Husqvarna ZTH6125, ZTH5223 User Manual

Workshop manual

ZTH

English

Svenska – 31

Contents

WORKSHOP MANUAL

RIDE-ON LAWN MOWER

ZTH

Contents Safety Instructions

General Instructions.............................................3

Special Instructions..............................................3

Explanation of Symbols Tools Technical Data Delivery and Dealer Service

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

To our Dealers...................................................19

Removing the Mower from its Packaging ..........19

Delivery Service.................................................20

Test Running......................................................24

Administration....................................................24

Design and Function

General..............................................................25

Mower Identification...........................................25

Engine................................................................27

Drive and Control...............................................27

Brakes................................................................27

Mower Deck.......................................................28

Repairs

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

..................................................................1

.................................................3

........................................5

.......................................................................6

........................................................7

................................11

................................................19

............................................25

..................................................................29

Electrical System

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

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

Engine............................................................... 61

Wiring Harness.................................................. 61

Clutch................................................................ 63

Hydraulic Pump................................................. 66

................................................ 43

................................................ 53

.................................................. 61

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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 box es” 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 forwardfacing 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.

WARNING! Xxxxxxx xxxx xxxxxxxx xxx x. xxxx xxxxxx xx.

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.

IMPORTANT INFORMATION Xxxxxxx xxxx xxxxxxxx xxx x xxxx xxxxxx xx.

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.

FuelChokeSlowFastNeutralReverse

Warning!

Battery acid is corrosive, explosive and flammable.

Park brake

CE conformity marking

Warning! Rotating blades, stand clear of the chute.

Do not stand here.

Do not touch rotating parts.

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 hav e ready access to sock et 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

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)

ZTH5223 ZTH6125

Cutting height Adjustable 38 mm (1.5") to

152 mm (6") in 64 mm (0.25") increments

Blade engagement 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 Hydrostatic drive Dual Hydro-gear pumps and

Tightening torque, pipe couplings

Hydraulic pumps (2) Hydro Gear BDP 10A 404 Hydro Gear BDP 10A 404

61 Nm (45 ft/lb) 61 Nm (45 ft/lb)

Parker/Ross Wheel drive motors

41 Nm (30 ft/lb) 41 Nm (30 ft/lb)

Adjustable 38 mm (1.5") to 152 mm (6") in 64 mm (0.25") increments

Warner Mag-Stop Electromagnetic clutch

Dual Hydro-gear pumps and Parker/Ross Wheel drive motors

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TECHNICAL DATA

Model

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 Hydraulic oil 1.9 litres (2 qt.), 15W-50

Hydraulic oil cooler Yes Yes Speed forward Variable, max. 12.9 km/h

Speed reverse Variable, max. 3.23 km/h

Rear tires Carlisle 24" X 12.00 - 12 Tubeless

ZTH5223 ZTH6125

122 Nm (90 ft/lb) 122 Nm (90 ft/lb)

1.9 litres (2 qt.), 15W-50

Synthetic

(8 mph)

(2 mph)

Turf Master

Synthetic

Variable, max. 12.9 km/h (8 mph)

Variable, max. 3.23 km/h (2 mph)

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

Seat 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)

44 litres (11.4 US Gal.), 22 litres/ tank

Adjustable, high-back seat with armrests

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TECHNICAL DATA

Model

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

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 (Oilfoam).

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 (Oilfoam).

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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 (Oilfoam).

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 v alves (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.

Maintenance Page Pre-

use

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. -

Daily Weekly At

least

After use

once

year

▼

●

❍

▼

●

❍

●

❍

▼

▼▼

❍

Maintenance intervals

in hours

25 50 100 300

▼

●

▼

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DELIVERY AND DEALER SERVICE

Daily Weekly At

Maintenance Page Pre-

use

After use

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) .

Change the hydraulic oil (every 300 hours). 56 ●

Maintenance intervals least once

year

in hours

25 50 100 300

●

▼▼

●●

●

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

- ❍❍

Change the air cleaner’s pre-ﬁlter (Oil-foam). - ▼▼ Change air ﬁlter (paper ﬁlter)

Carry out a 300 hour service

(every 200 hours).

- ▼▼

13 ●●

Check/adjust the park brake. 34 ●●

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.

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.

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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DELIVERY SERVICING

Delivery Servicing

To our Dealers

The quality of delivery servicing is vital to aftersales success. It is in e veryone’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 any problems.

• You will gain a regular customer who recommends you and your company to others.

• Together we will strengthen our brand and take joint responsibility for our products and customers.

Complete all the paperwork meticulously. Fill in warranty and delivery documents, etc. and ensure that the customer receives the right operating

instructions for his/her mower. Keep a register of customers and their mowers (with serial numbers , etc.). The information contained in the

customer register is invaluable for marketing and when ordering spare parts.

When supplying a mower, you should also give the customer all information necessary for the safe operation and care of the machine. Pay particular attention to informing the customer about:

• Safety instructions.

• Mower controls.

• Checking oil levels and the oil to be used when topping-up.

• The ﬁrst oil change after the running-in period.

• The necessity and advantages of observing the maintenance schedules and regularly returning the mower for servicing.

• What type of fuel to use.

• Ways of achieving the best results with the mower. The use of BioClip.

• The accessories available for his/her mower.

• Warranty conditions.

• Your company and the person to be contacted if there are any problems.

Removing the Mower from its Packaging

Mowers are normally delivered from the factory in special packaging - a wooden crate with a solid bottom.

WARNING! Handle the transport crate carefully. Keep the goods as level as possible. Use long pallet forks.

Mower on its delivery baseplate

8011-549

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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 of the crate from the wooden baseplate. The mower (rear wheels not ﬁtted) is secured to the baseplate by plastic straps and wooden b loc ks. Certain

components that are to be ﬁtted to the mower, or handed to the purchaser on delivery, are wrapped separately in plastic bags.

Remove the plastic sheeting covering the mower. When unpacking the mower, check that there is no transport damage. Any damage is to be reported to the

transport company in the normal way. The packaging is not to be returned.

Delivery Service

1. Charge the battery. The mower is normally delivered with a charged battery topped-up with electrolyte.

2. Raise the rear of the mower until it is clear of the baseplate and the rear wheels can rotate freely. Hold ﬁrmly in position using blocks or jack stands.

3. With the valves facing outwards, ﬁt the rear wheels. Fit and tighten the wheel nuts on the wheel bolts.

4. Check and adjust the pressure in all the tires. The recommended pressure is 1 bar (15 PSI).

Fitting the rear wheels

8011-503

5. On both motion control levers, remove the lower bolts and loosen the upper bolts. Swing the levers to the upright position. Hand tighten the lower bolts in the rectangular holes. The levers are adjusted at a later stage.

6. Push the levers out into their neutral slots.

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8011-502

Lever mount

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