Husqvarna Lawn Mower ZTH5223 User Manual

Workshop manual  
ZTH  
English  
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WORKSHOP MANUAL  
RIDE-ON LAWN MOWER  
ZTH  
Contents  
Contents ..................................................................1  
Safety Instructions .................................................3  
General Instructions.............................................3  
Special Instructions..............................................3  
Explanation of Symbols ........................................5  
Tools .......................................................................6  
Technical Data ........................................................7  
Delivery and Dealer Service ................................11  
Pre-delivery Service...........................................11  
After the First 8 Hours........................................12  
25 Hour Service .................................................12  
50 Hour Service .................................................12  
100 Hour Service ...............................................13  
300 Hour Service ...............................................13  
At Least Once a Year.........................................14  
Maintenance Schedule ......................................15  
Delivery Servicing ................................................19  
To our Dealers ...................................................19  
Removing the Mower from its Packaging ..........19  
Delivery Service.................................................20  
Test Running......................................................24  
Administration ....................................................24  
Design and Function ............................................25  
General ..............................................................25  
Mower Identification...........................................25  
Engine................................................................27  
Drive and Control...............................................27  
Brakes................................................................27  
Mower Deck.......................................................28  
Repairs ..................................................................29  
Engine................................................................29  
Adjusting the Throttle Wire.................................31  
Checking and Adjusting the Choke Wire ...........32  
Fuel tank ............................................................33  
Adjusting Motion Control Lever Linkages ..........34  
Adjusting Motion Control Lever Spring-back......34  
Adjusting the Park Brake ...................................34  
Mower Deck.......................................................35  
Spindle Blade Bearings.....................................36  
Sharpening and Balancing Blades.....................37  
Setting the Mower Deck ....................................38  
Deck Belt............................................................38  
Hydraulic Pump Belt ..........................................40  
Front Wheel Bearings ........................................41  
Electrical System ................................................ 43  
Troubleshooting ................................................ 43  
Wiring Assembly ............................................... 43  
Battery............................................................... 46  
Fuses ................................................................ 46  
Relays ............................................................... 47  
Starter Motor Contactor..................................... 47  
Ignition and Start Switch ................................... 48  
Hour Meter ........................................................ 48  
Blade Switch ..................................................... 49  
Mower Deck Clutch........................................... 49  
Motion Control Switches ................................... 50  
Park Brake Interlock Switch .............................. 51  
Welding ............................................................. 52  
Hydraulic System ................................................ 53  
Hydraulics Hygiene ........................................... 53  
Hydraulic Oils.................................................... 54  
Correct Oil Leaks .............................................. 54  
Keep Hydraulic Oil Clean.................................. 54  
Work Methods................................................... 54  
ZTH Hydraulic System ...................................... 55  
Hydraulic Tank .................................................. 56  
The Cooler for the Hydraulic System ................ 57  
Hydraulic Filter .................................................. 57  
Hydraulic Lines.................................................. 57  
Hydraulic Pump................................................. 58  
Hydraulic Motors ............................................... 60  
Troubleshooting .................................................. 61  
Engine............................................................... 61  
Wiring Harness.................................................. 61  
Clutch................................................................ 63  
Hydraulic Pump................................................. 66  
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SAFETY INSTRUCTIONS  
Safety Instructions  
General Instructions  
This workshop manual has been written for users who have a good understanding of the repair and  
servicing of ride-on mowers.  
The workshop where the ride-on mower is repaired must have have all the safety systems demanded by  
local regulations.  
No one is to attempt to repair the ride-on mower without having first read and understood the contents of  
this manual.  
The ride-on mower has been safety tested. Safety approval applies only when the ride on-mower uses  
parts or equipment supplied or recommended by Husqvarna Turf Care.  
Special Instructions  
The fuel used in the ride-on mower is hazardous if used incorrectly. Pay particular attention to the following:  
The fuel and the fumes it gives off are toxic.  
Eye and skin complaints can result from incorrect exposure.  
Breathing difficulties can result from incorrect exposure.  
The fuel and fumes are highly flammable.  
When using compressed air, users must not direct the air stream towards themselves or any other person.  
Air may penetrate the blood stream and cause life-threatening damage.  
Use hearing protectors when test driving.  
After test driving, do not touch the muffler before it has cooled down (danger of burns). This especially  
applies if the ride-on mower has a catalytic converter. If consumed, the lining on and in the catalytic  
converter element can damage health. Wear protective gloves whenever working on the catalytic converter  
or the silencer.  
With the engine running, many engine and drive system components become hot and may cause burns if  
touched. Do not touch such components before they have cooled down.  
When draining oil from a hot engine or hot hydraulic system, be aware that the oil can be hot enough to  
cause burns. Wear protective glasses whenever there is a risk of splashing.  
The mower blades are sharp. To avoid cuts, always wear protective gloves when handling the blades.  
Wear protective glasses when working with springs. Springs can detach from their mounts and fly with  
great force into unprotected eyes.  
Use the right tools for each job. Check all tools before using them and repair or replace as necessary.  
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SAFETY REGULATIONS  
Keep the workplace clean and tidy. Ensure that illumination is good, that tools which are not being used  
are stored appropriately and that all waste (scrap, swarf, etc.) is immediately placed in the appropriate  
container. Pay particular attention to keeping the floor clean so that there is no risk of slipping or tripping.  
Be extremely careful when handling battery acid. Severe burns may result if the acid touches the skin. If  
acid is spilt on the skin, drench immediately with running water.  
Always wear protective glasses when handling battery acid. Blindness may result if acid gets into the eyes.  
If there is an accident, take immediate action and contact a doctor as soon as possible.  
Be careful when working on the battery. Explosive gas is formed in the battery. Never handle the battery  
when smoking or in the vicinity of naked flames or sparks (the battery may explode and cause severe  
injuries).  
During certain maintenance and service operations, it is required that the mower be rendered incapable of  
starting. This is to prevent injury to those working on or standing near the mower.  
Hydrostatic braking may be lost if there is a failure in the hydrostatic drive.  
Certain solvents and cleaning agents are flammable. Do not use them whenever there is a less dangerous  
alternative. Never use flammable solvents in areas where there is a risk of ignition. Dispose of used  
cleaning agents in sealed containers.  
Respect the environment. Ensure that all solvents, waste oil and used oil filters are handled in an  
environment-friendly way. Observe all local regulations on the environment. A Husqvarna workshop must  
look clean at all times!  
In this workshop manual, “warning 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).  
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EXPLANATION OF SYMBOLS  
Explanation of Symbols  
The symbols below are used on the mower and in this manual. Study them carefully and be aware of what  
they mean.  
WARNING!  
Xxxxxxx xxxx xxxxxxxx xxx x.  
xxxx xxxxxx xx.  
Is used in this manual to make the user aware that there is a danger of personal injury, especially if the  
special instructions are not followed.  
IMPORTANT INFORMATION  
Xxxxxxx xxxx xxxxxxxx xxx x  
xxxx xxxxxx xx.  
Is used in this manual to make the user aware that there is a danger of material damage, especially if the  
special instructions are not followed. It is also used where it is judged that there is a danger of incorrect  
handling or incorrect assembly/fitting.  
Reverse  
Neutral  
Fast  
Slow  
Choke  
Fuel  
Warning! Rotating blades,  
stand clear of the chute.  
CE conformity  
marking  
Park brake  
Warning!  
Do not touch rotating  
parts.  
Battery acid is corrosive, explosive and  
flammable.  
Do not stand here.  
Max. sound emission.  
Use ear protectors.  
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TOOLS  
Tools  
The mower’s special design means that most repair and maintenance work can be carried out using  
standard tools.  
Servicing of engines and hydraulic pumps requires special tools.These are listed in the service manuals of  
the individual manufacturers.  
The mower (engine excluded) has mainly UNC or UNF screw/bolt/nut threads. Certain nuts have special  
stiffy threads for securing. It is vital that exactly the right size tools (i.e. imperial measurement) are used on  
these.  
Those working on the mower must 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.  
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TECHNICAL DATA  
Technical Data  
Model  
ZTH5223  
ZTH6125  
Model part number  
Engine (spec. number)  
Cylinder diameter  
Cylinder stroke  
Cylinder volume  
Power  
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  
Kawasaki (FH721V-AS04)  
75.2 mm (2.96 in.)  
76 mm (2.99 in.)  
675 cc (41.19 cu.in.)  
25 hp  
Engine RPM  
2,950 RPM  
2,950 RPM  
Idle RPM  
1,550 RPM  
1,550 RPM  
Spark plugs (2)  
Oil capacity, engine (total)  
Engine weight  
NGK BPR4ES  
NGK BRR1550  
1.8 litres (3.8 US pints)  
41.2 kg (90.8 lbs)  
1549 mm (61 in.)  
533.4 mm (21 in.)  
122 Nm (90 ft/lb)  
1.8 litres (3.8 US pints)  
40.5 kg (89.3 lbs)  
1321 mm (52 in.)  
457.2 mm (18 in.)  
122 Nm (90 ft/lb)  
Cutting width  
Blade length  
Tightening torque, blade bolt  
Cutting height  
Adjustable 38 mm (1.5") to  
152 mm (6") in 64 mm  
(0.25") increments  
Adjustable 38 mm (1.5") to  
152 mm (6") in 64 mm  
(0.25") increments  
Blade engagement  
Warner Mag-Stop  
Warner Mag-Stop  
Electromagnetic clutch  
Electromagnetic clutch  
Slip torque, clutch  
271 Nm (200 ft/lb)  
1.74 - 1.93 ohms at 23°C (68°F)  
12 - 14 V  
271 Nm (200 ft/lb)  
1.74 - 1.93 ohms at 23°C (68°F)  
12 - 14 V  
Clutch coil resistance  
Supply voltage clutch  
Tightening torque, clutch bolt  
Blade tip speed  
67 Nm (50 ft/lb)  
4,704 m/min.  
67 Nm (50 ft/lb)  
4,541 m/min  
Anti-scalp rollers  
6, adjustable  
6, adjustable  
Tightening torque, bolt for  
mower deck pulley  
61 Nm (45 ft/lb)  
61 Nm (45 ft/lb)  
Hydrostatic drive  
Dual Hydro-gear pumps and  
Dual Hydro-gear pumps and  
Parker/Ross Wheel drive motors  
Parker/Ross Wheel drive motors  
Tightening torque, pipe  
couplings  
41 Nm (30 ft/lb)  
41 Nm (30 ft/lb)  
Hydraulic pumps (2)  
Hydro Gear BDP 10A 404  
Hydro Gear BDP 10A 404  
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TECHNICAL DATA  
Model  
ZTH5223  
ZTH6125  
Displacement  
10.2 cc/r (0.623 cu. in./rev)  
70 bars (1000 PSI)  
145 bars (2,100 PSI)  
110°C (230°F)  
10.2 cc/r (0.623 cu. in./rev)  
70 bars (1000 PSI)  
145 bars (2,100 PSI)  
110°C (230°F)  
Nominal working pressure  
Max. hydraulic pressure  
Max. hydraulic oil temp  
Weight, hydraulic pump  
Hydraulic motors (2)  
3.6 kg (8 lbs)  
3.6 kg (8 lbs)  
Parker Ross  
Parker Ross  
Tightening torque, wheel motor  
hub nut  
122 Nm (90 ft/lb)  
122 Nm (90 ft/lb)  
Hydraulic oil  
1.9 litres (2 qt.), 15W-50  
Synthetic  
1.9 litres (2 qt.), 15W-50  
Synthetic  
Hydraulic oil cooler  
Speed forward  
Yes  
Yes  
Variable, max. 12.9 km/h  
(8 mph)  
Variable, max. 12.9 km/h  
(8 mph)  
Speed reverse  
Rear tires  
Variable, max. 3.23 km/h  
(2 mph)  
Variable, max. 3.23 km/h  
(2 mph)  
Carlisle 24" X 12.00 - 12 Tubeless  
Turf Master  
Carlisle 24" X 12.00 - 12 Tubless  
Turf Master  
Tightening torque, lug nuts  
Front tires  
100 Nm (75 ft/lb)  
100 Nm (75 ft/lb)  
Carlisle 13" X 5.00 - 6 Tubeless  
12 V with 15 A charging system  
Carlisle 13" X 5.00 - 6 Tubeless  
12 V with 15 A charging system  
Electrical system  
Fuel capacity  
44 litres (11.4 US Gal.), 22 litres/  
tank  
44 litres (11.4 US Gal.), 22 litres/  
tank  
Seat  
Adjustable, high-back seat with  
armrests  
Adjustable, high-back seat with  
armrests  
Overall length  
2057 mm (81 in.)  
1346 mm (53 in.)  
1600 mm (63 in.)  
1073 mm (42.25 in.)  
464.5 kg (1024 lbs.)  
2057 mm (81 in.)  
1575 mm (62 in.)  
1829 mm (72 in.)  
1073 mm (42.25 in.)  
464.5 kg (1024 lbs.)  
Overall width (chute up)  
Overall width (chute down)  
Overall height  
Weight  
Tightening torque, standard  
bolts  
1/4"  
12 Nm (9 ft/lb)  
25 Nm (18 ft/lb)  
44 Nm (33 ft/lb)  
12 Nm (9 ft/lb)  
25 Nm (18 ft/lb)  
44 Nm (33 ft/lb)  
5/16"  
3/8"  
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TECHNICAL DATA  
Model  
ZTH5223  
ZTH6125  
7/16"  
70 Nm (52 ft/lb)  
110 Nm (80 ft/lb)  
70 Nm (52 ft/lb)  
110 Nm (80 ft/lb)  
1/2"  
Accessories  
BioClip adapter  
Foot controlled mower deck lift  
Deluxe seat  
Optional  
Optional  
Optional  
Optional  
Optional  
Optional  
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TECHNICAL DATA  
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DELIVERY AND DEALER SERVICE  
Delivery and Dealer Service  
Pre-delivery Service  
1. Charge the battery.  
2. Mount the rear tires.  
3. Check and adjust the tire pressure in all  
tires. All tires should be1 bar (15 PSI).  
4. Fit the motion control levers in the normal  
position.  
5. Connect the rod to the seat stop.  
6. Connect the contactor to the cable for the  
seat’s safety switch.  
7. Fit the armrests to the seat’s back  
support.  
8. Check that the engine has the right  
quantity of oil.  
9. Check that the hydraulic tank has the  
right quantity of oil.  
10. Adjust the position of the motion control  
levers.  
11. Fuel the mower and open the gas valve.  
12. Connect exhaust fume extraction.  
13. Start the engine.  
14. Vent the hydraulic system.  
15. .Check that there is drive to both wheels  
16. Check mower deck settings.  
17. Check:  
The park brake safety switch.  
The seat safety switch.  
The motion control lever safety switches.  
Correct park brake operation.  
Forward drive.  
Reverse drive.  
Blade engagement.  
18. Check the idling speed (1,550 ±50 rpm).  
19. Check max. engine speed (2,800 ±75  
rpm).  
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DELIVERY AND DEALER SERVICE  
20. Inform the customer of the:  
Necessity and advantages of following  
the maintenance schedules.  
Necessity and advantages of having the  
mower inspected every 300 hours.  
The effect on resale value of regular  
servicing and a fully stamped service  
book.  
The use of BioClip.  
21. Complete the sales certificate, etc.  
After the First 8 Hours  
Change the motor oil.  
25 Hour Service  
1. Check the fuel pump air filter.  
2. Check the oil level in the hydraulic  
system.  
3. Check tire pressure.  
4. Lubricate the mower deck’s belt  
tensioner.  
5. Lubricate the hydraulic pump’s belt  
tensioner.  
6. Check/clean the engine’s cold air intake.  
7. Clean the air cleaner’s pre-filter (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 in dusty operating conditions.  
3. Lubricate the bearings of the front  
wheels.  
4. Lubricate the shafts of the motion control  
levers.  
5. Lubricate the mower deck struts.  
6. Lubricate the cutting height regulator.  
7. Check/adjust the park brake.  
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DELIVERY AND DEALER SERVICE  
100 Hour Service  
1. Carry out a 25 hour service.  
2. Carry out a 50 hour service.  
3. Change the engine oil.  
4. Check if the hydraulic oil needs changing  
(every 300 hours).  
5. Check if the engine’s oil filter needs  
changing (every 200 hours).  
6. Clean/change the spark plugs.  
7. Change the fuel filter in the fuel line.  
8. Clean the engine and transmission  
cooling fins.  
9. Clean and check if the air filter’s paper  
cartridge needs changing (every 200  
hours).  
300 Hour Service  
1. Inspect the machine. Reach agreement  
with the customer on what additional  
work is to be carried out.  
2. Carry out a 25 hour service.  
3. Carry out a 50 hour service.  
4. Carry out a 100 hour service.  
5. Change the oil and the filter in the  
hydraulic system.  
6. Clean the combustion chamber and  
grind the valve seats.  
7. Check the play in the engine valves.  
8. Change the air cleaner’s pre-filter (Oil-  
foam).  
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DELIVERY AND DEALER SERVICE  
At Least Once aYear  
1. Clean the engine’s cold air intake (25  
hours).  
2. Change the air cleaner’s pre-filter (Oil-  
foam).  
3. Change the paper cartridge in the air  
filter (200 hours).  
4. Change the engine oil (100 hours).  
5. Change the engine’s oil filter (200 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.  
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DELIVERY AND DEALER SERVICE  
Maintenance Schedule  
The table below lists the maintenance required by the ride-on mower. Several of the points not covered in  
this workshop manual will be found in the Operating Instructions.  
Daily  
Weekly At Maintenance intervals  
least  
once  
a
in hours  
Maintenance  
Page Pre- After  
use use  
25  
50 100 300  
year  
Check for fuel and oil leaks.  
Check the park brake.  
-
-
Check engine oil level (every fueling).  
Check the fuel pump air filter.  
Check the safety systems.  
21  
-
-
Check/clean the engine’s cold air intake.  
Check the mower deck.  
-
38  
-
Check fasteners (bolts, nuts, etc.).  
Start engine and blades; check for abnormal  
noise.  
-
Clean the underside of the mower deck.  
Check hydraulic system oil level.  
Check the condition of belts, pulleys, etc.  
Check for any damage.  
-
22  
38  
-
Check tire pressure.  
20  
-
Clean thoroughly around the engine.  
Clean thoroughly around the hydraulic system.  
Clean thoroughly around belts, pulleys, etc.  
Lubricate mower deck belt tensioner.  
Lubricate belt tensioner for hydraulic pumps.  
Lubricate all wires.  
53  
-
-
-
-
Lubricate driver’s seat mechanisms.  
Lubricate the throttle control.  
-
-
Clean the engine’s cold air intake.  
Lubricate mower deck links.  
-
-
Lubricate front wheel mounts (every 200 hours).  
Lubricate front wheel bearings.  
-
-
Lubricate the shafts of the motion control levers.  
Lubricate mower deck struts.  
-
-
Lubricate the mower deck’s height regulator.  
-
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DELIVERY AND DEALER SERVICE  
Daily  
Weekly At Maintenance intervals  
least  
once  
a
in hours  
Maintenance  
Page Pre- After  
use use  
25  
50 100 300  
year  
Check/adjust the cutting height regulator.  
Clean the air cleaner’s pre-filter (Oil-foam).  
38  
-
2)  
-
Clean the air cleaner’s filter (paper filter).  
1)  
22  
56  
-
Change the motor oil  
.
Change the hydraulic oil (every 300 hours).  
Change the engine’s oil filter (every 200 hours).  
Clean/change the spark plugs.  
Change the fuel filter in the fuel line.  
Clean the cooling fins.  
-
-
-
4)  
-
Check the play in the engine valves  
.
Change the air cleaner’s pre-filter (Oil-foam).  
-
2)  
-
Change air filter (paper filter) (every 200 hours).  
4)  
13  
34  
Carry out a 300 hour service  
Check/adjust the park brake.  
.
1) First change after 8 hours. With heavy operating conditions or high ambient temperature, change every 50 hours. 2) In dusty conditions, clean and  
change more frequently. 3) Where the mower is in daily use, lubrication must be carried out twice a week. 4) To be carried out by an authorized workshop.  
= Covered in this workshop manual.  
= Not coverd in this workshop manual or the Operating Instructions.  
= Covered in the Operating Instructions.  
WARNING!  
Service procedures may only be carried out on the motor or mower deck when:  
• The motor has been switched off.  
• The ignition key has ben removed.  
• The ignition cables have been removed from the spark plugs.  
• The park brake has been applied.  
• The mower deck has been disengaged.  
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DELIVERY AND DEALER SERVICE  
Service Records  
Remember to enter all service work in the Service Log at the back of the Operating Instructions.  
Record details of any major repairs.  
Enter the meter reading and date. Stamp and sign the stamp field.  
In your customer register, make a note of the work that has been carried out.  
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DELIVERY AND DEALER SERVICE  
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DELIVERY SERVICING  
Delivery Servicing  
To our Dealers  
The quality of delivery servicing is vital to aftersales success. It is in everyone’s interest that the aftermarket  
operates smoothly:  
The customer will be satisfied with his/her mower and know who he/she can contact for help with any  
problems.  
You will gain a regular customer who recommends you and your company to others.  
Together we will strengthen our brand and take joint responsibility for our products and customers.  
Complete all the paperwork meticulously.  
Fill in warranty and delivery documents, etc. and ensure that the customer receives the right operating  
instructions for his/her mower.  
Keep a register of customers and their mowers (with serial numbers, etc.).The information contained in the  
customer register is invaluable for marketing and when ordering spare parts.  
When supplying a mower, you should also give the customer all information necessary for the safe  
operation and care of the machine. Pay particular attention to informing the customer about:  
Safety instructions.  
Mower controls.  
Checking oil levels and the oil to be used when topping-up.  
The first oil change after the running-in period.  
The necessity and advantages of observing the maintenance schedules and regularly returning the  
mower for servicing.  
What type of fuel to use.  
Ways of achieving the best results with the mower. The use of BioClip.  
The accessories available for his/her mower.  
Warranty conditions.  
Your company and the person to be contacted if there are any problems.  
Removing the Mower from its  
Packaging  
Mowers are normally delivered from the  
factory in special packaging - a wooden crate  
with a solid bottom.  
WARNING!  
Handle the transport crate  
carefully. Keep the goods as  
level as possible.  
Use long pallet forks.  
8011-549  
Mower on its delivery baseplate  
English-19  
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DELIVERY SERVICING  
The baseplate itself stands on a pallet and the whole assembly can be handled using a standard forklift  
truck. To keep the goods as level as possible, two people should assist the truck driver. Driving and lifting  
must both be performed with care.  
Remove the upper part of the crate from the wooden baseplate.  
The mower (rear wheels not fitted) is secured to the baseplate by plastic straps and wooden 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, check that there is no transport damage. Any damage is to be reported to the  
transport company in the normal way.  
The packaging is not to be returned.  
Delivery Service  
1. Charge the battery. The mower is  
normally delivered with a charged  
battery topped-up with electrolyte.  
2. Raise the rear of the mower until it is  
clear of the baseplate and the rear  
wheels can rotate freely. Hold firmly in  
position using blocks or jack stands.  
3. With the valves facing outwards, fit the  
rear wheels. Fit and tighten the wheel  
nuts on the wheel bolts.  
4. Check and adjust the pressure in all the  
tires. The recommended pressure is 1  
bar (15 PSI).  
8011-503  
Fitting the rear wheels  
5. On both motion control levers, remove  
the lower bolts and loosen the upper  
bolts. Swing the levers to the upright  
position. Hand tighten the lower bolts in  
the rectangular holes. The levers are  
adjusted at a later stage.  
6. Push the levers out into their neutral  
slots.  
8011-502  
Lever mount  
English-20  
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DELIVERY SERVICING  
7. In the space to the left of the hydraulic  
tank, cut the cable tie holding the rod to  
the top of the seat. Remove the split  
cotter, swing the seat backwards and  
connect the rod to the seat. Replace the  
split cotter.  
Check that the contactor on the cable to  
the bottom of the seat is connected.  
Swing the seat down and check that it is  
held by the catch on the left.  
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-21  
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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 “FULLmark.  
ADD  
FULL  
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.  
ADD  
FULL  
The engine (excluding oil filter) holds 1.5  
litres of oil.  
8009-159  
Engine dipstick  
-20 C -10 C 0 C  
10 C  
20 C 30 C 40 C  
SAE40  
SAE30  
SAE10W-30/SAE10W-40  
SAE5W-20  
-4 F 14 F  
32 F 50 F  
68 F 86 F 104 F  
8009-140  
Viscosity chart  
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 necessary.  
8011-565  
Hydraulic tank  
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  
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DELIVERY SERVICING  
WARNING!  
Gasoline is highly ammable.  
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  
Selecting the gasoline tank  
WARNING!  
Never run the engine indoors in  
conned 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  
drive the mower forwards and off.  
Air relief screw for the hydraulic system  
22. Check mower deck settings as per the  
instructions (see ”Adjusting Motion  
Control Lever Linkages” on page 34).  
English-23  
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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 engine 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  
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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 Identication  
Each mower is individually identified by the  
details given on plate sited between the  
battery and the engine.  
Reading downwards, the plate gives:  
The model number  
The I.D. code.  
The serial number.  
8011-593  
Quote these when ordering spare parts.  
Mower identification  
English-25  
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DESIGN AND FUNCTION  
The engine identifiers are located on a  
barcoded decal. This is sited on the left side  
of the crankcase, directly opposite the starter  
motor. The decal gives:  
The engine code.  
The engine number.  
Quote these when ordeing spare parts.  
8009-205  
Engine identification  
The hydraulic pump identifiers are located on  
a bardcoded decal. This is sited on the left  
side of the pump housing. The decal gives:  
The pump type code (BDP-10....).  
The pump serial number.  
8011-594  
Hydraulic pump identification  
The hydraulic motor identifiers are located on  
a round, metal plate. This is sited on the end  
of the motor housing. The plate gives:  
The hydraulic motor type code and  
model.  
The hydraulic motor serial number.  
8011-595  
Hydraulic motor identification  
English-26  
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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.  
The table below shows the information to be quoted when ordering engine manuals:  
Kawasaki’s  
engine type  
Publication  
Kawasaki no.  
Model  
Power  
ZTH5223  
ZTH6125  
FH680V-AS15  
FH721V-AS04  
17.5 kW (23 hp) 99924-2045-03  
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 &  
Repair Manual”.  
Brakes  
Hydrostatic braking (see “Drive and Control”)  
provides brake control when the mower is  
being powered 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  
8011-507  
on each rear wheel is engaged by a lever on  
the left of the mower operator. The lever and  
the brake bands are mechanically linked.  
Air screw on hydraulic pump  
English-27  
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