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Workshop manual ZTH - K&T Parts House Lawn Mower Parts

1. 8011 504 Connnecting the rod to the seat IMPORTANT INFORMATION Risk of incorrect assembly fitting 8 Fit the armrests Position the armrests with the greatest possible distance between them The bolt heads should be on the inside i e towards the seat back and washers and nuts on the outside Armrests bolts washers and anti slip nuts are packed in a plastic bag accompanying the mower 8011 505 Fitting the armrests 9 Check the engine oil level With the mower standing on a flat surface check the engine oil level Unscrew the dipstick and pull it out Wipe the dipstick dry and push it back Do not screw the dispstick down Pull the dipstick up again and read the oil level 8011 501 Checking the engine oil level English 2 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 excluding oil filter holds 1 5 litres of oil 8009 159 20 C 10C 0C 10 C 20 C 30 C 40 C 32 F 50 F 68 F 86 F 104 F 8009 140 10 Check the oil level in the hydraulic tank The level must be 19 25 mm below the top of the tank Top up if nece
2. 5 Disconnect the fuel line with its filter from the fuel pump 6 Disconnect the connecting cable pigtail from the frame harness connector at the side of the starter motor 7 Disconnect the cable from the starter motor 8 Disconnect the cables from the ground 8011 621 bolt in front of the starter motor Engine assembly 9 Raise and support the back of the mower on blocks or similar 10 Remove the clip holding the oil drain hose 11 Remove the deck belt and clutch see Electrical System Mower deck clutch 12 Loosen the bolt 2 and twist the clutch tie down 10 aside see the Engine mounts diagram 13 Using a square 1 2 ratchet wrench loosen the pump belt Roll the belt off the pulley on the engine crankshaft 14 Remove the four outer bolts in the engine mounts WARNING Heavy lift 40 5 kg Handle the engine with care Place it safely where it cannot 8011 606 topple over Engine mounts 15 Lift the motor directly upwards and secure it in a safe place English 29 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS Fitting 1 10 11 12 13 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 Put the four upper engine m
3. OFF IGNITION SWITCH io N Lu Z X tz T Sy zO Yn Zz O HOUR METER LEFT MOTION CONTROL LEVER NEUTRAL PRESS 1 2 3 4 5 6 7 8 FUSE HOLDER PTO 7 5 AMP IGNITION 20 AMP 8011 629 ZTH console harness English 44 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM There are two connectors connecting the frame harness 13 to the console harness 1 TO 104414 Blk Black Blu Blue Gra Gray Grn Green PARK BRAKE SWITCH BRAKE ON BRAKE OFF Pur Purple Wht White Yel Yellow BRAKE RELAY RUN RELAY START RELAY oA Lu Z o lt I Lu lt o L BATTERY STARTER SOL GND TO ENG HAKL WHT KILL WIRE WHT GRA ERA REGULATOR 6 GRA io PUR FUEL SOLENOID PUR TO 104964 TO ENGINE PIGTAIL HARNESS TO ENGINE 104415 KAWASAKI BI DIR DIODE 8011 628 ZTH frame harness The engine pigtail page 43 plugs into the Engine Pigtail socket of the frame harness English 45 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM Battery The battery is mainten
4. The table below shows the information to be quoted when ordering engine manuals Model Kawasaki S Power Publication engine type Kawasaki no ZTH5223 FH680V AS15 17 5 kW 23 hp 99924 2045 03 ZTH6125 FH721V AS04 18 6 kW 25 hp 99924 2045 03 When repairing engines use genuine spare parts only The warranty will be invalidated if other parts are used Drive and Control Via a belt the engine supplies direct clutchles drive to two hydraulic pumps The pumps have axial pistons Each pump feeds oil to a fixed non adjustable hydraulic motor one by each drive wheel The rate and direction of oil flow is steplessly adjusted via a mechanical linkage by the motion control levers Adjustment is actuated by a swash plate that regulates the stroke length of the hydraulic pistons The swash plate is an integral part of each pump The mower can be made to turn or reverse by controling the rate and direction of flow to the hydraulic motors The hydraulic motors control the speed and direction of the drive wheels To swing the mower around its center simply drive one wheel forwards and the other backwards Hydrostatic braking occurs whenever there is no flow of oil from the pumps Instructions for the repair of the hydraulic pumps are given in the Hydro Gear BDP 10A 21L Service amp Repair Manual Brakes Hydrostatic braking see Drive and Control provides brake control when the mower is being po
5. The serial number Quote these when ordering spare parts 8011 593 Mower identification English 25 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DESIGN AND FUNCTION The engine identifiers are located ona barcoded decal This is sited on the left side of the crankcase directly opposite the starter motor The decal gives e The engine code e The engine number Quote these when ordeing spare parts 8009 205 The hydraulic pump identifiers are located on a bardcoded decal This is sited on the left side of the pump housing The decal gives e The pump type code BDP 10 e The pump serial number 8011 594 The hydraulic motor identifiers are located on a round metal plate This is sited on the end of the motor housing The plate gives e The hydraulic motor type code and model e The hydraulic motor serial number 8011 595 Hydraulic motor identification English 26 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 adjustment and repair of the engines The manuals can be ordered from authorized service workshops
6. To ensure safe transport the bearing English 36 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 e Blade bolts 122 Nm 90 lb ft e Pulley bolts 61 Nm 45 lb ft Sharpening and Balancing Blades WARNING Blades with any cracking must not be used Do not straighten a damaged blade if there is any danger of crack formation e Remove the blades e Check that the blades do not have cracks nee or any other damage If they do scrap Grinding a blade them e Clamp ina screw vice see diagram and file until sharp Balancing is as follows e Fix a mandrel for example horizontally in a screw vice see diagram e Push a blade onto the mandrel and check that it is evenly balanced The diagram shows a blade which needs adjusting This blade should be ground at the edge indicated by the straight arrow e The fitting procerdure is the reverse of the removal procedure The tightening torque for the blade bolts is 122 Nm 90 lb ft AR 6012 089 English 37 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS Setting the Mower Deck Leveling 1 Position the mower on a lev
7. 1 Check that the brake lever is in the on position that the blade engagement switch is pushed in that the motion control levers are in the neutral slots and that there is someone on the driver s seat If all correct 2 Check the 20 amp fuse If OK 3 Check the battery for charge should be 12 to 13 volts and that the battery cables are making good contact at both ends If OK 4 With all levers and switches properly positioned for start and an operator on the seat hold index finger and thumb against the start relay and turn the ignition switch to RUN A sharp click should be felt in the relay If not change the relay and try again If a click is felt 5 Check that all harness connections to the various switches and the engine are properly connected If all OK 6 Disconnect the yellow lead from the starter s contactor attach the red lead of a voltmeter to this wire and ground the black lead to the mower chassis With all levers and switches properly positioned for start and an operator on the seat turn the ignition to RUN The voltmeter should read 12 to 13 5 volts If there is no voltage the harness may have a broken wire a connection ina cable connector may be damaged or a switch broken incorrectly set e Symptom The ignition fuse blows with the ignition switch at RUN but does not blow if the engine connector is disconnected Suggested procedure 1 With engine connector connected disconnect the seat and
8. Engine mounts Belt routing for the mower deck www mymowerparts com 8011 606 8011 580 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Dismantling and Assembling Adjustments and Specific Repairs See the Kawasaki Service Manual for the engine and auxiliary systems Troubleshooting See section 8 of the Kawasaki Service Manual The above section contains a troubleshooting guide for the engine and auxiliary systems It also has separate troubleshooting instructions for the starter motor Adjusting the Throttle Wire Adjusting Throttle Lever Tension If there is insufficient throttle lever friction throttle settings can alter while the mower is being operated This can be corrected via the lever s pivot bolt 1 Free the control console and pull forwards 2 Tighten the throttle lever s pivot bolt 8011 599 Checking and Adjusting the Throttle Wire Check that the engine responds to the throttle control and that the correct engine speed is achieved at full throttle If adjustment is necessary adjust the lower wire as follows 1 Loosen the clam
9. Hour Service ssaseesseeseesreesrressresrreenreenneena 13 Park Brake Interlock SWitCh oeren 51 300 Hour Service snssnssnsenisninienissnnsnneninneneee 13 Welding s sinaaien ates meet ctsa on aise 52 At Least Once a YCAaL seeececseeeeteseeseeseeneeees 14 Hydraulic System ccccccccscsecsesteseeseeseeseeneaee 53 Maintenance Schedule si tinge tates 15 Hydraulics Hygiene ccccccccscseseseseseseseseseees 53 Delivery Servicing cee 19 Hydraulic OMS iciissndeascuttatestcsdateccatha etch eaculeeds 54 To OUr Dealers e a ae E 19 Correct Oil lA S a anaana 54 Removing the Mower from its Packaging 19 Keep Hydraulic Oil Clean vcscscscnseneeiene 54 Delivery Service sists aceite asta ations 20 Work MethodS Sossichai5i tr crtorscstortil ticle erditedeans 54 TeSt RUNNING iinr aare reeset aed 24 ZTH Hydraulic System ccccccscscesesseseeseeeeeees 55 Administrations 22s scekeces seth cccehentezes inns e 24 Hydraulic Tank esc saesecandicsid ast chciarcsnatahenstears 56 Design and Function soseer edian 25 The Cooler for the Hydraulic System Pee eee 57 ET AEI Ke EAE EO 25 Hydraulic Filter ccccccssssssssccssssesesesesesesesersees 57 Mower Identification sssecsecsecesessecseeseeeeees 25 Hydraulic Line iv ctscosiscconesatscececdadsaaenstatearssaibands 57 Engine Edupatledincmeatiadach E A 27 Hydraulic Pump fans CELIA ons eee ts Live Cee Loe 58 Drive and Control seenen 27 Hydraulic Mot
10. deck to its lowest position 2 Remove the operator s foot plate 3 Remove the outer deck belt guards 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 Loosen the bolt 2 and twist the clutch tie down 10 aside see the Engine mounts diagram 7 Using a square 1 2 ratchet wrench slacken the pump belt and roll it off the pulley for one of the hydraulic pumps 8 Remove the old belt 8011 623 9 Fit the new belt on the crankshaft pulley 10 Swing the idler pulley towards the engine and fit the belt 11 Fit the belt around the pulley on the right looking upwards from below the mower 12 Attach the spring and use a square 1 2 ratchet wrench to cancel the force exerted by the belt tensioner 13 Fit the belt around the left pulley looking upwards from below the mower 14 Check that the belt is not twisted and that it runs correctly around all the pulleys 15 Check that there is perceptible play between the clutch and the clutch tie down 10 when the clutch flange is turned by hand see the Engine mounts diagram Adjust twist the tie down and 8011 624 using the nut 1 tighten the bolt 2 Belt routing for the hydraulic pumps 16 Fit the deck belt Check that the belt is not twisted and that it runs correctly around all the p
11. stands Engage the parking brake and remove both rear tires wheels With the parking brake still engaged remove all spring tension by loosening the spring locknut Unlock the jam nut against the yoke and loosen the bolt until the head is about 1 2 inch away from the trunnion Relock the jam nut against the yoke Tighten the spring locknut until bolt head trunnion gap closes to 1 8 to 1 4 inch Yoke Jam nut Trunnion Disengage the parking brake hand lever and check that the spring is still under tension This is important in order to hold ae Sour the linkage from going over center Adjusting the park brake Repeat steps 2 and 3 on the opposite brake band If the brake band is making noise while in operation rattling squealing etc it may be necessary to readjust the parking brake band IMPORTANT INFORMATION This brake system has been designed as a parking brake and is intended to hold the unit in place when it is not being operated It must not be used as an emergency stopping brake or brake and linkage damage may occur This brake system is not designed to be the only means of holding the unit in place while transporting in a truck or on a trailer The unit must be tied down at all times while it is being transported or brake and linkage damage may occur English 34 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS Mower Deck WARNING No work is to be done on the mower
12. under the console the engine runs poorly and surges Suggested procedure 1 Disconnect the hour meter If the symptoms disappear replace the hour meter English 62 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING Clutch e 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 Connect the meter leads to the clutch 5 Check the meter reading CMS 175 237 Nm 2 45 2 71 Q CMS 200 271 Nm 1 74 1 93 Q The values above are at 23 C 68 F If the reading falls within the acceptable range measure the supply voltage at the clutch If not replace the clutch e Measuring the supply voltage at the clutch 1 Turn the engine off 2 Connect the meter leads at the clutch connector 3 Set the meter to read volts Ensure that the wires will not become entangled in the rotating parts of the clutch 5 Start the engine and engage the PTO switch 6 Measure the voltage across the leads at the connectors 7 The voltage should be 12 14 volts DC If the clutch still fails to operate replace the clutch 8 If voltage is not within the 12 14 volt range measure input voltage and output voltage at the clutch switch Any drop in voltage is unacceptable 1 Connector Q Ohmmeter 8011 567 Measuring resistance 1 Connector V Voltmeter 8
13. 011 568 Voltage measurement English 63 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING Problem Clutch will not engage Blown fuse Low voltage supply Incorrect coil resistance Inadequate current supply Rotor armature air gap too large more than 0 125 3 18 mm Brake will not engage Armature brake poles worn out Contaminated friction surfaces Clutch slips Low voltage supply Inadequate current supply English 64 Possible causes e Low coil resistance e Defective battery e Faulty charging system e Bad wiring or connections PTO switch e Defective battery e Faulty charging system e Bad wiring or connectors PTO switch e Damaged coil e Broken clutch lead wire e Faulty electrical system e Rotor armature wear End of useful life End of useful life Engine oil leak on brake e Defective battery e Faulty charging system e Bad wiring or connectors PTO switch e Broken clutch lead wire e Faulty electrical system Solution Replace with new MagStop unit Replace Repair or replace Repair or replace Replace Repair or replace Repair or replace Replace with new MagStop unit Repair Measure coil resistance and supply voltage at the clutch If both are correct electrical system is faulty Repair or replace Replace with new MagStop unit Replace with new MagStop unit Repair lea
14. 1 5 Remove the control lever by removing the bolts 3 and spring washers 4 6 Remove the bolt to the park brake arm on the right side of the park brake shaft Remove the arm and the released washers from the park brake shaft 7 Pull out the park brake shaft and lever to the left When the shaft is pulled out the tubular shafts first 33 and then 31 will be freed 8 Disconnect the cable connection to the switch and remove the tubular shaft 9 Remove the switch from the tubular shaft Fitting The fitting procedure is the reverse of the removal procedure Pay particular attention to the following Check and position the switches before fitting the tubular shaft Position the switches so that there is a click when the inner flat surface of the arm continuation shaft 5 passes over the outside corner of the tubular shaft s lever mount Check the setting of the linkages see Hydraulic System Hydraulic Pump Linkage Adjustment Check the setting of the reverse detent spring see Hydraulic System Hydraulic Pump Reverse Spring Detent Adjustment Park Brake Interlock Switch Refer to the ZTH electrical system diagram Changing i 2 3 Disengage the park brake Drop the deck to its lowest position Remove the bolts 9 The tapped plate 8 is freed when the switch is loosened Separate the connector from the switch 7 Pull it directly upwards Push the connector onto the new switch there i
15. 5 and O ring 33 from the tank 3 Disconnect the hose 27 and O ring 33 from the tank 4 Remove the bolts 10 nuts located beneath the bracket and their washers 13 Lift the tank away Fitting The fitting procedure is the reverse of the removal procedure Use new O ring flares English 56 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 HYDRAULIC SYSTEM The Cooler for the Hydraulic System Removing 1 Remove the right rear wheel To eliminate any excess pressure remove then replace the hydraulic tank cap Loosen the hose clamps 16 but leave the hoses attached to the cooler Remove the bolts 14 spacers 15 and nuts 12 ak oN Hold the bottom of the cooler higher than the hydraulic tank and disconnect the hoses 27 28 from the cooler Fitting The fitting procedure is the reverse of the removal procedure Hydraulic Filter Use genuine Husqvarna filters only The use of pirate parts can invalidate the warranty Changing Filters When changing the oil in the hydraulic tank change the filter also Dispose of the used filter in accordance with the environmental regulations relating to engine oil filters An oil filter chain may be used for removal but not for fitting 1 Screw the filter 3 from the filter head 4 refer to the ZTH hydraulic system diagram 2 Smear the new filter s gasket with clean hydraulic oil 3 Screw on the new filter u
16. 623 or 606 561 4983 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 Adjustment WARNING Ensure the mower is securely supported on blocks or jack stands Keep hands feet and clothing away from rotating tires This adjustment must be made with the rear wheels rotating Raise the rear of the mower and support it securely on blocks or jack stands so that the wheels are free to rotate 1 2 9 10 11 Remove the seat rod so that the seat can swing down onto the frame Tilt the seat forward and to engage the seat safety switch place a length of 2 x 4 between the foot plate and the center of the seat Loosen the jam nuts 20 directly behind each ball joint 10 32 on the pump control links These links can now be rotated using the other nuts 9 The jam nuts have a left hand thread Start the engine the park brake must be engaged and the motion control levers in the neutral slots Run the engine at approximately half throttle Release the park brake so that the rear wheels can rotate Working on one side at a time put the motion control lever into the neutral position in the drive channel Adjust the motion control linkage by turning the two nuts 9 in the proper direction Tur
17. For Husqvarna Parts Call 606 678 9623 or 606 561 4983 Workshop manual ZTH English www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Husqvarna Parts Call 606 678 9673 or 606 561 4983 q WORKSHOP MANUAL RIDE ON LAWN MOWER ZTH Contents 0a aI ES DI e E eet ts 1 Electrical System es a a a a a l 43 Safety Instructions cceeeceeeeeeeeeeeeeeees 3 Troubleshooting 5 s ice eatechesteteied bateete eodewctstees 43 General Instructions eee eeeeeeereeeneeeeeees 3 Wiring ASSEMDIy cccccccesecesesseseeseeseseeteeees 43 Special Instructions q seGrcecneaaecsacttoe 3 Bay eee ee 46 Explanation of Symbols cee 5 PI elit E E sien ciotbestconexs 46 TOONS spi ieoa oaa o a eS lee tee 6 TIE E E E 47 Technical Data a et een eee es 7 Starter Motor Contactol cccccccccccccececcececcecees 47 Delivery and Dealer Service eee 11 Ignition and Start Switch ccceseseseeeseeeeeeeeeeee 48 Pre delivery ServiCe sees eee 11 Hour Meter ssnsssssississinsnisninisnirniesrnsnnsnnnnnnennne 48 After the First 8 HOUIS cccis cies tetenneaancwnnain 12 EEO EESIN O tic 202 ates ote ee tee 49 25 Hour Service ou eee eeeeeeeeeeeeeeeeeeaeeteneeeeeeeeees 12 Mower Deck CIUtCH ccccccccccccecccccccccececcececceeeee 49 50 Hour Service 2 cccceeeceeeeeeeeeeeeeeeeeeeeeneeeees 12 Motion Control Switches a aaaea annaua 50 100
18. ION 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 R NEBDA N l Reverse Neutral Fast Slow Choke Fuel Warning Park brake CE conformity Warning Rotating blades Do not touch rotating marking stand clear of the chute parts i Q Som CE ae M 4 D 105 05 db Battery acid is corrosive explosive and Do not stand here ae i Max sound emission flammable Use ear protectors English 5 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 exclude
19. Tightening torque pipe couplings Hydraulic pumps 2 TECHNICAL DATA ZTH5223 968 99 91 60 Kawasaki FH680V AS15 75 2 mm 2 96 in 76 mm 2 99 in 675 cc 41 19 cu in 23 hp 2 950 RPM 1 550 RPM NGK BPR4ES 1 8 litres 3 8 US pints 40 5 kg 89 3 Ibs 1321 mm 52 in 457 2 mm 18 in 122 Nm 90 ft lb Adjustable 38 mm 1 5 to 152 mm 6 in 64 mm 0 25 increments Warner Mag Stop Electromagnetic clutch 271 Nm 200 ft lb 1 74 1 93 ohms at 23 C 68 F 12 14V 67 Nm 50 ft lb 4 704 m min 6 adjustable 61 Nm 45 ft lb Dual Hydro gear pumps and Parker Ross Wheel drive motors 41 Nm 30 ft lb Hydro Gear BDP 10A 404 ZTH6125 Kawasaki FH721V AS04 75 2 mm 2 96 in 76 mm 2 99 in 675 cc 41 19 cu in 25 hp 2 950 RPM 1 550 RPM NGK BRR1550 1 8 litres 3 8 US pints 41 2 kg 90 8 Ibs 1549 mm 61 in 533 4 mm 21 in 122 Nm 90 ft lb Adjustable 38 mm 1 5 to 152 mm 6 in 64 mm 0 25 increments Warner Mag Stop Electromagnetic clutch 271 Nm 200 ft lb 1 74 1 93 ohms at 23 C 68 F 12 14V 67 Nm 50 ft lb 4 541 m min 6 adjustable 61 Nm 45 ft lb Dual Hydro gear pumps and Parker Ross Wheel drive motors 41 Nm 30 ft lb Hydro Gear BDP 10A 404 English 7 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 Model Displacement Nominal working pressure Max hydraulic pressure Max hydraulic oil temp We
20. V with 15 A charging system 44 litres 11 4 US Gal 22 litres tank Adjustable high back seat with armrests 2057 mm 81 in 1575 mm 62 in 1829 mm 72 in 1073 mm 42 25 in 464 5 kg 1024 Ibs 12 Nm 9 ft lb 25 Nm 18 ft lb 44 Nm 33 ft lb www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TECHNICAL DATA Model 7 16 1 2 Accessories BioClip adapter Foot controlled mower deck lift Deluxe seat ZTH5223 70 Nm 52 ft lb 110 Nm 80 ft lb Optional Optional Optional ZTH6125 70 Nm 52 ft lb 110 Nm 80 ft lb Optional Optional Optional English 9 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TECHNICAL DATA English 1 0 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Fue
21. ZTH electrical system diagram Changing 1 Free the control console and pull forwards Disconnect the wires at the back of the switch 11 2 3 Push in the plastic catch on the switch s short side and draw the switch out through the console panel 4 With the plastic catch and two contact pins facing upwards push the new switch into the console panel unitl it is correctly seated oi Refit the control console Mower Deck Clutch Measuring the Supply Voltage See the Troubleshooting section towards the back of this manual Measuring Coil Resistance See the Troubleshooting section towards the back of this manual Troubleshooting Guide See the Troubleshooting section towards the back of this manual Removing 1 Drop the deck to its lowest position 2 Remove the operator s foot plate 3 Using a 9 16 socket on the bolt of the idler pulley loosen the deck belt Roll the belt off the deck pulleys 4 Roll the belt off the clutch pulley on the crankshaft 5 Disconnect the cable feeding the clutch The connector is located next to the left engine mount 6 Remove the bolt 9 and the lock washer 8 7 Remove the clutch 7 and the spacer 6 Reconnect the wires at the back of the switch 8011 592 8011 6022 Loosen the deck belt English 49 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM Fitting The fittin
22. a Parts Call 606 678 9623 or 606 561 4983 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 e Symptom The starter motor works but the engine does not turn over Suggested procedure 1 Check the fuel level and the position of the fuel valve lever 2 If OK disconnect the hose hold the end in a container and crank the engine If no fuel comes out the fuel pump is faulty or the line is blocked If fuel does come out 3 Remove the air filter cover and air filter The fuel valve can be seen in front of the carburetor With the seat switch depressed hold a finger against the valve and turn the ignition switch to RUN A sharp click will be felt if the valve opens the carburetor will then be getting fuel If not 4 Disconnect the main harness from the engine Locate the red and violet wires in the main harness connector Attach the red lead from a voltmeter to this connector and ground the black lead to the mower chassis With an operator in the seat and the ignition turned to RUN the voltmeter should register 12 volts If it does the fuel valve is faulty If there is no voltage the problem may be in the harness wires the connectors or the ignition switch e Symptom The starter motor does not work Suggested procedure
23. ake 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 English 1 4 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Maintenance intervals least in hours Maintenance Page Pre After once 25 50 100 300 use use a year Check for fuel and oil leaks O Check the park brake Check engine oil level every fueling 21 e Check the fuel pump air filter v Check the safety systems vy Check clean the engine s cold air intake Check the mower deck 38 Check fasteners bolts nuts etc O0O lt Start engine and blades check for abnormal noi
24. ance 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 WARNING The battery contains corrosive acid Wear goggles Do not tip the battery over The battery gives off explosive fumes Keep it away from all naked sparks and flames Never smoke in the vicinity of the battery Never let children or untrained staff handle or work on the battery Procedures in the Event of Acid Contact External Drench with running water Internal Drink copious quantities of water or milk See a doctor as soon as possible Eyes Drench with running water See a doctor as soon as possible Fuses Refer to the ZTH electrical system diagram The fuses 23 24 plug into a holder on the left of the hydraulic tank They are of the flat pin type commonly used in automobiles There are two active fuses and sockets for two spares Fuse rating and function working along the holder from right to left is 20 A main fuse 7 5 A deck clutch Socket for spare fuse Socket for spare fuse 8011 596 Fuses English 46 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 plug
25. brake switches and the blue and violet lead from the hour meter Does the 20 amp ignition fuse still blow when the ignition is now turned English 6 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING to RUN If yes the problem is probably in the engine harness engine components or ignition switch Disconnect the fuel valve If the fuse does not blow the problem is probably in the fuel valve If from point 1 above the fuse does not blow reattach the hour meter connectors If the fuse blows the hour meter is probably faulty If the hour meter is OK reconnect the brake switch and pull the brake on If the fuse holds reconnect the seat switch and turn the ignition to RUN If the fuse holds remove and then replace the relays one at time and try again A blown fuse here indicates that the relay is faulty If it has been established that the problem is in one of the safety interlock circuits that the battery is delivering 12 volts and that the main fuse is OK but that the engine will not turn over the brake relay can be easily tested as set out below IMPORTANT INFORMATION Disconnecting the brake relay bypasses that part of the interlock system which prevents the mower moving with the brake on Engage the brake disconnect the brake relay and attempt to start the engine If the engine now turns over and the main fuse holds the brake relay is probably faulty Symptom Clicking
26. 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 English 4 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 EXPLANAT
27. ch 10 Remove the ignition key and the rubber cap 20 Remove the nut 19 and the ignition switch 10 Thread the toothed plate connector onto the throat of the new ignition switch Feed the switch into the console from the rear Turn the switch so that the single pin faces towards the blade switch Start the nut 19 off on its thread and twist the switch to the correct position in the console panel Try the key in the switch and then tighten the nut 8011 599 Freeing the control console Remove the key and fit the rubber cap 20 Reinsert the key Reconnect the wires at the back of the ignition switch Refit the control console Hour Meter Refer to the ZTH electrical system diagram Changing 1 ar N D Free the control console and pull forwards Disconnect the wires at the back of the hour meter 12 Prise the catches apart and remove the hour meter s locking plate Pull the hour meter out of the console panel Ensuring that the numbers are turned to the correct position to be seen by the operator insert the new hour meter in the console panel Fit the locking frame push in manually and check that the catches have fastened Connect the two violet wires to the right pin and the black to the left Refit the control console English 48 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM Blade Switch Refer to the
28. d 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 English 6 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 Technical Data Model Model part number Engine spec number Cylinder diameter Cylinder stroke Cylinder volume Power Engine RPM Idle RPM Spark plugs 2 Oil capacity engine total Engine weight Cutting width Blade length Tightening torque blade bolt Cutting height Blade engagement Slip torque clutch Clutch coil resistance Supply voltage clutch Tightening torque clutch bolt Blade tip speed Anti scalp rollers Tightening torque bolt for mower deck pulley Hydrostatic drive
29. deck or belts until the engine has been rendered incapable of starting Remove the ignition key or both spark plug cables 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 Using a 9 16 socket on the bolt of the idler pulley loosen the deck belt Roll the belt off the deck pulleys 5 Remove the deck s rear anti scalp rollers WARNING Danger of personal injury crushed fingers or limbs etc If the deck height control lever is not secured by a locking pin the deck will spring upwards when the chains are released 6 Release the four chains from their mounts on the lift arms top of chain 7 On both sides of the deck remove the bolts 17 and pivot pins 50 of the rear bearings see the ZTH mower deck diagram 8 Pull the deck out Fitting 1 Slide the deck into position under the mower 2 Using two lengths of 2 x 4 one towards the edge of each of the deck s short sides support the deck 4 off the ground 3 Grease the pivot pins 50 of the rear bearings with copious amounts of corrosion preventing grease Line up the shaft bearings and slide the pivot pins into place Fit the bolts and nuts 17 5 holding the pivot pins in place see the 8011 601 ZTH mower deck diagram Supporting the deck on lengths of 2 x 4 English 35 www mymowerparts c
30. eck 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 i Charge the battery The mower is normally delivered with a charged battery topped up with electrolyte 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 With the valves facing outwards fit the rear wheels Fit and tighten the wheel nuts on the wheel bolts Check and adjust the pressure in all the tires The recommended pressure is 1 bar 15 PSI 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 Push the levers out into their neutral slots English 20 8011 503 Fitting the rear wheels 8011 502 Lever mount www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY SERVICING 7 Inthe 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 of the seat is connected Swing the seat down and check that it is held by the catch on the left
31. el 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 4 Place a 0 635 cm 1 4 shim between the 2 x 4 and the rear edges of the deck This will allow the correct down angle at the front of the deck 5 Adjust the four lower chain bolts so that they are centered in the oblong slots IMPORTANT INFORMATION Ensure that all four bearings suspending the deck to the mower are tightly bolted to the frame 6 Check that all the chains are equally tensioned If they are not adjust the appropriate lower chain bolt in its slot Adjusting Cutting Height Raise and secure the deck height lever to the transport position 6 Measure from the cutting edge of the blades to the flat level surface The distance should be150 mm 6 Drop and secure the lever at for example the 2 cutting height Measure as above The distance should be 50 mm 2 Deck 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 Belts 1 Drop the deck to its lowest position 2 Remove the operator s foot plate 3 Remove the outer deck belt guards English 38 8011 601 Leveling the mower deck 8011 622 Slacke
32. eld In your customer register make a note of the work that has been carried out English 17 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY AND DEALER SERVICE English 18 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 e The customer will be satisfied with his her mower and know who he she can contact for help with any problems e You will gain a regular customer who recommends you and your company to others e 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 e Safety instructions e Mower controls e Checking oil levels and the oil to be used when topping up e The f
33. em drive the mower forwards and off 22 Check mower deck settings as per the instructions see Adjusting Motion Control Lever Linkages on page 34 English 23 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 that the engine stops if with the park brake engaged a motion control lever is folded inwards i e across the operator Test both the left and the right motion control levers Check that the engine stops if with the park brake disengaged the operator gets up from the driver s seat Check that with the drive in neutral and the park brake disengaged the mower does not move on flat ground Increase the throttle setting the mower must still remain stationary Check that the park brake operates correctly Check that the mower moves straight forwards backwards when both motion control levers are simultaneously moved an equal distance forwards backwards Check that the mower turns normally when driving forwards and backwards Check that the mower deck operates correctly and that there is no abnormal noise Check that engine idling speed is 1 550 50 rpm Check that the speed regulator gives a maximum engi
34. g procerdure is the reverse of the removal procedure Pay particular attention to the following e The tightening torque for the bolt 9 is 67 Nm 50 ft lb e With the bolt 9 tightened there should be perceptible play between the clutch and the clutch tie down 10 when the clutch flange is turned by hand If necessary adjust twist the tie down e Ensure that the cable cannot be damaged and secure it with a cable tie Motion Control Switches These micro switches are difficult to access By pulling the control console forwards it is possible to change the right switch without any other major dismantling However this does require two people When changing the left switch the tubular shafts 31 33 of the motion control levers must be lowered or removed The procedure for doing this is detailed below and may also be used for the right switch 8011 589 Hydraulic pump linkages English 50 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 spacers 21 and washers 11 4 Release the front end of the ball joints 32 from the tubular shafts 31 33 by removing the bolts 14 nuts 22 and washers 1
35. ged into any of the sockets in the holder Relay function working along the holder from right to left is e Brake relay e Run relay e Start relay Removing 8011 597 Pull relays directly upwards If necessary Relays carefully work a screwdriver under the relay and lever upwards Fitting The relays have an asymetric pin pattern and will fit into the sockets in one way only Press each relay down until the body contacts the holder Starter Motor Contactor Changing 1 Disconnect the cable connecting the battery to the chassis To avoid damaging the battery terminals use two wrenches 2 Pull the cables off the contactor 3 Remove the contactor the nuts are under the frame plate 4 Position the new contactor so that the pin for the control cable is towards the chassis wall The black cable connects to the front binding screw 5 Connect the control cable yellow to its 8011 598 pin Starter motor contactor 6 Connect the wires to to the battery and starter motor as shown in the diagram Replace the connector guards 7 Connect the cable between the battery and the chassis English 47 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM Ignition and Start Switch Refer to the ZTH electrical system diagram Changing 1 Free the control console and pull forwards Disconnect the wires at the back of the ignition swit
36. h 54 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 HYDRAULIC SYSTEM ZTH Hydraulic System 8011 588 ZTH hydraulic system The hydraulic pumps are controlled via mechanical links by the motion control levers 8011 589 Hydraulic pump linkages English 55 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 Hydraulic Tank Draining 1 HYDRAULIC SYSTEM 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 put drained oil back into the system It is not necessary to drain the entire hydraulic system when performing scheduled hydraulic system oil changes Change only the oil in the tank 8011 590 Hydraulic tank drain cap Anytime the hydraulic oil is changed the oil filter should also be changed Filling Fill the tank with clean oil direct from the manufacturer s container For oil type refer to the hydraulic tank decal or the lubrication chart The use of non approved oils can invalidate the warranty The level must be around 19 25 mm 3 4 1 below the top of the tank Vent the system using the air screws on the hydraulic pumps and top up as necessary Removing 1 Drain the hydraulic tank as above 2 Disconnect the 7 tube 2
37. ight hydraulic pump Hydraulic motors 2 Tightening torque wheel motor hub nut Hydraulic oil Hydraulic oil cooler Speed forward Speed reverse Rear tires Tightening torque lug nuts Front tires Electrical system Fuel capacity Seat Overall length Overall width chute up Overall width chute down Overall height Weight Tightening torque standard bolts 1 4 5 16 3 8 English 8 TECHNICAL DATA ZTH5223 10 2 cc r 0 623 cu in rev 70 bars 1000 PSI 145 bars 2 100 PSI 110 C 230 F 3 6 kg 8 Ibs Parker Ross 122 Nm 90 ft lb 1 9 litres 2 qt 15W 50 Synthetic Yes Variable max 12 9 km h 8 mph Variable max 3 23 km h 2 mph Carlisle 24 X 12 00 12 Tubeless Turf Master 100 Nm 75 ft lb Carlisle 13 X 5 00 6 Tubeless 12 V with 15 A charging system 44 litres 11 4 US Gal 22 litres tank Adjustable high back seat with armrests 2057 mm 81 in 1346 mm 53 in 1600 mm 63 in 1073 mm 42 25 in 464 5 kg 1024 Ibs 12 Nm 9 ft lb 25 Nm 18 ft lb 44 Nm 33 ft lb ZTH6125 10 2 cc r 0 623 cu in rev 70 bars 1000 PSI 145 bars 2 100 PSI 110 C 230 F 3 6 kg 8 Ibs Parker Ross 122 Nm 90 ft lb 1 9 litres 2 qt 15W 50 Synthetic Yes 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 100 Nm 75 ft lb Carlisle 13 X 5 00 6 Tubeless 12
38. ilters are dimensioned to cope with particles developed within the system If impurities enter from outside filters tend to clog quickly and become ineffective Any dirt entering a hydraulic system accelerates the production of further impurities A vicious circle arises there is much disruption and a lot of time is lost in cleaning The particles causing most damage are those which are of roughly the same size as the play between the moving parts in system components Normal play in pumps and valves is from 3 5 um and upwards 1 um 0 001 mm It should be noted that a particle measuring 40 um can only just be seen by the naked eye The main impurities generated in system operation are e Wear particles mainly from components with moving parts e g pumps and hydraulic motors e Dust entering the hydraulic oil tank via air vents e Water formed by condensation water vapor enters with air from outside e Particles of dirt entering the system via moving piston rods etc e Sediments etc produced by the breaking down of the hydraulic oil e Corrosive matter produced in the system as a result of oil not being changed in time Old oil tends to be rich in water and other aggressive substances e Dirt entering the system during service or repair work e g Contamination during the changing or topping up of oil Dust in the workshop Sealing agents and similar Dirt from storage and handling prior to fitting Fibers from rags fi
39. ion from outside is responsible for by far the greater part of the impurities in the oil in hydraulic systems Correct Oil Leaks Cavitation from injested air can cause internal hydraulic pump and wheel motor damage Air can enter the system anywhere there is an oil leak Therefore it is very important that oil leaks be repaired immedately Keep Hydraulic Oil Clean Dirt and other forms of contamination are the greatest enemies of hydraulic systems Long system life and high efficiency very much depend on hydraulic oil being kept in good condition Use only the grade of oil stated in the lubrication chart Make sure that hydraulic oil is inspected at regular intervals and that levels are kept topped up All high quality hydraulic oils are supplied in clean containers and have been filtered as free from impurities as possible It is when the containers are opened or stored that problems arise Do not open a container before the area around the cap seal or similar has been wiped clean of all dust dirt fibers and water Any other container funnel or hose used when filling the hydraulic system must be clean Work Methods Cleanliness is also vital for any components being removed from or fitted to a hydraulic system However it must be borne in mind that used components sent to a workshop will often be specially inspected and or tested Such components should be dispatched in the condition they were prior to removal Otherwise the true reason fo
40. ions 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 e The fuel and the fumes it gives off are toxic e Eye and skin complaints can result from incorrect exposure e Breathing difficulties can result from incorrect exposure e 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 ma
41. irst oil change after the running in period e The necessity and advantages of observing the maintenance schedules and regularly returning the mower for servicing e What type of fuel to use e Ways of achieving the best results with the mower The use of BioClip e The accessories available for his her mower e Warranty conditions e 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 8011 549 Mower on its delivery baseplate English 19 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 blocks 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 ch
42. k Replace with new MagStop unit Replace Repair or replace Repair Repair Measure clutch coil resistance and supply voltage at the clutch If both are correct electrical system is www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING Overloaded clutch Contaminated friction surfaces Noisy clutch vibrations Failed bearing Adapter plate rattles e against anti rotation pin Clutch loose on shaft Clutch not mounted square e Broken spring WARNING Clogged deck faulty spindle etc Engine oil leak on clutch Loose mounting bolt not tightened to the correct torque Insufficient play at the adapter plate Some noise is normal Loose mounting bolt not tightened to the correct torque Mounting bolt too long and bottoms on the crankshaft before the clutch bites Mounting washer too thin and deforms when bolt is tightened Shaft bottoms on the clutch Ground drive spacer mounting shoulder not square Clutch integral key hitting end of keyway in engine shaft Incorrect or no chamfer on ground drive spacer Loose mounting faulty Repair or replace Remove excess grass Replace spindle Repair leak Replace with new MagStop unit Replace tighten to specification Check clean adjust If noise is excessive repair or replace anti rotation pin device Tighten mounting bolt to specification Use correct length bo
43. l 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 English 1 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Lubricate the mower deck s belt tensioner 5 Lubricate the hydraulic pump s belt tensioner 6 Check clean the engine s cold air intake 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 i
44. lace hydraulic filter Replace pump Clean the exterior of the mower especially the cooler Replace hydraulic cooler Fill to proper level or change oil Raise the cutting height drive more slowly Aerate the system Check all connections and hoses for leaks Tighten clean test run Replace seal test run Replace seal and gasket Replace hose seal and gasket English 6 7 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 114 00 80 26 GEN erparts cott2
45. linkage bent loose or incorrectly adjusted linkage system e Drive belt slipping or pulley damaged e Oil level low or oil contaminated e Excessive loading long grass e Air trapped in the hydraulic system Corrective action Adjust to proper pressure Repair adjust or replace the linkages on both sides Tighten the bypass Check all connections and hoses for leaks Adjust the speed regulator Fill to proper level or change oil Raise the cutting height drive more slowly Aerate the system Tighten bypass Check all connections and hoses for leaks Replace filter Adjust the speed regulator Repair or adjust the linkages on both sides Repair clean or replace drive belt Fill to proper level or change oil Raise the cutting height drive more slowly Aerate the system www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING Unit operating hot External oil leak e Bypass loose e Inlet leak e Clogged damaged hydraulic filter e Defective hydraulic pump e Build up of of grass cuttings e Hydraulic cooler clogged or damaged e Oil level low or oil contaminated e Excessive loading long grass e Air trapped in the hydraulic system e Inlet leak Loose connection seal e Damaged seal or gasket e Hose leaking but oil reaching the pump Tighten the bypass Check all connections and hoses for leaks Rep
46. lt Use correct washer Use proper spacer at least1 4 thick Replace Space clutch away from radius in shaft keyway Increase chamfer on ground drive spacer Replace clutch A clutch with broken rivets or springs may separate from the shaft and cause personal injury English 65 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 troubleshooting checklist below is designed to help determine the cause of problems Troubleshooting Checklist Hydraulic WARNING Do not attempt any servicing or adjustments with the engine running Take great care when inspecting drive belts pulleys and motion control lever linkages Pump Problem Cause Vehicle does not drive track straight Unit is noisy Unit has no low power English 66 e Vehicle tires improperly inflated e Pump linkage bent loose or incorrectly adjusted e Bypass loose e Inlet leak Engine RPM high e Oil level low or oil contaminated e Excessive loading long grass e Air trapped in the hydraulic system e Bypass loose e Inlet leak e Clogged damaged hydraulic filter Engine RPM low e Pump
47. lters etc Dirt from parts not cleaned prior to dismantling Dirt and dust entering the system from contaminated protective plugs Especially if the system is not regularly used even microscopic quantities of water will accelerate the rusting of ground and polished surfaces This hastens the formation of sediments that can clog filters and give rise to circulation and cavitation problems in hydraulic pumps Minute fibers and threads from cleaning rags or clothing can form fluff which will obstruct nozzles and other narrow apertures The fibers themselve do not cause significant damage but the clogging they generate greatly accelerates component wear Every particle of dirt in hydraulic systems acts as a grinding agent Abrasion is increased more impurities are produced and permanent damage is caused Particle quantity increases every time work is done on hydraulic systems Although most particles will have been trapped by the filters after a few hours operation it is obviously good practice to avoid all unnecessary opening of hydraulic systems even if carried out by professionals English D3 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Contaminat
48. n these nuts far enough to just stop the wheel rotating Move the motion control lever forward then into the neutral position and then into the neutral slot The wheel must stop completely at this point Now move the motion control lever into the reverse position and release it The lever should return to neutral on its own If not the reverse spring detent must be adjusted check below Tighten the jam nuts directly behind each ball joint 10 32 Adjust the linkage on the other side in the same way Reattach the seat rod to the seat Reverse Spring Detent Adjustment 1 2 Stop the engine and remove the key Pull the motion control lever back to the reverse position and then release it The lever should spring back and stop centrally in line with the neutral slot i e it should be possible to move the lever directly back to the locked neutral position without touching the sides of the slot If adjustment is required move the seat to the back of its slide rails before tilting it forward and removing the rod from the seat frame Swing the seat down onto the frame Sufficient to allow the bolt to slide in its slot loosen the nut 27 fastening the spring 17 to its upper mount Swing the motion control lever out into the neutral slot While it is there pull it against the back face of the neutral slot English D9 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 HYDRAULIC SYSTEM Holding
49. n 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 English 12 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY AND DEALER SERVICE 100 Hour Service Carry out a 25 hour service Carry out a 50 hour service Change the engine oil POON rs 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 Change the fuel filter in the fuel line 8 Clean the engine and transmission cooling fins 9 Clean and check if the air filters 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 Carry out a 25 hour service Carry out a 50 hour service Carry out a 100 hour service af ON Change the oil and the filter in the hydraulic system 6 Clean the combustion chamber and grind the valve seats Check the play in the engine valves 8 Change the air cleaner s pre filter Oil foam English 13 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY AND DEALER SERVICE At Least Once a Year 1 Clean the engine s cold air int
50. ne speed of 2 800 75 rpm Administration Fill in the sales certificate and customer register etc Remember to fill in the serial number on page 4 and to sign the delivery service in the Operating Instructions English 24 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 hydrostatic drive system comprising a hydraulic pump and a hydraulic motor The hydraulic pumps are driven by a belt from the engine s crankshaft The mower is steered by the independent adjustment of the speed and direction of each rear wheel The front wheels are free to turn in whichever direction is most suitable The mower deck is mounted underneath the mower and is supplied with a side discharge chute as standard The range of accessories includes a BioClip kit of guide plates and blades for mounting beneath the mower deck casing 8011 591 ZTH ride on mower Mower Identification IX Each mower is individually identified by the details given on plate sited between the opens 268998160 battery and the engine cent no ZTHS229KAA Reading downwards the plate gives sence ne wsTOUS The model number D The I D code D O e
51. ning the belt tensioner www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Fitting the new belt is the reverse of the procedure given above Ensure that belt routing is as per the accompanying diagram 8 Check that the belt is not twisted and that it runs correctly around all the pulleys 8011 580 Belt routing for the mower deck Belt Tensioning Assembly The belt is automatically tensioned by a spring 18 To cancel the force of the spring use a 9 16 socket on the bolt 33 when removing or fitting the belt Check that there is no abnormal noise indicating that the idler pulley is loose on its shatt If it is loose tighten the bolt 33 or change the idler pulley Check that the idler arm is not loose on its bearing If it is tighten the nut 34 or change the bushing 38 8011 617 Belt tensioning assembly English 39 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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
52. ntil the gasket contacts the filter head 4 Manually turn the filter a further one and a half turns Removing 1 Drain the hydraulic tank as per the instructions given above 2 Disconnect the hoses 25 26 and O rings 33 from the filter head 4 3 Remove the bolts 10 and washers 11 Remove the entire filter unit Fitting The fitting procedure is the reverse of the removal procedure Use new O ring flares Hydraulic Lines Two types of hydraulic lines are used high pressure hoses and pipes For pipes earlier mower models the fitting instructions given below apply they do not need to be observed for mowers with hyrdaulic hoses between pumps and motors English D 7 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 HYDRAULIC SYSTEM Fitting IMPORTANT INFORMATION Pipes between hydraulic pumps and hydraulic motors must not be subjected to bending or compression To avoid pipe fatigue and the resultant leaks and fractures the fitting procedures below must be observed 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 O rings 34 and only hand tightening the fittings at either end connect the pipe between pump and motor 5 Tighten the hydraulic pump bol
53. ny 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 English 3 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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
54. om For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS Fit the deck s rear anti scalp rollers Attach the chains to the lift arms Fit the belt as per the routing diagram Check that the belt is not twisted and that it runs correctly around all the pulleys NO a 8 Check deck height and horizontality as per Setting the mower deck 9 Fit the operator s foot plate 10 Fit the deck belt outer guards 8011 580 Belt routing of the mower deck Spindle Blade Bearings WARNING Wear protective gloves when working on or with blades To remove a blade undo the retaining bolt 25 When fitting a blade tighten the bolt to 122 Nm 90 ft lb Removing Bearings 1 Roll the belt off see Changing Belts 2 Remove the bolt 28 and the pulley 3 Lock the pulley using a bolt through the hole in the pulley and a holding tool 3 Raise the mower deck to its highest position Lift the front end of the mower and support it on blocks or similar 4 Remove the bolts 12 and nuts 5 and pull downwards to remove the bearing and blade 5 Separate the blade from its bearing Repairing Bearings If there is too much play the bearing 44 can 8011 618 be replaced if the bearing surfaces of the ZTH mower deck housing 46 have not been damaged Pressing downwards remove the spindle 41 If there is extensive damage replacement of the complete bearing assembly 2 is recommended
55. or plate acts as a guard preventing contact with the belt and the other pulleys 8011 580 Belt routing for the mower deck WARNING The mower blades are extremely sharp To prevent personal injury wear protective gloves when handling the blades The blades do not require shear pins Impact protection is provided by the blades skating on their shafts if they hit an immoveable object The discharge chute is on the right side of the mower deck It is spring loaded and can be raised For mulching a BioClip kit is available as an accessory The kit comprises guide plates and BioClip blades It is fitted to the underside of the mower deck The mower deck is suspended to the bottom of the mower via two backward inclined struts and four adjustable chains Six anti scalp rollers on the underside of the mower deck prevent the casing catching on the ground Cutting height is set by a lever on the right of the operator Inserting a pin through the holes in the deck height adjustment plates sets a limit to the downward movement of the lever English 28 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Disconnect the gas and choke wires from the carburetor rn iai Tom Y L o NA U
56. ors cceccssssesessssesesestseseseeessesens 60 Brakes 1 e cc0d c8stea iania iinit eiae aed 27 Troubleshooting cccccccccccececcsseeeseseseseseees 61 Mower Dek cc sseieentscteitecnteinecsiinedaliintesatan 28 aea E Maeda stance mlaaeeacteee at 61 PRE ere I a oiec 33h a Ae eat ta ae ae ater 29 Wiring HarnesS cccccccccsesesesssesesssesseseseeeseees 61 EMQING t0sccatecssesedstiecsesstidtenasteddnednsasesnsbesatin 29 Clute nate acer tee eet Ves eta cate te tia Ria 63 Adjusting the Throttle Wire 31 Hydraulic Pm sceiescscteisauteesrastaclueetastwscnsye 66 Checking and Adjusting the Choke Wire 32 FUCA ive cee ale secede tiracet iia tiaeevedtatilsentieteres 33 Adjusting Motion Control Lever Linkages 34 Adjusting Motion Control Lever Spring back 34 Adjusting the Park Brake sssceeeee 34 Mower Deck isch fie clits cites Aids ech eeeste laden 35 Spindle Blade BearingS eee eeeeeeeeeeeeee 36 Sharpening and Balancing Blades 37 Setting the Mower Deck 2 ecseeeeeeeeees 38 Deck Bei e a E e ae e a e kd tns 38 Hydraulic Pump Belt ssec 40 Front Wheel Bearings seseeeeeeeeeeererrrereee 41 English 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 English 2 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 SAFETY INSTRUCTIONS Safety Instructions General Instruct
57. ount isolators 22 in the engine bed small diameter end in the engine bed hole Check that the clutch tie down 10 is not deformed straighten if necessary and lower the engine into position The engine weighs 40 5 kg Inserting the spacers 22 washers 28 21 and bolts 19 from below fit the engine mounts The tightening torque for the retaining nuts 20 is 110 Nm 80 ft Ib Fit the pump belt on the pulley Attach the spring and use a square 1 2 ratchet wrench to cancel the force exerted by the belt tensioner Fit the washer 6 and mower deck clutch 7 Connect the cable to the connector 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 clutch tie down 10 when the clutch flange is turned by hand Adjust twist the tie down and using the nut 1 tighten the bolt 2 Ensure that the cable cannot be damaged and secure it with a cable tie Roll the mower belt into place on the clutch pulley Check that the belt is routed as per the diagram and that it is not twisted Fit the operator s foot plate Fit the clip for the oil drain hose Connect the 3 cables to the ground bolt Connect the cable to the starter motor Connect the pigtail to the frame harness Connect the fuel line to the fuel pump English 30 7 c A lt 7 t ee era ar eos TN 7 4
58. ping screw holding the wire s outer casing and set the lever to the full throttle position 2 Check that the throttle wire is attached to the correct hole in the lower lever see 8011 554 Checking and adjusting the throttle wire English 3 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS the diagram 3 Pull the throttle wire casing to the far right and tighten the clamping screw Checking and Adjusting the Choke Wire If the engine produces black smoke or is difficult to start the choke wire upper wire may be incorrectly adjusted To adjust the choke proceed as follows 1 Release the clamping screw that secures the wire casing and set the choke control to maximum choke 2 Check that the throttle wire is attached to the upper lever see the diagram 3 Pull the choke wire casing to the far right and tighten the clamping screw 8011 555 Checking and adjusting the choke wire English 32 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 WARNING Fire and health hazard Avoid spills Wipe dry if necessary 2 Drain the tank that is to be remo
59. r the fault may be difficult to ascertain and testing may give false results Furthermore returned components that have been cleaned may mistakenly be presumed to be free from defect and sent back without the appropriate action being taken The following are suggested as routine steps when working on hydraulic systems 1 Perform general cleaning as necessary 2 Protect the point area where the repair is to be carried out from dust and other impurities in the air Plastic covers and the suchlike can be used 3 Clean thoroughly using white spirit or an equivalent It is not sufficient to clean only those parts directly affected Places from where dirt can fall onto the work point must also be cleaned The same applies to any tools used at the site of the intervention Clean with a suitable brush wipe with a rag and repeat if necessary Finally spray the site hose connections etc with clean white spirit 4 Fit suitable protector plugs caps immediately after removing a hose or pipe Components even those being replaced hoses pipes etc should all be suitably protected 5 If they are not exchanged for new all old pipe connector parts must be cleaned with fresh white spirit and then blown with compressed air before refitting 6 Maintain strict hygiene when measuring pressures Before joining them spray both parts of quick couplings with white spirit Ensure that any protective plugs caps are clean before they are used again Englis
60. s only one way for the parts to mate K Using the bolts 9 and tapped plate 8 fasten the switch securely to its bracket 8011 600 Check that the start interlock functions Park brake interlock switch correctly English 5 1 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM Welding The following applies to arc MIG TIG and all other electrical welding methods IMPORTANT INFORMATION When performing electric welding on the mower take all necessary precautions to prevent damage to the electrical system 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 muffler or the ignition system Before carrying out welding on any other part of the mower 1 Remove the battery cables 2 Disconnect the connector between the engine pigtail and the frame harness 3 Connect the welding earth lead as near as possible to the point of welding English 52 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 hydraulic fluid filters are used F
61. se Clean the underside of the mower deck lt Check hydraulic system oil level 22 e Check the condition of belts pulleys etc 38 Check for any damage O Check tire pressure 20 Clean thoroughly around the engine O Clean thoroughly around the hydraulic system 53 Clean thoroughly around belts pulleys etc O Lubricate mower deck belt tensioner v Lubricate belt tensioner for hydraulic pumps vy Lubricate all wires v Lubricate driver s seat mechanisms v Lubricate the throttle control v Clean the engine s cold air intake viv Lubricate mower deck links O Lubricate front wheel mounts every 200 hours v Lubricate front wheel bearings Lubricate the shafts of the motion control levers Lubricate mower deck struts 5 qdd lt Lubricate the mower deck s height regulator English 15 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY AND DEALER SERVICE Daily Weekly At Maintenance intervals least in hours Maintenance Page Pre After once 25 50 100 300 use use a year Check adjust the cutting height regulator 38 J Clean the air cleaner s pre filter Oil foam viv Clean the air cleaner s filter gt paper filter v v Change the motor oil 22 e Change the hydraulic oil every 300 hours 56 J Change the engine s oil filter every 200 hours v v Clean change the
62. spark plugs O O Change the fuel filter in the fuel line v v Clean the cooling fins O O Check the play in the engine valves 4 a O O Change the air cleaner s pre filter Oil foam v v Change air filter paper filter 2 every 200 hours v v Carry out a 300 hour service 13 d Check adjust the park brake 34 e D First change after 8 hours With heavy operating conditions or high ambient temperature change every 50 hours 7 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 O Not coverd in this workshop manual or the Operating Instructions Vv Covered in the Operating Instructions WARNING Service procedures may only be carried out on the motor or mower deck when e The motor has been switched off The ignition key has ben removed e The ignition cables have been removed from the spark plugs e The park brake has been applied e The mower deck has been disengaged English 16 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 fi
63. ssary 8011 565 11 Adjust the motion control levers a Set the seat longitudinally in a comfortable position and swing the levers into the drive channel b Hold one of the levers at a comfortable midpoint and tighten the retaining bolts c Hold the other lever as far forward as the first and tighten the bolts 8011 522 Adjusting the motion control levers English 22 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DELIVERY SERVICING WARNING Gasoline is highly flammable Take great care 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 8011 550 Fueling 13 Select tank by moving the selector to the appropriate position 8011 506 WARNING Selecting the gasoline tank Never run the engine indoors in confined or poorly ventilated areas Exhaust fumes contain carbon monoxide poisonous 14 Connect exhaust fume extraction 15 Start the engine 16 Check that there is drive to both wheels 17 Vent the hydraulic system 18 Check that with the motion control levers in the neutral position both rear wheels are stationary 19 Remove the blocks supporting the back end 20 Raise the mower deck to its highest position 8011 507 21 Raise the back of the baseplate and Air relief screw for the hydraulic syst
64. the lever adjust the spring by sliding the bolt 37 in the slot to remove all the slop Retighten the bolt Check the adjustment by pulling the motion control lever back to the reverse position and releasing it If necessary make the same adjustment on the other side Reattach the seat rod to the seat frame Hydraulic Motors Removing O08 a OO ee de ND Drain the hydraulic tank as per the instructions given above Raise the mower and support on blocks or jack stands Remove the rear wheel on the side with the faulty motor Remove the cotter pin and hub nut Using an extractor if necessary pull the hub off the axle Remove the park brake as a single unit Clean as set out in the instructions Disconnect the hydraulic lines 21 22 or 23 24 and O rings from both the pump and the motor Remove the hydraulic motor from its bracket Dismantling and Assembling Refer to Parker Hydraulics Torglink Service Procedure for TE Hydraulic Motors Fitting The fitting procedure is the reverse of the removal procedure Use new O rings Pay particular attention to the following Fit hydraulic pipes as per the instructions under Hydraulic Lines The tightening torque for the hub nut is 122 Nm 90 ft lb After tightening align the nut with the cotter pin hole Adjust the park brake as set out in the instructions Vent the hydraulic system before operation English 60 www mymowerparts com For Husqvarn
65. tle nut 27 until there is zero play in the bearings Loosen the castle nut to the nearest hole and fit the cotter pin English 41 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 REPAIRS English 42 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 A To the engine ground bolt D To the pigtail G To the seat B To the solenoid E To the park brake H Console harness C To the electric clutch F To motion control lever J Frame harness 8011 584 ZTH electrical system To connect the engine to the frame harness 13 there is a pigtail This plugs into connector D see diagram above The Kawasaki pigtail is illustrated below Vio Violet Wht White Gra Gray 8011 587 Kawasaki pigtail English 43 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM The console harness 1 connects the console controls to the frame harness 12 3 4 RIGHT MOTION CONTROL LEVER Blk Black Blu Blue Gra Gray NEUTRAL PRESS Grn Green Pur Purple Wht White Yel Yellow SEAT SWITCH N O SWITCH 1 2 1 2 3 4 5 6 718 PTO SWITCH
66. ts 6 Tighten the hydraulic motor bolts 7 Tighten the pipe fittings to a torque of 41 Nm 30 ft lb Hydraulic Pump Removing 1 Drain the hydraulic tank as per the instructions given above Raise the mower and support on blocks or jack stands Remove the rear wheel on the side with the faulty pump PF oO NW Using a swivel jointed socket handle hold the idler pulley so that the belt can be rolled off the pulley beneath the pump see Changing belts Loosen the two lock screws holding the pump pulley and remove it from its shaft Clean as set out in the instructions Remove the hydraulic lines 21 22 or 23 24 and O rings 34 from both pump and motor oN OO Be careful not to damage the cooler when working on the right hydraulic pump Release the ball joint 10 from the pump lever 12 refer to the Hydraulic pump linkages diagram 9 Disconnect the hose 28 and O ring 33 from the pump 10 Disconnect the hose 26 and O ring 33 from the pump 11 Remove the pump s retaining bolts and lift it away Dismantling and Assembling Refer to Hydro Gear Service Manual for Bantam Duty Pump models 10A and 21L Fitting The fitting procedure is the reverse of the removal procedure Use new O rings Pay particular attention to the following e Fit hydraulic pipes as per the instructions under Hydraulic Lines English 58 www mymowerparts com For Husqvarna Parts Call 606 678 9
67. ulleys 17 Fit the operator s foot plate 18 Fit the outer deck belt guards English 40 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 the idler pulley is loose on its shaft If it is loose tighten the bolt 42 and the set screws 41 or change the bushing 44 Check that the idler arm is not loose on its bearing If it is tighten the bolt 49 or change the bushing 47 8011 616 Pump belt tensioning assembly Front Wheel Bearings Dismantling 1 Remove the grease cap 26 2 Raise and support the front of the mower on blocks or similar 3 Remove the cotter pin 30 Remove the castle nut 27 and pulling downwards remove the front fork 5 Remove the upper bearing 28 6 Taking great care not to damage the seal 31 use a hammer and a suitable rod or similar to knock the lower bearing out in a downwards direction 8011 619 Front wheel bearing Assembling The assembly procedure is the reverse of the dismantling procedure Lubricate the bearings with ball bearing grease Taking great care not to damage it tap the seal into position Adjust the cas
68. ved Keep the drained fuel in a closed container 3 Remove the hose clamp 5 from the fuel line 6 4 To catch any spills position a container below the outlet from the tank to the fuel line To ensure no damage is caused hold the hose barb 4 with pliers and pull the fuel line away Even when the tank is empty a small amount of fuel may leak out 5 The tank is fitted to the splashguard by a bolt and two studs Remove the bolt 16 and three nuts 10 all with washers 8 and springs 9 located on the underside of the splashguard 8011 607 Fuel tank 6 Remove the bolt 12 and tank spacer located on the inside of the splashguard 7 Lift the fuel tank 2 away Fitting The fitting procedure is the reverse of the removal procedure Working from the underside of the splashguard tighten each washer 8 spring 9 washer 8 combination using the appropriate nut 10 or bolt 16 Tighten until the spring starts to compress and then a further 1 5 turns English 33 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 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 Spring 1 8 1 4 Space 1 Raise the rear of the unit and place it on stable jack
69. wered by its engine Putting the motion control levers in the neutral position brakes the mower To move the mower manually open the air screws on the hydraulic pumps Oil is then circulated by the hydraulic motors and the machine can be moved short distances at low speed The mower also has a park brake This operates on both rear wheels A brake band on each rear wheel is engaged by a lever on Air screw on hydraulic pump the left of the mower operator The lever and the brake bands are mechanically linked 8011 507 English 27 www mymowerparts com For Husqvarna Parts Call 606 678 9623 or 606 561 4983 DESIGN AND FUNCTION Mower Deck WARNING The engine must not be started if the operator s floor plate or any of the guards for the mower deck s belt is are not securely in position 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 belt is automatically adjusted by a spring 2 operating on the pulley 3 attached to the top of the mower deck casing Via vertical shafts three other pulleys 4 5 7 each drive a separate blade Two idler pulleys 6 8 serve as belt guides The outermost pulleys are shielded by removable guards attached to the top of the mower deck casing The operator s flo

Workshop manual ZTH - K&T Parts House Lawn Mower Parts

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Workshop manual ZTH - K&amp;T Parts House Lawn Mower Parts

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Workshop manual ZTH - K&T Parts House Lawn Mower Parts