battery voltage at terminal B A S2 There must be no voltage on terminal 51 PTO switch test The PTO switch is a push pull switch with normally open and closed contacts Test for transfer of power with a voltmeter The switch contacts should be tested using an ohm meter after disconnecting the wiring connector Diode test The diodes are tested with an ohmmeter set to diode...

Page 52: ...K PU BK 1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO 7 Electromagnetic clut...

Page 53: ... PU PU WH BK PU BK 1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO 7 Electroma...

Page 54: ...1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO 7 Electromagnetic clutch 8 Dio...

Page 55: ... 1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO 7 Electromagnetic clutch 8 Di...

Page 56: ...PU PU PU WH BK PU BK 1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO 7 Electro...

Page 57: ...RE YE RE PU PU PU WH BK PU BK 1 2 WH BK A B 86 85 87a 87 30 6 L 3 1 2 5 S1 B G M S2 1 2 2 1 Colour Circuit Black Ground Red 12 VDC Battery Blue Start Green PTO Cable Color BK Black BR Brown GR Green PU Purple RE Red WH White YE Yellow Components 1 Engine a Starter b Magneto kill c Regulator d Fuel solenoid e Oil pressure 2 Battery 3 Starter solenoid 4 Starter relay 5 Key switch 6 Blade switch PTO ...

Page 58: ...STIGA S p A Via del Lavoro 6 31033 Castelfranco Veneto TV Italy www stiga com ...

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