How to Test a PTO Clutch for Resistance!

Melted PTO Switch?

In today's video, I'll be showing you how to test a PTO Clutch for resistance!

I've worked on this mower previously & we had a safety switch issue that we diagnosed, watch that video here:    • Fixing Electrical Issues - PTO not Engaging  

When performing a 12volt Test on this PTO Clutch, the clutch engaged & worked perfectly fine. To conduct this test, simply unplug your PTO clutch and put 12v directly to it. You should hear the electro-magnet engage.

However, once we tested for resistance, the reason for the melted PTO switch became clear.

Normally, a PTO Clutch will test at 2-4 Ohms of resistance (regardless of whether it works or not).

This PTO Clutch tested at 00.4 Ohms & was removed & replaced.

The reason the PTO clutch tested under 2ohms is because it has a "short-to-ground" somewhere inside the clutch itself, which lowers the resistance.

If the PTO clutch tested over 4ohms, there could be corrosion (caused by moisture) built up on the connector, or inside the electro-magnet itself. This corrosion would cause higher resistance.

Explanation on why the switch melted;

In an electrical circuit, if Voltage remains the same, and resistance is decreased, amperage increases.

Here's a textbook definition: "Voltage equals the amperage multiplied by the resistance in a circuit. If the voltage remains constant and the resistance is dropped, the amperage across the circuit must increase."

Essentially, with a short to ground there is little to no resistance, as electricity takes the path of least resistance. So because the 12v from the battery (around 14v from the magneto/charing system when the engine is running) always stays the same, and the resistance decreased due to the short-to-ground, this is what increases the amps in the circuit!

This increased amperage overloads the wires, which will then create additional heat on the wires & connectors, causing them to prematurely fail, and possibly melt.

I gave my customer 2 options for PTO Clutch replacements on this White Outdoors ZT50 mower.

The 1st was an OEM direct replacement;

Warner 5219-99 for $507.98

The 2nd was an Aftermarket Xtreme conversion kit;

Xtreme X0391 for S285.34

My customer opted for the more affordable option, so I went with the Xtreme!

We test the new PTO Clutch for resistance & it tests around 3.5 Ohms.

When installing the new Xtreme Clutch, you MUST use the top spacer they provide, as it prevents the PTO clutch from riding up the crankshaft!

If you don't use this, you'll void the warranty!

Also, make sure to engage the new PTO Clutch at half throttle, approx. 10 times before re-torquing the bolt to 50-55 ft-lbs.

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