Page 3 - Contents
English- 1 WORKSHOP MANUAL RIDE-ON LAWN MOWER ZTH Contents Contents ..................................................................1 Safety Instructions .................................................3 General Instructions .............................................3Special Instructions ........
Page 5 - SAFETY INSTRUCTIONS; Safety Instructions; General Instructions; The fuel and the fumes it gives off are toxic.
English- 3 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 loca...
Page 6 - SAFETY REGULATIONS
English- 4 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 cl...
Page 7 - EXPLANATION OF SYMBOLS; Explanation of Symbols; personal injury; special instructions are not followed.; material damage
English- 5 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 a...
Page 8 - TOOLS; Tools; The following are also required:; in such a way that tools can no longer get a firm grip.
English- 6 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)...
Page 9 - TECHNICAL DATA; Technical Data; Model
English- 7 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...
Page 11 - Accessories
English- 9 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
Page 13 - DELIVERY AND DEALER SERVICE; Delivery and Dealer Service
English- 11 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 ...
Page 14 - After the First 8 Hours
English- 12 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 o...
Page 16 - At Least Once a Year; Check/adjust the cutting height regulator.
English- 14 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 ...
Page 17 - Maintenance Schedule
English- 15 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 Ma...
Page 18 - • The motor has been switched off.
English- 16 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...
Page 19 - Service Records; Record details of any major repairs.
English- 17 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 th...
Page 21 - DELIVERY SERVICING; Delivery Servicing; To our Dealers; Complete all the paperwork meticulously.; Use long pallet forks.
English- 19 DELIVERY SERVICING Delivery Servicing To our Dealers The quality of delivery servicing is vital to aftersales success. It is in everyone’s interest that the aftermarket operates smoothly: • The customer will be satisfied with his/her mower and know who he/she can contact for help with an...
Page 22 - Remove the upper part of the crate from the wooden baseplate.; Delivery Service
English- 20 DELIVERY SERVICING The baseplate itself stands on a pallet and the whole assembly can be handled using a standard forklift truck. To keep the goods as level as possible, two people should assist the truck driver. Driving and lifting must both be performed with care. Remove the upper part...
Page 23 - Check the engine oil level.; IMPORTANT INFORMATION
English- 21 DELIVERY SERVICING 7. In the space to the left of the hydraulic tank, cut the cable tie holding the rod to the top of the seat. Remove the split cotter, swing the seat backwards and connect the rod to the seat. Replace the split cotter. Check that the contactor on the cable to the bottom...
Page 24 - Check the oil level in the hydraulic tank.
English- 22 DELIVERY SERVICING The oil level must be between the markings on the dipstick. If the level is near the “ADD” mark, top up with oil to the “FULL” mark. Oil is topped up via the hole in which the dipstick sits. Use grade SC-SH engine oil with a viscosity as per the chart below. The engine...
Page 25 - areas. Exhaust fumes contain
English- 23 DELIVERY SERVICING 12. Fill the gasoline tanks (unleaded gasoline with no oil and a minimum octane rating of 87). Environment-friendly, acrylate gas , e.g. Aspen, can be used to good advantage. 13. Select tank by moving the selector to the appropriate position. 14. Connect exhaust fume e...
Page 26 - Test Running; Check that the engine will not start with the park brake engaged.; Administration
English- 24 DELIVERY SERVICING Test Running Check that the engine will not start with the park brake engaged. Check that the engine will not start with the blade engagement button pulled out. Check that the engine will not start without someone sitting on the driver’s seat. Start the engine. Check t...
Page 27 - DESIGN AND FUNCTION; Design and Function; General; The model number
English- 25 DESIGN AND FUNCTION Design and Function General The Husqvarna ZTH is a compact, ride-on mower specially designed for mowing large areas of grass. It is operated via two motion control levers and has hydrostatic drive to the rear wheels. Each rear wheel is driven by an independent hydrost...
Page 28 - Quote these when ordeing spare parts.
English- 26 DESIGN AND FUNCTION The engine identifiers are located on a barcoded decal. This is sited on the left side of the crankcase, directly opposite the starter motor. The decal gives: • The engine code. • The engine number. Quote these when ordeing spare parts. The hydraulic pump identifiers ...
Page 29 - Engine
English- 27 DESIGN AND FUNCTION Engine Husqvarna’s ride-on mowers for professional users have two-cylinder, air-cooled engines from Kawasaki. Major engine repairs are not covered in this workshop manual. Users are referred to Kawasaki’s own manuals. These contain detailed information on the adjustme...
Page 30 - Mower Deck
English- 28 DESIGN AND FUNCTION Mower Deck The blades are driven by a V-belt from the engine crankshaft (1). The crankshaft has an electromagnetic clutch. This locks the deck pulley to the shaft when current is applied to the clutch (i.e. when the appropriate control panel switch is operated). The b...
Page 31 - REPAIRS; Repairs; Removing; Place it safely where it cannot
English- 29 REPAIRS Repairs Engine Removing 1. Close the fuel valve. 2. Disconnect the positive cable (red) from the battery. 3. If necessary, drain the motor oil. 4. Disconnect the gas and choke wires from the carburetor. 5. Disconnect the fuel line (with its filter) from the fuel pump. 6. Disconne...
Page 32 - Fitting
English- 30 REPAIRS Fitting 1. When changing engines, transfer the necessary components to the new engine. The chamfered side of the spacer (3) on the crankshaft above the pump pulley must face the engine.The hub collar of the pulley (5) must face downwards. 2. Put the four upper engine mount isolat...
Page 33 - Connect and adjust the gas and choke; Troubleshooting; Adjusting the Throttle Wire; Adjusting Throttle Lever Tension; Tighten the throttle lever’s pivot bolt.; Checking and Adjusting the Throttle Wire
English- 31 REPAIRS inlet. 14. Connect and adjust the gas and choke wires (see below). 15. Check that the oil drain valve is closed and fill the engine with oil (see Delivery Servicing\Delivery Service). 16. Connect the positive cable (red) to the battery’s positive terminal. 17. Open the fuel valve...
Page 35 - The fitting procedure is the reverse of the removal procedure.; Wipe dry if necessary.
English- 33 REPAIRS Fuel tank Removing Before removing the tank on the right of the mower, the rear wheel and the bolts holding the oil cooler for the hydraulics must be removed. 1. Close the fuel valve (13). 2. Drain the tank that is to be removed. Keep the drained fuel in a closed container. 3. Re...
Page 36 - See “Hydraulic system\Hydraulic pump\Adjusting the linkages”.; Adjusting the Park Brake
English- 34 REPAIRS Adjusting Motion Control Lever Linkages See “Hydraulic system\Hydraulic pump\Adjusting the linkages”. Adjusting Motion Control Lever Spring-back See “Hydraulic system\Hydraulic pump\Adjusting the Reverse Detent Spring”. Adjusting the Park Brake 1. Raise the rear of the unit and p...
Page 37 - Remove the operator’s foot plate.
English- 35 REPAIRS Mower Deck Removing 1. Drop the deck as far as it will go and lock the control lever in position with a pin. 2. Remove the operator’s foot plate. 3. Remove the deck belt outer guards. 4. Using a 9/16" socket on the bolt of the idler pulley, loosen the deck belt. Roll the belt...
Page 38 - Attach the chains to the lift arms.; Spindle Blade Bearings; Removing Bearings; Separate the blade from its bearing.; Repairing Bearings
English- 36 REPAIRS 4. Fit the deck’s rear anti-scalp rollers. 5. Attach the chains to the lift arms. 6. Fit the belt as per the routing diagram. 7. Check that the belt is not twisted and that it runs correctly around all the pulleys. 8. Check deck height and horizontality as per “Setting the mower ...
Page 39 - Replacing Bearings; Sharpening and Balancing Blades; Balancing is as follows:; a damaged blade if there is any
English- 37 REPAIRS assembly is supplied with an “O” ring (47) . The “O” ring must be removed before the pulley is fitted. Replacing Bearings The fitting procedure is the reverse of the removal procedure. Tightening torques: • Blade bolts 122 Nm (90 lb/ft). • Pulley bolts 61 Nm (45 lb/ft). Sharpenin...
Page 40 - Setting the Mower Deck; Leveling; Deck Belt; Changing Belts; Drop the deck to its lowest position.
English- 38 REPAIRS Setting the Mower Deck Leveling 1. Position the mower on a level, preferably concrete, surface. 2. Check the pressure in all four tires. This should be 15 psi. 3. Raise the mower on lengths of 2" x 4" placed edgewise under the cutting deck from front to rear (see diagram)...
Page 41 - Belt Tensioning Assembly
English- 39 REPAIRS 4. Using a 9/16" socket on the bolt of the idler pulley, loosen the deck belt. Roll the belt off the deck pulleys. 5. Roll the belt off the clutch pulley on the crankshaft. 6. Remove the old belt. 7. Fitting the new belt is the reverse of the procedure given above. Ensure tha...
Page 42 - Hydraulic Pump Belt; Changing Pump and Deck Belts
English- 40 REPAIRS Hydraulic Pump Belt Check the belt every 75 to 100 hours of operation. Inspect carefully for large cracks and significant damage. The small cracks that arise from normal use do not make it necessary to change the belt. Changing Pump and Deck Belts 1. Drop the deck to its lowest p...
Page 43 - Pump Belt Tensioning Assembly; Front Wheel Bearings; Dismantling
English- 41 REPAIRS Pump Belt Tensioning Assembly The belt is automatically tensioned by a spring (37). To cancel the force of the spring when removing or fitting the belt, use a 1/2" ratchet wrench in the square hole in the idler arm (45). Check that there is no abnormal noise indicating that t...
Page 45 - ELECTRICAL SYSTEM; Electrical System; See the “Troubleshooting” section towards the back of this manual.; Wiring Assembly; The diagram below shows the structure of the electrical system.
English- 43 ELECTRICAL SYSTEM Electrical System Troubleshooting See the “Troubleshooting” section towards the back of this manual. Wiring Assembly The diagram below shows the structure of the electrical system. To connect the engine to the frame harness (13), there is a pigtail. This plugs into conn...
Page 48 - Battery; Procedures in the Event of Acid Contact; Eyes: Drench with running water. See a doctor as soon as possible.; Refer to the “ZTH electrical system” diagram.
English- 46 ELECTRICAL SYSTEM Battery The battery is maintenance-free and the cells are sealed. Breaking the seal invalidates the warranty. To avoid exposing the battery terminals to dangerous stress, use two wrenches when connecting or disconnecting the battery cables. Procedures in the Event of Ac...
Page 49 - Starter Motor Contactor; Changing; Pull the cables off the contactor.
English- 47 ELECTRICAL SYSTEM Relays Refer to the “ZTH electrical system” diagram. The relays (22) plug into a holder under the seat (on the left). The three relays are identical and can be plugged into any of the sockets in the holder. Relay function (working along the holder from right to left) is...
Page 50 - Ignition and Start Switch; Hour Meter
English- 48 ELECTRICAL SYSTEM Ignition and Start Switch Refer to the “ZTH electrical system” diagram. Changing 1. Free the control console and pull forwards. 2. Disconnect the wires at the back of the ignition switch (10). 3. Remove the ignition key and the rubber cap (20). 4. Remove the nut (19) an...
Page 51 - Blade Switch; Mower Deck Clutch; Measuring the Supply Voltage
English- 49 ELECTRICAL SYSTEM Blade Switch Refer to the “ZTH electrical system” diagram. Changing 1. Free the control console and pull forwards. 2. Disconnect the wires at the back of the switch (11). 3. Push in the plastic catch on the switch’s short side and draw the switch out through the console...
Page 52 - The fitting procerdure is the reverse of the removal procedure.; Motion Control Switches
English- 50 ELECTRICAL SYSTEM Fitting The fitting procerdure is the reverse of the removal procedure. Pay particular attention to the following: • The tightening torque for the bolt (9) is 67 Nm (50 ft/lb). • With the bolt (9) tightened, there should be perceptible play between the clutch and the cl...
Page 53 - Park Brake Interlock Switch
English- 51 ELECTRICAL SYSTEM Removing 1. Swing the seat completely out of the way. 2. Release the mechanical link between the left park brake and the brake lever. 3. Release the dampeners (23) and springs (17) from the tubular shafts (31, 33) by removing the bolts (16) - each with two nuts (22) - s...
Page 54 - Welding; Remove the battery cables.
English- 52 ELECTRICAL SYSTEM Welding The following applies to arc, MIG, TIG and all other electrical welding methods. The engine’s ignition system has sensitive electrical components. Electrical welding must not, therefore, be carried out on the engine. Remove the component to be welded (e.g. the m...
Page 55 - HYDRAULIC SYSTEM; Hydraulic System; Hydraulics Hygiene
English- 53 HYDRAULIC SYSTEM Hydraulic System Hydraulics Hygiene If they are to operate well, hydraulic systems must be kept free from all impurities. During operation, particles that can cause both wear and malfunction are generated inside hydraulic systems. To separate these particles from the hyd...
Page 56 - Hydraulic Oils; Perform general cleaning as necessary.
English- 54 HYDRAULIC SYSTEM Hydraulic Oils The oil is as important as any other part of the hydraulic system. It has been shown that 70% of all problems with hydraulics are due either to the use of unsuitable oil grades or filling/topping-up with contaminated oil. Contamination from outside is resp...
Page 57 - ZTH Hydraulic System
English- 55 HYDRAULIC SYSTEM ZTH Hydraulic System The hydraulic pumps are controlled (via mechanical links) by the motion control levers. 8011-588 ZTH hydraulic system 8011-589 Hydraulic pump linkages
Page 58 - Hydraulic Tank; Draining; Drain the hydraulic tank as above.
English- 56 HYDRAULIC SYSTEM Hydraulic Tank Draining 1. The drain cap (29) is located on the underside of the tank in the front left corner (see the “ZTH hydraulic system” diagram). Drained hydraulic oil must be handled in accordance with the regulations governing the disposal of waste oil. Do not p...
Page 59 - The Cooler for the Hydraulic System; Hydraulic Filter; Changing Filters; Hydraulic Lines
English- 57 HYDRAULIC SYSTEM The Cooler for the Hydraulic System Removing 1. Remove the right rear wheel. 2. To eliminate any excess pressure, remove then replace the hydraulic tank cap. 3. Loosen the hose clamps (16) but leave the hoses attached to the cooler. 4. Remove the bolts (14), spacers (15)...
Page 60 - Hydraulic Pump
English- 58 HYDRAULIC SYSTEM Fitting 1. Clean the surfaces mating pumps and motors to their mounts. 2. Bolt the hydraulic pump loosely into place - it must still be possible to move the pump. 3. Bolt the hydraulic motor loosely into place - it must still be possible to move the motor. 4. Using new “...
Page 61 - Vent the hydraulic system before operation.; Linkage Adjustment; Remove the seat rod so that the seat can swing down onto the frame.; Reverse Spring Detent Adjustment; Stop the engine and remove the key.; Ensure the mower is securely supported on blocks or jack stands.
English- 59 HYDRAULIC SYSTEM • Ensure that the pump pulley aligns with the crankshaft pulley and the pulley for the other pump. • Ensure, on both sides, that the link between the motion control lever and the hydraulic pump is correctly adjusted. • Vent the hydraulic system before operation. Linkage ...
Page 62 - Hydraulic Motors
English- 60 HYDRAULIC SYSTEM 6. Holding the lever, adjust the spring by sliding the bolt (37) in the slot to remove all the slop. Retighten the bolt. 7. Check the adjustment by pulling the motion control lever back to the reverse position and releasing it. 8. If necessary, make the same adjustment o...
Page 63 - TROUBLESHOOTING; Check section 8 of the Kawasaki Service Manual.; Wiring Harness; Symptom: The starter motor works but the engine does not turn over.
English- 61 TROUBLESHOOTING Troubleshooting Engine Check section 8 of the Kawasaki Service Manual. The above section contains a troubleshooting guide for engine and auxiliary systems. It also has a special section on troubleshooting the starter motor. Wiring Harness • Symptom: The starter motor work...
Page 65 - Clutch
English- 63 TROUBLESHOOTING Clutch • Measuring clutch coil resistance. 1. Turn the engine and PTO switch off. 2. Disconnect the clutch at the clutch connector. 3. Set the meter to read ohms. 4. Connect the meter leads to the clutch. 5. Check the meter reading. CMS-175 (237 Nm) = 2.45 - 2.71 Ω . CMS-...
Page 67 - Noisy clutch/vibrations
English- 65 TROUBLESHOOTING faulty. Repair or replace. Overloaded clutch. • Clogged deck, faulty spindle, etc. Remove excess grass.Replace spindle. Contaminated friction • Engine oil leak on clutch. Repair leak. surfaces. Replace with new MagStop unit. Noisy clutch/vibrations Failed bearing. • Loose...
Page 68 - Problem
English- 66 TROUBLESHOOTING Hydraulic Pump In most cases, problems with the drive system are not due to a defective pump but to slipping drive belts, partially engaged bypass valves, loose or damaged control linkages, etc. Be sure to check all of these before assuming a pump is faulty.The troublesho...
