Husqvarna ZTH5223 manual

W orkshop manual ZTH English[...]

Svenska – 31 Sve-5 225/232/235 Bruk 97-11-25, 08.46 31[...]

English- 1 WORKSHOP MANUAL RIDE-ON LAWN MOWER ZTH Contents Contents ..................................................................1 Safety Instructions .................................................3 General Instructions .............................................3 Special Instructions ..............................................3 Explan[...]

English- 2[...]

English- 3 SAFETY INSTRUCTIONS Safety Instructions General Instructions This workshop manual has been written for users who ha ve a good understanding of the repair and ser vicing of ride-on mow ers. The workshop where the ride-on mower is repaired must ha ve ha ve all the saf ety systems demanded b y local regulations. No one is to attempt to repa[...]

English- 4 SAFETY REGULATIONS K eep 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 appropr iate container . P a y par ticular attention to keeping the floor clean so that there is no risk of slipping[...]

English- 5 EXPLANATION OF SYMBOLS Explanation of Symbols The symbols below are used on the mo wer and in this manual. Study them carefully and be aw are of what they mean. Is used in this manual to mak e the user aware that there is a danger of personal injury , especially if the special instructions are not follo wed. Is used in this manual to mak[...]

English- 6 TOOLS T ools The mower’ s special design means that most repair and maintenance work can be carried out using standard tools. Ser vicing of engines and h ydraulic pumps requires special tools. These are listed in the service manuals of the individual manuf acturers. The mower (engine e xcluded) has mainly UNC or UNF screw/bolt/nut thre[...]

English- 7 TECHNICAL DATA T echnical Data Model ZTH5223 ZTH6125 Model par t number 968 99 91 60 Engine (spec. number) Kaw asaki (FH680V -AS15) Kaw asaki (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.) P ower 23 hp 25 [...]

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. hydr aulic pressure 145 bars (2,100 PSI) 145 bars (2,100 PSI) Max. hydr aulic oil temp 110°C (230°F) 110°C (230°F) W eight, hydr aulic pump 3.6 kg (8 lbs) 3.6 kg (8 lbs) Hydraulic[...]

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 F oot controlled mower dec k lift Optional Optional Delux e seat Optional Optional Model ZTH5223 ZTH6125[...]

English- 10 TECHNICAL DATA[...]

English- 11 DELIVERY AND DEALER SERVICE Delivery and Dealer Ser vice Pre-delivery Service 1. Charge the batter y . 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 le vers in the normal position. 5. Connect the rod to the seat stop . 6. Connect the contactor to[...]

English- 12 DELIVERY AND DEALER SERVICE 20. Inf or m the customer of the: Necessity and advantages of f ollowing the maintenance schedules. Necessity and advantages of ha ving the mower inspected e very 300 hours. The eff ect on resale value of regular ser vicing and a fully stamped service book. The use of BioClip . 21. Complete the sales cer ti?[...]

English- 13 DELIVERY AND DEALER SERVICE 100 Hour Service 1. Carr y out a 25 hour service. 2. Carr y out a 50 hour service. 3. Change the engine oil. 4. Check if the h ydraulic oil needs changing (e very 300 hours). 5. Check if the engine’ s oil filter needs changing (e very 200 hours). 6. Clean/change the spark plugs. 7. Change the fuel filter [...]

English- 14 DELIVERY AND DEALER SERVICE At Least Once a Y ear 1. Clean the engine’ s cold air intake (25 hours). 2. Change the air cleaner’ s pre-filter (Oil- f oam). 3. Change the paper car tridge 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 [...]

English- 15 DELIVERY AND DEALER SERVICE Maintenance Schedule The table belo w lists the maintenance required by the ride-on mower . Sev eral of the points not cov ered in this workshop manual will be f ound in the Operating Instructions. Daily W eekly At least once a year Maintenance intervals in hours Maintenance P age Pre- use After use 25 50 100[...]

English- 16 DELIVERY AND DEALER SERVICE 1) First change after 8 hours. With heavy oper ating conditions or high ambient temperature, change e very 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) T o be carried out by an authorized workshop . ?[...]

English- 17 DELIVERY AND DEALER SERVICE Service Records Remember to enter all ser vice w or k 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 w ork that has been carr ied out.[...]

English- 18 DELIVERY AND DEALER SERVICE[...]

English- 19 DELIVERY SERVICING Delivery Ser vicing T o our Dealers The quality of delivery ser vicing is vital to aftersales success . It is in ev eryone’ s interest that the aftermarket operates smoothly: • The customer will be satisfied with his/her mower and kno w who he/she can contact f or help with any problems . • Y ou will gain a reg[...]

English- 20 DELIVERY SERVICING The baseplate itself stands on a pallet and the whole assembly can be handled using a standard f or klift truck. T o keep the goods as le vel as possib le, two people should assist the truc k driver . Driving and lifting must both be perf ormed with care. Remov e the upper par t of the crate from the w ooden baseplate[...]

English- 21 DELIVERY SERVICING 7. In the space to the left of the h ydraulic tank, cut the cable tie holding the rod to the top of the seat. Remov e the split cotter , swing the seat bac kwards and connect the rod to the seat. Replace the split cotter . Check that the contactor on the cab le to the bottom of the seat is connected. Swing the seat do[...]

English- 22 DELIVERY SERVICING The oil le vel must be betw een the markings on the dipstick. If the lev el is near the “ADD” mark, top up with oil to the “FULL ” mar k. Oil is topped up via the hole in which the dipstick sits . Use grade SC-SH engine oil with a viscosity as per the char t below . The engine (e xcluding oil filter) holds 1.[...]

English- 23 DELIVERY SERVICING 12. Fill the gasoline tanks (unleaded gasoline with no oil and a minimum octane rating of 87). Environment-friendly , acr ylate gas , e .g. Aspen, can be used to good advantage . 13. Select tank by mo ving the selector to the appropriate position. 14. Connect e xhaust fume extr action. 15. Star t the engine. 16. Check[...]

English- 24 DELIVERY SERVICING T est Running Check that the engine will not start with the par k brak e 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 dr iv er’ s seat. Star t the engine. Check that the engine stops if , with the par k [...]

English- 25 DESIGN AND FUNCTION Design and Function General The Husqvarna ZTH is a compact, ride-on mower specially designed f or mowing large areas of gr ass. It is operated via two motion control le vers and has h ydrostatic drive to the rear wheels. Each rear wheel is driven b y an independent h ydrostatic driv e system comprising a hydr aulic p[...]

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 par ts. The h ydr aulic pump identifiers are located on a bardcoded decal. This [...]

English- 27 DESIGN AND FUNCTION Engine Husqvarna’ s r ide-on mo wers f or professional users ha ve tw o-cylinder , air-cooled engines from Kaw asaki. Major engine repairs are not cov ered in this workshop manual. Users are referred to Ka wasaki’ s own manuals. These contain detailed inf or mation on the adjustment and repair of the engines. The[...]

English- 28 DESIGN AND FUNCTION Mower Dec k The blades are driv en by a V -belt from the engine crankshaft (1). The crankshaft has an electromagnetic clutch. This locks the dec k pulley to the shaft when current is applied to the clutch (i.e. when the appropriate control panel s witch is operated). The belt is automatically adjusted by a spring (2)[...]

English- 29 REPAIRS Repairs Engine Removing 1. Close the fuel valv e. 2. Disconnect the positive cab le (red) from the batter y . 3. If necessar y , 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. Disconnect the connecting cable (pigtail) from th[...]

English- 30 REPAIRS Fitting 1. When changing engines, transf er the necessar y components to the ne w engine. The chamf ered side of the spacer (3) on the crankshaft abov e the pump pulley must f ace the engine. The hub collar of the pulley (5) m ust f ace downw ards. 2. Put the f our upper engine mount isolators (22) in the engine bed (small diame[...]

English- 31 REPAIRS inlet. 14. Connect and adjust the gas and choke wires (see below). 15. Check that the oil dr ain valv e is closed and fill the engine with oil (see Delivery Ser vicingDeliv er y Ser vice). 16. Connect the positive cab le (red) to the batter y’ s positive terminal. 17. Open the fuel valv e. Dismantling and Assembling Adjustme[...]

English- 32 REPAIRS the diagram. 3. Pull the throttle wire casing to the f ar right and tighten the clamping screw . Checking and Adjusting the Choke Wire If the engine produces blac k smoke or is difficult to star t, the chok e wire (upper wire) ma y be incorrectly adjusted. T o adjust the choke, proceed as f ollows: 1. Release the clamping screw[...]

English- 33 REPAIRS Fuel tank Removing Bef ore removing the tank on the right of the mower , the rear wheel and the bolts holding the oil cooler for the h ydraulics must be remov ed. 1. Close the fuel valv e (13). 2. Drain the tank that is to be remov ed. K eep the drained fuel in a closed container . 3. Remov e the hose clamp (5) from the fuel lin[...]

English- 34 REPAIRS Adjusting Motion Control Le ver Linkages See “Hydraulic systemHydraulic pumpAdjusting the linkages”. Adjusting Motion Control Le ver Spring-back See “Hydraulic systemHydraulic pumpAdjusting the Re verse Detent Spring”. Adjusting the P ark Brake 1. Raise the rear of the unit and place it on stable jac k stands. Engage[...]

English- 35 REPAIRS Mower Dec k Removing 1. Drop the deck as f ar as it will go and loc k the control le ver in position with a pin. 2. Remov e the operator’ s foot plate . 3. Remov e the deck belt outer guards . 4. Using a 9/16" sock et on the bolt of the idler pulley , loosen the deck belt. Roll the belt off the deck pulle ys. 5. Remov e t[...]

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 dec k height and horizontality as per “Setting the mower dec k”. 9. Fit the operator’ s foot plat[...]

English- 37 REPAIRS assembly is supplied with an “O” ring (47) . The “O” ring must be removed bef ore the pulley is fitted. Replacing Bearings The fitting procedure is the re verse of the remov al procedure. Tightening torques: • Blade bolts 122 Nm (90 lb/ft). • Pulley bolts 61 Nm (45 lb/ft). Sharpening and Balancing Blades • Remov [...]

English- 38 REPAIRS Setting the Mower Dec k Leveling 1. P osition the mower on a le vel, pref erably concrete, surf ace. 2. Check the pressure in all f our tires. This should be 15 psi. 3. Raise the mower on lengths of 2" x 4" placed edgewise under the cutting dec k from front to rear (see diagram). 4. Place a 0.635 cm (1/4") shim be[...]

English- 39 REPAIRS 4. Using a 9/16" sock et on the bolt of the idler pulley , loosen the deck belt. Roll the belt off the deck pulle ys. 5. Roll the belt off the clutch pulley on the crankshaft. 6. Remov e the old belt. 7. Fitting the new belt is the re verse of the procedure given abo ve . Ensure that belt routing is as per the accompanying [...]

English- 40 REPAIRS Hydraulic Pump Belt Check the belt e very 75 to 100 hours of operation. Inspect carefully f or large cracks and significant damage. The small crac ks that arise from nor mal use do not mak e it necessar y to change the belt. Changing Pump and Deck Belts 1. Drop the deck to its lo west position. 2. Remov e the operator’ s foot[...]

English- 41 REPAIRS Pump Belt T ensioning Assembly The belt is automatically tensioned by a spring (37). T o cancel the f orce 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 the idler pulley is loose on its shaft. If it [...]

English- 42 REPAIRS[...]

English- 43 ELECTRICAL SYSTEM Electrical System T roubleshooting See the “T roubleshooting” section towards the bac k of this manual. Wiring Assembl y The diagram belo w shows the structure of the electrical system. T o connect the engine to the frame har ness (13), there is a pigtail. This plugs into connector “D” (see diagram abo ve). The[...]

English- 44 ELECTRICAL SYSTEM The console harness (1) connects the console controls to the frame har ness. ABCDE F 8011-629 ZTH console harness Blk = Black Blu = Blue Gra = Gray Grn = Green Pur = Purple Wht = White Yel = Yellow[...]

English- 45 ELECTRICAL SYSTEM There are two connectors connecting the frame harness (13) to the console har ness (1). The engine pigtail (page 43) plugs into the “Engine Pigtail” sock et of the frame harness. 8011-628 ZTH frame harness Blk = Black Blu = Blue Gra = Gray Grn = Green Pur = Purple Wht = White Yel = Yellow[...]

English- 46 ELECTRICAL SYSTEM Battery The batter y is maintenance-free and the cells are sealed. Breaking the seal in validates the w arranty . T o av oid exposing the battery ter minals to dangerous stress, use two wrenches when connecting or disconnecting the batter y cab les. Procedures in the Event of Acid Contact External: Drench with running [...]

English- 47 ELECTRICAL SYSTEM Relays Ref er to the “ZTH electrical system” diagram. The rela ys (22) plug into a holder under the seat (on the left). The three rela ys are identical and can be plugged into any of the sock ets in the holder . Rela y function (working along the holder from right to left) is: • Brak e relay • Run rela y • St[...]

English- 48 ELECTRICAL SYSTEM Ignition and Start Switch Ref er to the “ZTH electrical system” diagram. Changing 1. F ree the control console and pull f orwards. 2. Disconnect the wires at the back of the ignition s witch (10). 3. Remov e the ignition ke y and the rubber cap (20). 4. Remov e the nut (19) and the ignition s witch (10). 5. Thread [...]

English- 49 ELECTRICAL SYSTEM Blade Switch Ref er to the “ZTH electrical system” diagram. Changing 1. F ree the control console and pull forwards . 2. Disconnect the wires at the back of the s witch (11). 3. Push in the plastic catch on the s witch’ s shor t side and dra w the s witch out through the console panel. 4. With the plastic catch a[...]

English- 50 ELECTRICAL SYSTEM Fitting The fitting procerdure is the re verse of the remo val procedure . P a y par ticular attention to the f ollowing: • The tightening torque f or the bolt (9) is 67 Nm (50 ft/lb). • With the bolt (9) tightened, there should be perceptible pla y betw een the clutch and the clutch tie down (10) when the clutch [...]

English- 51 ELECTRICAL SYSTEM Removing 1. Swing the seat completely out of the wa y . 2. Release the mechanical link between the left park brake and the br ake le ver . 3. Release the dampeners (23) and springs (17) from the tubular shafts (31, 33) by remo ving the bolts (16) - each with two nuts (22) - spacers (21) and w ashers (11). 4. Release th[...]

English- 52 ELECTRICAL SYSTEM W elding The f ollowing applies to arc, MIG, TIG and all other electrical welding methods. The engine’ s ignition system has sensitive electrical components. Electrical welding must not, theref ore, be carried out on the engine. Remov e the component to be welded (e.g. the muffler) or the ignition system. Bef ore ca[...]

English- 53 HYDRAULIC SYSTEM Hydraulic System Hydraulics Hygiene If they are to oper ate well, h ydraulic systems must be k ept free from all impurities. Dur ing operation, par ticles that can cause both wear and malfunction are gener ated inside hydr aulic systems. T o separate these par ticles from the h ydraulic fluid, filters are used. Filter[...]

English- 54 HYDRAULIC SYSTEM Hydraulic Oils The oil is as impor tant as any other part of the hydraulic system. It has been shown that 70% of all problems with h ydraulics are due either to the use of unsuitable oil gr ades or filling/topping-up with contaminated oil. Contamination from outside is responsible f or by f ar the greater par t of the [...]

English- 55 HYDRAULIC SYSTEM ZTH Hydraulic System The h ydraulic pumps are controlled (via mechanical links) by the motion control le vers. 8011-588 ZTH h ydraulic system 8011-589 Hydraulic pump linkages[...]

English- 56 HYDRAULIC SYSTEM Hydraulic T ank Draining 1. The drain cap (29) is located on the underside of the tank in the front left corner (see the “ZTH h ydraulic system” diagram). Drained h ydraulic oil must be handled in accordance with the regulations gov erning the disposal of waste oil. Do not put drained oil bac k into the system. 2. I[...]

English- 57 HYDRAULIC SYSTEM The Cooler for the Hydraulic System Removing 1. Remov e the right rear wheel. 2. T o eliminate any excess pressure , remov e then replace the h ydraulic tank cap . 3. Loosen the hose clamps (16) but lea ve the hoses attached to the cooler . 4. Remov e the bolts (14), spacers (15) and nuts (12). 5. Hold the bottom of the[...]

English- 58 HYDRAULIC SYSTEM Fitting 1. Clean the surf aces mating pumps and motors to their mounts. 2. Bolt the h ydraulic pump loosely into place - it must still be possib le to mov e the pump. 3. Bolt the h ydraulic motor loosely into place - it must still be possib le to mov e the motor . 4. Using new “O” rings (34), and only hand tightenin[...]

English- 59 HYDRAULIC SYSTEM • Ensure that the pump pulley aligns with the cr ankshaft pulley and the pulle y for the other pump . • Ensure, on both sides , that the link between the motion control le ver and the h ydraulic pump is correctly adjusted. • V ent the h ydraulic system bef ore operation. Linkage Adjustment This adjustment must be [...]

English- 60 HYDRAULIC SYSTEM 6. Holding the le ver , adjust the spring by sliding the bolt (37) in the slot to remov e all the slop . Retighten the bolt. 7. Check the adjustment b y pulling the motion control le ver bac k to the rev erse position and releasing it. 8. If necessar y , make the same adjustment on the other side. 9. Reattach the seat r[...]

English- 61 TROUBLESHOOTING T r oubleshooting Engine Check section 8 of the Ka wasaki Service Manual. The abov e section contains a troubleshooting guide f or engine and auxiliar y systems. It also has a special section on troubleshooting the starter motor . Wiring Harness • Symptom: The star ter motor works but the engine does not turn ov er . S[...]

English- 62 TROUBLESHOOTING to R UN? 2. If yes , the problem is probab ly in the engine har ness , engine components or ignition switch. Disconnect the fuel valv e. If the fuse does not blow , the prob lem is probably in the fuel v alve . 3. If , from point 1 abov e, the fuse does not blo w , reattach the hour meter connectors. If the fuse blo ws, [...]

English- 63 TROUBLESHOOTING Clutch • Measuring clutch coil resistance. 1. T ur n the engine and PT O s witch 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-200 (271 Nm) = 1.74 - 1.93 Ω . The valu[...]

English- 64 TROUBLESHOOTING Prob lem P ossible causes Solution Clutch will not engage Blown fuse . • Low coil resistance . Replace with ne w MagStop unit. • Defectiv e batter y . Replace . • F aulty charging system. Repair or replace. • Bad wiring or connections, PT O s witch Repair or replace. Low v oltage supply . • Defectiv e batter y [...]

English- 65 TROUBLESHOOTING f aulty . Repair or replace. Overloaded clutch. • Clogged deck, f aulty spindle, etc. Remove e xcess grass. Replace spindle. Contaminated friction • Engine oil leak on clutch. Repair leak. surf aces. Replace with new MagStop unit. Noisy clutc h/vibrations F ailed bear ing. • Loose mounting (bolt not tightened Repla[...]

English- 66 TROUBLESHOOTING Hydraulic Pump In most cases, prob lems with the drive system are not due to a def ective pump b ut to slipping drive belts, partially engaged bypass valv es, loose or damaged control linkages, etc. Be sure to check all of these bef ore assuming a pump is f aulty .The troubleshooting chec klist below is designed to help [...]

English- 67 TROUBLESHOOTING • Bypass loose. Tighten the bypass. • Inlet leak. Check all connections and hoses f or leaks. • Clogged/damaged hydr aulic filter . Replace h ydraulic filter . • Defectiv e hydraulic pump . Replace pump . Unit operating hot. • Build-up of of grass cuttings. Clean the e xter ior of the mow er , especially the [...]

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Svenska – 31 Sve-5 225/232/235 Bruk 97-11-25, 08.46 31[...]

114 00 80-26 2002W 20 ´+H("¶6D¨[...]

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