Husqvarna ZTH Ride-On Lawn Mower OEM Service & Repair Manual

Workshop manual ZTH English For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English- 1 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 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English- 2 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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 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. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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 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). For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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 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. Fuel Choke Slow Fast Neutral Reverse Warning! Max. sound emission. Use ear protectors. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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) 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. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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.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 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English- 8 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 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

Husqvarna ZTH Ride-On Lawn Mower OEM Service & Repair Manual

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