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so today i'm going to be talking about
burnt out pto switches
and how to possibly solve that issue
[Applause]
so i got a machine here and the guy
basically had a no pto start issue he
would
pop his pto switch nothing would happen
now i
worked on this machine previously it's a
white outdoor zero turn
you can check that video out in the top
right of your screen now if you haven't
seen that video i would highly recommend
watching
that first just to get an idea of things
but to kind of fill you in if you're not
going to watch that and the pto would
not engage
after diagnosing a few things i found
that it was a left hand
reverse safety switch that was bad so i
replaced that and it worked right away
so again that's why we only
put 12 volts to the pto and when i
replaced this uh
left-hand reverse switch you guys can
see intermittent sometimes i tested it
and it had continuity other times
it didn't and with the new switch in
with this still hooked up it didn't work
so as soon as i replaced this the thing
fired right up and the pto worked fine
so again that's why we thought the
problem had been solved we returned
the machine to the customer and then
about two and a half weeks later
he called me up and just said the pto
switch he would pop it and nothing would
happen
and he said that he thinks it was just a
faulty pto switch
at which point i had another one in
stock so i gave it to him
he popped it in and it said it worked
perfectly fine so we just assumed
that it was just a bad pto switch he did
not tell me though that
he was running into melting pto switches
so we can see here
that a couple of the connectors are bent
and twisted
and you guys can actually probably make
it out that they're starting to melt
this was melted and i never knew that
because he didn't show me now if you're
running into an issue of
melted pto switches or your wires are
getting really hot
you have an amperage issue specifically
too many amps
normally the number one cause of burnt
out pto switches
is your pto itself you have a magnet
here and
essentially it just engages it sends an
electrical current through
and the magnet picks up on a disk which
then transfers your
crankshaft power to your pulley down
there and basically turns your belts
so you guys will be able to hear it
click
so what you get is essentially more
or less resistance when we test these
two connectors and i'm going to show you
how to do that so
you're going to need a multimeter and
you're going to have to probe the wires
now if it's on the machine
you could technically back probe so it's
good to separate the pto by itself
so that you can directly probe the
terminal here
and a pto on average is supposed to have
anywhere from two to four
ohms of resistance so you're going to
take your multimeter here
and you're gonna set it to ohms and
we're running it on 200 because we're
testing
in between two to four you guys can see
that right now it's an average of
zero zero point five ohms of resistance
and we're supposed to have two to four
so what's happened here
is we have a short somewhere in the
windings
the magnetic pickup inside of this pto
and because it has a short it's drawing
more amperage
through the system and these two wires
go back to the pto switch and that's
what's burning out the pto switches
so i have a new pto switch that i'm
going to be running and i just purchased
a new pto for my customer this is an
outdoor power
extreme pto he opted for the
aftermarket one this is the aftermarket
now the one that came
on it was an ogura it's a gt-1a
mt-09 now the warren pto
said is a factory replacement so
possibly a factory replacement for this
one here
that ran for about 500 and this extreme
pto clutch ran for 285 so my customer
always at their discretion what parts
they run when i give them the option
between oem or aftermarket
and he chose aftermarket so we're going
to be setting this up
but before i hook it up i'm going to
test the resistance on this
just to show you guys what a pto should
properly test like
and the number for this is a stenz 255
two nine five x that's for the extreme
and this replaces the warner 5219-99 and
if you guys can see here
they pack these things full of
anti-corrosion
grease so that goes in there and that
prevents resistance from building up
from
rust or corrosion on that connector
which is nice to see
so again with your multimeter set to 200
ohms of resistance i've taken
my leads here and i've just plugged them
into the terminal now the horizontal
connector there that's your positive it
says red and on
the vertical here that's your negative
but you guys can see i have that plugged
in
and we're measuring 3.3 ohms of
resistance
so again ptos are supposed to measure on
average two to four
and we're measuring 3.3 so this pto is
good
which it obviously should be because
it's brand new so
i'm going to disassemble all of this i'm
going to
clip off this zip tie we're going to
hook this onto the machine
and test everything out okay so just
comparing my ptos here i don't have a
washer
on the original one but the new one has
i guess you could call that a thrust
washer and
on the flip side of this we have a
little
adapter spacer here so that's going to
have to get some
nickel annie sees put onto it but this
is how i pulled off the original one
and i guess my customer or someone else
might have had this off already but like
i said in my video
we just had an issue where it wouldn't
engage so all i did was do a 12 volt
test
to make sure that the pto itself engaged
where we back probed that connector
put 12 volts to it it clicked and that
let me know that the pto itself was good
but what that didn't let me know was
whether or not the windings in here
had a short or some kind of issue and
that was the problem so
again once i found out that he was
melting pto switches then i knew right
away that pto had to be replaced so it's
just a case of r r
guys which is remove and replace again
i'm just gonna have to go and look
through but it appears
the way they ship this is this goes on
the top this washer here the thick one
so we're going to be torquing that to 50
to 55 foot pounds
and again you could just go ahead and
measure your bolt there whether it's a 3
8 or a 7 16
or an m10 but in this case we're going
to run about 50
foot-pounds of torque on this and just
something to be aware of
there are two different length bolts the
original one is slightly longer
however it had a lock washer so if you
add the thicknesses of those
washers it brings it up to the same
thread
length so again i'm going to be using
the new
bolt even though it doesn't have a lock
washer on it because they don't give you
one and like i said we're going to be
using a little bit of permatex
nickel anti-seize and i'm just going to
be putting that onto the adapters and
the washers so
if this ever needs to come apart for
whatever reason then
he can take it off and he won't have to
worry about things seizing because you
have to remember
if a pto ever seizes to a shaft it's
unlike a pulley that you can kind of
heat up
or you know take a pry bar to and mangle
these are going to be difficult
to get at and you're not going to be
able to run a torch in there to heat
things up to expand them so
again you want to make sure you're
running some kind of anti-seize
to make sure that if these ever have to
come off they come off nicely okay so i
got the new pto
installed and i've torqued it to 50
foot-pounds just like
the instructions said so i'm going to
put a new pto switch in it and we're
going to test this thing out and i'm
just going to be using a little bit of
permatex
dielectric grease on my connector here
so
same as the pto plug had i'm going to do
that for the pto switch
and like i said brand new pto switch
install that
everything should work
okay so i just got back from my
neighbor's house i went and cut my front
yard and i went and cut my buddy kyle's
he lives two doors down
so i cut his front yard as well i just
wanted to use the machine and put it
under a load and what i was
kind of feeling for after i stopped
cutting
was to see if the switch was hot and i
went and
felt up underneath just to see if any of
the wires were warm
and everything seems to be good
everything's cool to the touch
there's no heat in the plug it was in
fact the pto that needed to
be replaced and i mean the resistance
test showed that
the old pto was only testing 0.4 ohms
and the new one was testing 3.5 which is
again supposed to be
anywhere between two to four ohms and
that's it guys so this thing
is done ready to be returned back to the
customer fingers crossed there's no
other issues with
anything relating to the wiring or
electronics before i take this back to
the customer though
i'm going to be changing the oil and the
oil filter as well as the air filter
so i probably won't put that in the
video but that'll just be a
extra little thing to do for my service
before i bring it back to my customer
but that's it for today's video if you
guys enjoyed it think about leaving me a
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thanks for watching
[Applause]
you
