QuestionHi,
I am trying to get my bothers Toro Z5000 mower running. It has a Kohler Courage 21 engine and is the SV610 model.
The mower has a new solenoid and ignition switch but the starter will not work unless the solenoid leads are crossed with a wrench. After crossing the solenoid the engine cranks but there is no spark to the plug. I have verified this with an inline spark tester. I have also verified the ignition module coil is good with a multi-meter...it check within the range it is suppose to.
I noticed there is a hella 12v relay next to the fuse box. Could this be causing the problem? I have no idea how to check the relay as it has 5 leads on it.
I also checked the fuses....all good. I noticed online there is a mention of a diode; possibly this could be why I am not getting a spark?
Here's a link to the service manual:
http://www.kohlerengines.com/onlinecatalog/pdf/tp_2548_a.pdf
Thanks so much for your help.
Adam
AnswerHello Adam:
From your Description it Sounds like there is a Safety Switch that is Preventing the Coil from Firing.
>>Have you Checked All the Safety Switches?
>>I Suggest you Check the Ign Module First and then the Safety Switches if the Ign Module (Coil) is Good. Remember that the Ign Module May Check Good, but if the Safety Switches Check Good, then Most likely the Coil is in the Early Stages of Breaking Down and will Cause this Problem.
>>You can Check the Ign Module (Coil) by Using the Following Instruction File.
The Following is an Instruction File I Made for Checking and Repairing this Problem.
>>Run the Engine Until it Quits (if it will Start).
>>Remove the Spark Plug. Wrap a Wire Around the Threads and Attach the Other End of the Wire to the Engine Block Turn the Engine and See if the Plug Fires.
>>If No, then Disconnect the Shut Off Wire at the Control Bracket First, Check for Fire at the Plug. If Still No Fire at the Plug; Then Disconnect the Shut Off Wire at the Coil (usually requires removal of the blower housing) and Check for Fire at the Plug.
>>If No Fire at the Plug , then the Coil/Ign Module is Bad. The Coil/Ign Module to Flywheel Gap is .020in.
>>On Some Model JD Engines, there is a Igniter that Goes Bad and Not the Coil. The Igniter is the Same as an Ignition Module. If the Plug Fires at Anytime During these 2 Checks, then a Safety Switch or Wire May be the Problem. Yes the Engine will Turn Even with a Bad Seat Safety Safety Switch. Usually if the Engine will Not Turn with the Ign Switch; the Blade Safety or Neutral/Clutch Safety Switch is Usually the Cause of this.
>>The Starter Turns and the Engine Doesn't Fire is an Indication of a Bad Coil/Ign Module or a Faulty Blade Safety Switch.
>>The Blade and Clutch Safety Switches Prevent the Starter from Engaging so the Blades or the Mower Does Not Move when the Starter Turns the Engine.
>>The Seat Safety is Designed to Stop the Engine if the Blades are Engaged or the Clutch Safety is Not Engaged when you Leave the Seat.
>>The Following is an Instruction File for the Safety Switch System. Any Input is Appreciated.
>>The Color Code of the Wires May be Different than those I Use as a Reference in the Instruction File.
>>**PLEASE REMEMBER THAT THE INSTRUCTIONS FOR CHECKING THE SAFETY SWITCHES IS JUST THAT!!! FOR CHECKING ONLY.
>>I NEVER Suggest a Mower be Operated with a Safety Device or Switch Disconnected or Bypassed.
>>**Now. On Some Model Mowers you can Simply Unplug the Safety Switch from the Harness. On Other Models you have to Place a Jumper Wire Between the Harness Terminals (on the 4 Post Switch (Clutch/Brake) Jumper from Same Color Wire (Example: White to White) First and then Check for Fire, Now Include the Black to Black Wires if No Fire.
>>Check the Clutch/Brake and the Blade/PTO Safety Switches First.
>>Check the Seat Safety Last. Usually the Seat Safety is Not in the System for Starting the Engine. Just to Ensure Someone is in the Seat when Engaging the Transaxle and/or Blades. Use a Paper Clip or a Short Wire to Make a Jumper.**
>>Use a Volt/OHM/Continuity Meter and Check the Continuity of the Switch. The Meter should Show when the Contacts are Closed and Open. The Meter will Swing All the Way Over when the Switch Contacts are Closed and Swing Back to the Rest Point when the Switch Contacts are Open.
>>If the Safety Switches Check Good, then Check the Ign Module (Coil).
>>The Following is an Instruction File for the Safety Switch System. Any Input is Appreciated.
>>The Color Code of the Wires May be Different than those I Use as a Reference in the Instruction File.
>>**PLEASE REMEMBER THAT THE INSTRUCTIONS FOR CHECKING THE SAFETY SWITCHES IS JUST THAT!!! FOR CHECKING ONLY.
>>I NEVER Suggest a Mower be Operated with a Safety Device or Switch Disconnected or Bypassed.
>>**Now. On Some Model Mowers you can Simply Unplug the Safety Switch from the Harness. On Other Models you have to Place a Jumper Wire Between the Harness Terminals (on the 4 Post Switch (Clutch/Brake) Jumper from Same Color Wire (Example: White to White) First and then Check for Fire, Now Include the Black to Black Wires if No Fire. Check the Clutch/Brake and the Blade/PTO Safety Switches First. Then Check the Oil Guard Switch (if Applicable). Check the Seat Safety Last. Usually the Seat Safety is Not in the System for Starting the Engine. Just to Ensure Someone is in the Seat when Engaging the Transaxle and/or Blades. Use a Paper Clip or a Short Wire to Make a Jumper.**
>>Use a Multimeter and Check the Continuity of the Switch. The Meter should Show when the Contacts are Closed and Open. The Meter will Swing All the Way Over when the Switch Contacts are Closed and Swing Back to the Rest Point when the Switch Contacts are Open.
>>On Page 20 of 118, the Trouble Shooting Directs you to the Interlock Switch which is a Safety Switch.
>>Is this Switch Good?
>>If you Hit a Snag or this Does Not Correct the Problem, I am Here if You Require More Assistance. Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Be Safe and Happy. Thanks.
Good Luck
Respectfully
John
PS: I am Allowed to Answer 10 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 8pm EST (US). My New Day Starts then. Comments and Ratings are Greatly Appreciated. Thanks.
Respectfully
John
