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Workshop manual
ZTH
English
Svenska – 31
Sve-5 225/232/235 Bruk 97-11-25, 08.4631
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WORKSHOP MANUAL
RIDE-ON LAWN MOWER
ZTH
Contents
Contents
..................................................................1
Safety Instructions
.................................................3
General Instructions.............................................3
Special Instructions..............................................3
Explanation of Symbols
........................................5
Tools
.......................................................................6
Technical Data
........................................................7
Delivery and Dealer Service
................................11
Pre-delivery Service...........................................11
After the First 8 Hours........................................12
25 Hour Service.................................................12
50 Hour Service.................................................12
100 Hour Service...............................................13
300 Hour Service...............................................13
At Least Once a Year.........................................14
Maintenance Schedule ......................................15
Delivery Servicing
................................................19
To our Dealers...................................................19
Removing the Mower from its Packaging ..........19
Delivery Service.................................................20
Test Running......................................................24
Administration....................................................24
Design and Function
............................................25
General..............................................................25
Mower Identification...........................................25
Engine................................................................27
Drive and Control...............................................27
Brakes................................................................27
Mower Deck.......................................................28
Repairs
..................................................................29
Engine................................................................29
Adjusting the Throttle Wire.................................31
Checking and Adjusting the Choke Wire ...........32
Fuel tank............................................................33
Adjusting Motion Control Lever Linkages ..........34
Adjusting Motion Control Lever Spring-back......34
Adjusting the Park Brake ...................................34
Mower Deck.......................................................35
Spindle Blade Bearings.....................................36
Sharpening and Balancing Blades.....................37
Setting the Mower Deck ....................................38
Deck Belt............................................................38
Hydraulic Pump Belt ..........................................40
Front Wheel Bearings........................................41
Electrical System
................................................ 43
Troubleshooting ................................................ 43
Wiring Assembly ............................................... 43
Battery............................................................... 46
Fuses ................................................................ 46
Relays............................................................... 47
Starter Motor Contactor..................................... 47
Ignition and Start Switch ................................... 48
Hour Meter........................................................ 48
Blade Switch ..................................................... 49
Mower Deck Clutch........................................... 49
Motion Control Switches ................................... 50
Park Brake Interlock Switch.............................. 51
Welding............................................................. 52
Hydraulic System
................................................ 53
Hydraulics Hygiene........................................... 53
Hydraulic Oils.................................................... 54
Correct Oil Leaks .............................................. 54
Keep Hydraulic Oil Clean.................................. 54
Work Methods................................................... 54
ZTH Hydraulic System...................................... 55
Hydraulic Tank.................................................. 56
The Cooler for the Hydraulic System................ 57
Hydraulic Filter.................................................. 57
Hydraulic Lines.................................................. 57
Hydraulic Pump................................................. 58
Hydraulic Motors............................................... 60
Troubleshooting
.................................................. 61
Engine............................................................... 61
Wiring Harness.................................................. 61
Clutch................................................................ 63
Hydraulic Pump................................................. 66
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SAFETY INSTRUCTIONS
Safety Instructions
General Instructions
This workshop manual has been written for users who have a good understanding of the repair and
servicing of ride-on mowers.
The workshop where the ride-on mower is repaired must have have all the safety systems demanded by
local regulations.
No one is to attempt to repair the ride-on mower without having first read and understood the contents of
this manual.
The ride-on mower has been safety tested. Safety approval applies only when the ride on-mower uses
parts or equipment supplied or recommended by Husqvarna Turf Care.
Special Instructions
The fuel used in the ride-on mower is hazardous if used incorrectly. Pay particular attention to the following:
• The fuel and the fumes it gives off are toxic.
• Eye and skin complaints can result from incorrect exposure.
• Breathing difficulties can result from incorrect exposure.
• The fuel and fumes are highly flammable.
When using compressed air, users must not direct the air stream towards themselves or any other person.
Air may penetrate the blood stream and cause life-threatening damage.
Use hearing protectors when test driving.
After test driving, do not touch the muffler before it has cooled down (danger of burns). This especially
applies if the ride-on mower has a catalytic converter. If consumed, the lining on and in the catalytic
converter element can damage health. Wear protective gloves whenever working on the catalytic converter
or the silencer.
With the engine running, many engine and drive system components become hot and may cause burns if
touched. Do not touch such components before they have cooled down.
When draining oil from a hot engine or hot hydraulic system, be aware that the oil can be hot enough to
cause burns. Wear protective glasses whenever there is a risk of splashing.
The mower blades are sharp. To avoid cuts, always wear protective gloves when handling the blades.
Wear protective glasses when working with springs. Springs can detach from their mounts and fly with
great force into unprotected eyes.
Use the right tools for each job. Check all tools before using them and repair or replace as necessary.
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SAFETY REGULATIONS
Keep the workplace clean and tidy. Ensure that illumination is good, that tools which are not being used
are stored appropriately and that all waste (scrap, swarf, etc.) is immediately placed in the appropriate
container. Pay particular attention to keeping the floor clean so that there is no risk of slipping or tripping.
Be extremely careful when handling battery acid. Severe burns may result if the acid touches the skin. If
acid is spilt on the skin, drench immediately with running water.
Always wear protective glasses when handling battery acid. Blindness may result if acid gets into the eyes.
If there is an accident, take immediate action and contact a doctor as soon as possible.
Be careful when working on the battery. Explosive gas is formed in the battery. Never handle the battery
when smoking or in the vicinity of naked flames or sparks (the battery may explode and cause severe
injuries).
During certain maintenance and service operations, it is required that the mower be rendered incapable of
starting. This is to prevent injury to those working on or standing near the mower.
Hydrostatic braking may be lost if there is a failure in the hydrostatic drive.
Certain solvents and cleaning agents are flammable. Do not use them whenever there is a less dangerous
alternative. Never use flammable solvents in areas where there is a risk of ignition. Dispose of used
cleaning agents in sealed containers.
Respect the environment. Ensure that all solvents, waste oil and used oil filters are handled in an
environment-friendly way. Observe all local regulations on the environment. A Husqvarna workshop must
look clean at all times!
In this workshop manual, “warning boxes” containing further safety instructions will be found next to certain
work instructions. Observe these safety instructions, they are there for your protection.
In this workshop manual, all locators (“right”, “left”, etc.) are judged as viewed from behind the forward-
facing mower (i.e. as if standing directly behind the mower when it is ready to drive forwards).
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EXPLANATION OF SYMBOLS
Explanation of Symbols
The symbols below are used on the mower and in this manual. Study them carefully and be aware of what
they mean.
Is used in this manual to make the user aware that there is a danger of
personal injury
, especially if the
special instructions are not followed.
Is used in this manual to make the user aware that there is a danger of
material damage
, especially if the
special instructions are not followed. It is also used where it is judged that there is a danger of incorrect
handling or incorrect assembly/fitting.
WARNING!
Xxxxxxx xxxx xxxxxxxx xxx x.
xxxx xxxxxx xx.
IMPORTANT INFORMATION
Xxxxxxx xxxx xxxxxxxx xxx x
xxxx xxxxxx xx.
Park brake
Do not stand here.
Battery acid is corrosive, explosive and
flammable.
CE conformity
marking Warning! Rotating blades,
stand clear of the chute. Do not touch rotating
parts.
FuelChokeSlowFastNeutralReverse
Warning!
Max. sound emission.
Use ear protectors.
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TOOLS
Tools
The mower’s special design means that most repair and maintenance work can be carried out using
standard tools.
Servicing of engines and hydraulic pumps requires special tools. These are listed in the service manuals of
the individual manufacturers.
The mower (engine excluded) has mainly UNC or UNF screw/bolt/nut threads. Certain nuts have special
stiffy threads for securing. It is vital that exactly the right size tools (i.e. imperial measurement) are used on
these.
Those working on the mower must have ready access to socket wrench sets and open end wrenches of the
following sizes:
• 3/8"
• 7/16"
• 1/2"
• 9/16"
• 5/8"
• 11/16"
• 3/4"
The following are also required:
• Torque wrenches, 12 Nm - 110 Nm.
• 15/16" socket for torque tightening of blade bolts.
• 7/8" open end wrench or combination wrench for torque tightening of hydraulic lines.
• A set of small, imperial measurement, Allen keys.
WARNING!
If metric or other unsuitable tools are used, there is a danger that they will slip
and cause personal injury. They may also damage the surfaces of the nut or bolt
in such a way that tools can no longer get a firm grip.
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TECHNICAL DATA
Technical Data
Model
ZTH5223 ZTH6125
Model part number 968 99 91 60
Engine (spec. number) Kawasaki (FH680V-AS15) Kawasaki (FH721V-AS04)
Cylinder diameter 75.2 mm (2.96 in.) 75.2 mm (2.96 in.)
Cylinder stroke 76 mm (2.99 in.) 76 mm (2.99 in.)
Cylinder volume 675 cc (41.19 cu.in.) 675 cc (41.19 cu.in.)
Power 23 hp 25 hp
Engine RPM 2,950 RPM 2,950 RPM
Idle RPM 1,550 RPM 1,550 RPM
Spark plugs (2) NGK BPR4ES NGK BRR1550
Oil capacity, engine (total) 1.8 litres (3.8 US pints) 1.8 litres (3.8 US pints)
Engine weight 40.5 kg (89.3 lbs) 41.2 kg (90.8 lbs)
Cutting width 1321 mm (52 in.) 1549 mm (61 in.)
Blade length 457.2 mm (18 in.) 533.4 mm (21 in.)
Tightening torque, blade bolt 122 Nm (90 ft/lb) 122 Nm (90 ft/lb)
Cutting height Adjustable 38 mm (1.5") to
152 mm (6") in 64 mm
(0.25") increments
Adjustable 38 mm (1.5") to
152 mm (6") in 64 mm
(0.25") increments
Blade engagement Warner Mag-Stop
Electromagnetic clutch Warner Mag-Stop
Electromagnetic clutch
Slip torque, clutch 271 Nm (200 ft/lb) 271 Nm (200 ft/lb)
Clutch coil resistance 1.74 - 1.93 ohms at 23°C (68°F) 1.74 - 1.93 ohms at 23°C (68°F)
Supply voltage clutch 12 - 14 V 12 - 14 V
Tightening torque, clutch bolt 67 Nm (50 ft/lb) 67 Nm (50 ft/lb)
Blade tip speed 4,704 m/min. 4,541 m/min
Anti-scalp rollers 6, adjustable 6, adjustable
Tightening torque, bolt for
mower deck pulley 61 Nm (45 ft/lb) 61 Nm (45 ft/lb)
Hydrostatic drive Dual Hydro-gear pumps and
Parker/Ross Wheel drive motors Dual Hydro-gear pumps and
Parker/Ross Wheel drive motors
Tightening torque, pipe
couplings 41 Nm (30 ft/lb) 41 Nm (30 ft/lb)
Hydraulic pumps (2) Hydro Gear BDP 10A 404 Hydro Gear BDP 10A 404
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TECHNICAL DATA
Displacement 10.2 cc/r (0.623 cu. in./rev) 10.2 cc/r (0.623 cu. in./rev)
Nominal working pressure 70 bars (1000 PSI) 70 bars (1000 PSI)
Max. hydraulic pressure 145 bars (2,100 PSI) 145 bars (2,100 PSI)
Max. hydraulic oil temp 110°C (230°F) 110°C (230°F)
Weight, hydraulic pump 3.6 kg (8 lbs) 3.6 kg (8 lbs)
Hydraulic motors (2) Parker Ross Parker Ross
Tightening torque, wheel motor
hub nut 122 Nm (90 ft/lb) 122 Nm (90 ft/lb)
Hydraulic oil 1.9 litres (2 qt.), 15W-50
Synthetic 1.9 litres (2 qt.), 15W-50
Synthetic
Hydraulic oil cooler Yes Yes
Speed forward Variable, max. 12.9 km/h
(8 mph) Variable, max. 12.9 km/h
(8 mph)
Speed reverse Variable, max. 3.23 km/h
(2 mph) Variable, max. 3.23 km/h
(2 mph)
Rear tires Carlisle 24" X 12.00 - 12 Tubeless
Turf Master Carlisle 24" X 12.00 - 12 Tubless
Turf Master
Tightening torque, lug nuts 100 Nm (75 ft/lb) 100 Nm (75 ft/lb)
Front tires Carlisle 13" X 5.00 - 6 Tubeless Carlisle 13" X 5.00 - 6 Tubeless
Electrical system 12 V with 15 A charging system 12 V with 15 A charging system
Fuel capacity 44 litres (11.4 US Gal.), 22 litres/
tank 44 litres (11.4 US Gal.), 22 litres/
tank
Seat Adjustable, high-back seat with
armrests Adjustable, high-back seat with
armrests
Overall length 2057 mm (81 in.) 2057 mm (81 in.)
Overall width (chute up) 1346 mm (53 in.) 1575 mm (62 in.)
Overall width (chute down) 1600 mm (63 in.) 1829 mm (72 in.)
Overall height 1073 mm (42.25 in.) 1073 mm (42.25 in.)
Weight 464.5 kg (1024 lbs.) 464.5 kg (1024 lbs.)
Tightening torque, standard
bolts
1/4" 12 Nm (9 ft/lb) 12 Nm (9 ft/lb)
5/16" 25 Nm (18 ft/lb) 25 Nm (18 ft/lb)
3/8" 44 Nm (33 ft/lb) 44 Nm (33 ft/lb)
Model
ZTH5223 ZTH6125
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TECHNICAL DATA
7/16" 70 Nm (52 ft/lb) 70 Nm (52 ft/lb)
1/2" 110 Nm (80 ft/lb) 110 Nm (80 ft/lb)
Accessories
BioClip adapter Optional Optional
Foot controlled mower deck lift Optional Optional
Deluxe seat Optional Optional
Model
ZTH5223 ZTH6125
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TECHNICAL DATA
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DELIVERY AND DEALER SERVICE
Delivery and Dealer Service
Pre-delivery Service
1. Charge the battery.
2. Mount the rear tires.
3. Check and adjust the tire pressure in all
tires. All tires should be1 bar (15 PSI).
4. Fit the motion control levers in the normal
position.
5. Connect the rod to the seat stop.
6. Connect the contactor to the cable for the
seat’s safety switch.
7. Fit the armrests to the seat’s back
support.
8. Check that the engine has the right
quantity of oil.
9. Check that the hydraulic tank has the
right quantity of oil.
10. Adjust the position of the motion control
levers.
11. Fuel the mower and open the gas valve.
12. Connect exhaust fume extraction.
13. Start the engine.
14. Vent the hydraulic system.
15. .Check that there is drive to both wheels
16. Check mower deck settings.
17. Check:
The park brake safety switch.
The seat safety switch.
The motion control lever safety switches.
Correct park brake operation.
Forward drive.
Reverse drive.
Blade engagement.
18. Check the idling speed (1,550 ±50 rpm).
19. Check max. engine speed (2,800 ±75
rpm).
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DELIVERY AND DEALER SERVICE
20. Inform the customer of the:
Necessity and advantages of following
the maintenance schedules.
Necessity and advantages of having the
mower inspected every 300 hours.
The effect on resale value of regular
servicing and a fully stamped service
book.
The use of BioClip.
21. Complete the sales certificate, etc.
After the First 8 Hours
Change the motor oil.
25 Hour Service
1. Check the fuel pump air filter.
2. Check the oil level in the hydraulic
system.
3. Check tire pressure.
4. Lubricate the mower deck’s belt
tensioner.
5. Lubricate the hydraulic pump’s belt
tensioner.
6. Check/clean the engine’s cold air intake.
7. Clean the air cleaner’s pre-filter (Oil-
foam).
50 Hour Service
1. Carry out a 25 hour service.
2. Clean/change the air cleaner’s filter
cartridge (paper filter). Perfom more
reqularly in dusty operating conditions.
3. Lubricate the bearings of the front
wheels.
4. Lubricate the shafts of the motion control
levers.
5. Lubricate the mower deck struts.
6. Lubricate the cutting height regulator.
7. Check/adjust the park brake.
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DELIVERY AND DEALER SERVICE
100 Hour Service
1. Carry out a 25 hour service.
2. Carry out a 50 hour service.
3. Change the engine oil.
4. Check if the hydraulic oil needs changing
(every 300 hours).
5. Check if the engine’s oil filter needs
changing (every 200 hours).
6. Clean/change the spark plugs.
7. Change the fuel filter in the fuel line.
8. Clean the engine and transmission
cooling fins.
9. Clean and check if the air filter’s paper
cartridge needs changing (every 200
hours).
300 Hour Service
1. Inspect the machine. Reach agreement
with the customer on what additional
work is to be carried out.
2. Carry out a 25 hour service.
3. Carry out a 50 hour service.
4. Carry out a 100 hour service.
5. Change the oil and the filter in the
hydraulic system.
6. Clean the combustion chamber and
grind the valve seats.
7. Check the play in the engine valves.
8. Change the air cleaner’s pre-filter (Oil-
foam).
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DELIVERY AND DEALER SERVICE
At Least Once a Year
1. Clean the engine’s cold air intake (25
hours).
2. Change the air cleaner’s pre-filter (Oil-
foam).
3. Change the paper cartridge in the air
filter (200 hours).
4. Change the engine oil (100 hours).
5. Change the engine’s oil filter (200 hours).
6. Change the oil and the filter in the
hydraulic system.
7. Check/adjust the cutting height regulator.
8. Check/adjust the park brake (50 hours).
9. Clean/change the spark plugs (100
hours).
10. Change the fuel filter in the fuel line (100
hours).
11. Clean the cooling fins (100 tim).
12. Check the play in the engine valves (300
hours).
13. A 300 hour service to be carried out by
an authorized workshop.
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DELIVERY AND DEALER SERVICE
Maintenance Schedule
The table below lists the maintenance required by the ride-on mower. Several of the points not covered in
this workshop manual will be found in the Operating Instructions.
Daily Weekly At
least
once
a
year
Maintenance intervals
in hours
Maintenance Page Pre-
use
After
use
25 50 100 300
Check for fuel and oil leaks. -
❍
Check the park brake. -
●
Check engine oil level (every fueling). 21
●
Check the fuel pump air filter. -
▼
Check the safety systems. -
▼
Check/clean the engine’s cold air intake. -
▼
Check the mower deck. 38
●
Check fasteners (bolts, nuts, etc.). -
❍
Start engine and blades; check for abnormal
noise. -
❍
Clean the underside of the mower deck. -
▼
Check hydraulic system oil level. 22
●
Check the condition of belts, pulleys, etc. 38
●
Check for any damage. -
❍
Check tire pressure. 20
●
Clean thoroughly around the engine. -
❍
Clean thoroughly around the hydraulic system. 53
●
Clean thoroughly around belts, pulleys, etc. -
❍
Lubricate mower deck belt tensioner. -
▼
Lubricate belt tensioner for hydraulic pumps. -
▼
Lubricate all wires. -
▼
Lubricate driver’s seat mechanisms. -
▼
Lubricate the throttle control. -
▼
Clean the engine’s cold air intake. -
▼▼
Lubricate mower deck links. -
❍
Lubricate front wheel mounts (every 200 hours). -
▼
Lubricate front wheel bearings. -
▼
Lubricate the shafts of the motion control levers. -
▼
Lubricate mower deck struts. -
▼
Lubricate the mower deck’s height regulator. -
▼
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DELIVERY AND DEALER SERVICE
1)
First change after 8 hours. With heavy operating conditions or high ambient temperature, change every 50 hours.
2)
In dusty conditions, clean and
change more frequently.
3)
Where the mower is in daily use, lubrication must be carried out twice a week.
4)
To be carried out by an authorized workshop.
●
= Covered in this workshop manual.
❍
= Not coverd in this workshop manual or the Operating Instructions.
▼
= Covered in the Operating Instructions.
Daily Weekly At
least
once
a
year
Maintenance intervals
in hours
Maintenance Page Pre-
use
After
use
25 50 100 300
Check/adjust the cutting height regulator. 38
●
Clean the air cleaner’s pre-filter (Oil-foam). -
▼▼
Clean the air cleaner’s filter
2)
(paper filter). -
▼▼
Change the motor oil
1)
. 22
●●
Change the hydraulic oil (every 300 hours). 56 ●●
Change the engine’s oil filter (every 200 hours). - ▼▼
Clean/change the spark plugs. - ❍❍
Change the fuel filter in the fuel line. - ▼▼
Clean the cooling fins. - ❍❍
Check the play in the engine valves 4) .-❍❍
Change the air cleaner’s pre-filter (Oil-foam). - ▼▼
Change air filter (paper filter) 2) (every 200 hours). -▼▼
Carry out a 300 hour service 4) . 13 ●●
Check/adjust the park brake. 34 ●●
WARNING!
Service procedures may only be carried out on the motor or mower deck when:
• The motor has been switched off.
• The ignition key has ben removed.
• The ignition cables have been removed from the spark plugs.
• The park brake has been applied.
• The mower deck has been disengaged.
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DELIVERY AND DEALER SERVICE
Service Records
Remember to enter all service work in the Service Log at the back of the Operating Instructions.
Record details of any major repairs.
Enter the meter reading and date. Stamp and sign the stamp field.
In your customer register, make a note of the work that has been carried out.
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DELIVERY AND DEALER SERVICE
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