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.  
-
-
G
G
Check engine oil level (every fueling).  
Check the fuel pump air filter.  
Check the safety systems.  
21  
-
M
-
M
Check/clean the engine’s cold air intake.  
Check the mower deck.  
-
M
G
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  
-
M
G
G
G
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.  
G
53  
-
-
M
M
-
-
M
M
M
Lubricate driver’s seat mechanisms.  
Lubricate the throttle control.  
-
-
Clean the engine’s cold air intake.  
Lubricate mower deck links.  
-
M
M
-
Lubricate front wheel mounts (every 200 hours).  
Lubricate front wheel bearings.  
-
M
-
M
M
M
M
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  
-
G
M
M
G
G
M
M
M
M
G
G
M
2)  
-
M
Clean the air cleaner’s filter (paper filter).  
1)  
22  
56  
-
G
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.  
G
M
M
-
-
-
4)  
-
Check the play in the engine valves  
.
Change the air cleaner’s pre-filter (Oil-foam).  
-
M
2)  
-
M
Change air filter (paper filter) (every 200 hours).  
4)  
13  
34  
G
Carry out a 300 hour service  
Check/adjust the park brake.  
.
G
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.  
G = Covered in this workshop manual.  
= Not coverd in this workshop manual or the Operating Instructions.  
M = 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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DESIGN AND FUNCTION  
Mower Deck  
WARNING!  
The engine must not be started if the operators oor plate or any of the guards for  
the mower decks 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  
floor 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  
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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.  
4. Disconnect the gas and choke wires from  
the carburetor.  
5. Disconnect the fuel line (with its filter)  
from the fuel pump.  
6. Disconnect the connecting cable (pigtail)  
from the frame harness connector at the  
side of the starter motor.  
7. Disconnect the cable from the starter  
motor.  
8011-621  
8. Disconnect the cables from the ground  
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  
topple over.  
8011-606  
Engine mounts  
15. Lift the motor directly upwards and  
secure it in a safe place.  
English-29  
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REPAIRS  
Fitting  
1. 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.  
2. Put the four upper engine mount  
isolators (22) in the engine bed (small  
diameter end in the engine bed hole).  
3. 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.  
4. 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/  
lb).  
5. 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.  
6. Fit the washer (6) and mower deck clutch  
(7). Connect the cable to the connector.  
8011-606  
Engine mounts  
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.  
7. 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.  
8. Fit the operator’s foot plate.  
9. Fit the clip for the oil drain hose.  
8011-580  
10. Connect the 3 cables to the ground bolt.  
11. Connect the cable to the starter motor.  
12. Connect the pigtail to the frame harness.  
13. Connect the fuel line to the fuel pump  
Belt routing for the mower deck  
English-30  
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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 Specic 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  
Freeing the controle console  
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 clamping 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  
8011-554  
the correct hole in the lower lever, see  
Checking and adjusting the throttle wire  
English-31  
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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  
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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 removed.  
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)  
8011-607  
and three nuts (10) - all with washers (8)  
Fuel tank  
and springs (9) - located on the  
underside of the splashguard.  
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  
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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 stands. Engage the parking  
brake and remove both rear tires/wheels.  
2. 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  
3. Disengage the parking brake hand lever  
and check that the spring is still under  
tension.This is important in order to hold  
the linkage from going over-center.  
8011-581  
Adjusting the park brake  
4. Repeat steps 2 and 3 on the opposite  
brake band.  
5. 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  
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REPAIRS  
Mower Deck  
WARNING!  
No work is to be done on the mower 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.  
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. Remove the deck’s rear anti-scalp  
rollers.  
WARNING!  
Danger of personal injury (crushed ngers 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  
“ZTH mower deck” diagram).  
8011-601  
Supporting the deck on lengths of 2” x 4”  
English-35  
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REPAIRS  
4. Fit the deck’s rear anti-scalp rollers.  
5. Attach the chains to the lift arms.  
6. Fit the belt as per the routing diagram.  
7. Check that the belt is not twisted and that  
it runs correctly around all the pulleys.  
8. Check 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  
be replaced if the bearing surfaces of the  
housing (46) have not been damaged.  
8011-618  
ZTH mower deck  
Pressing downwards, remove the spindle  
(41).  
If there is extensive damage, replacement of  
the complete bearing assembly (2) is  
recommended.  
To ensure safe transport, the bearing  
English-36  
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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:  
Blade bolts 122 Nm (90 lb/ft).  
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.  
Remove the blades.  
Check that the blades do not have cracks  
or any other damage. If they do, scrap  
them.  
6012-088  
Grinding a blade  
Clamp in a screw vice (see diagram) and  
file until sharp.  
Balancing is as follows:  
Fix a mandrel (for example) horizontally  
in a screw vice (see diagram).  
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.  
The fitting procerdure is the reverse of  
the removal procedure.  
The tightening torque for the blade bolts  
is 122 Nm (90 lb/ft).  
6012-089  
Balancing a blade  
English-37  
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REPAIRS  
Setting the Mower Deck  
Leveling  
1. Position the mower on a level, 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.  
8011-601  
Leveling the mower 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.  
8011-622  
Slackening the belt tensioner  
English-38  
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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.  
7. 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  
shaft. 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  
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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 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.  
Slackening belt tension  
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,  
using the nut (1), tighten the bolt (2).  
8011-624  
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 pulleys.  
17. Fit the operator’s foot plate.  
18. Fit the outer deck belt guards.  
English-40  
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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).  
4. 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 castle 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  
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REPAIRS  
English-42  
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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.  
D. To the pigtail  
G. To the seat  
A. To the engine ground bolt  
E. To the park brake  
F. To motion control lever  
C. To the electric clutch  
H. Console harness  
J. Frame harness  
B. To the solenoid  
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  
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ELECTRICAL SYSTEM  
The console harness (1) connects the console controls to the frame harness.  
Blk = Black  
Blu = Blue  
Gra = Gray  
Grn = Green  
Pur = Purple  
Wht = White  
Yel = Yellow  
A
B
C
D
E
F
8011-629  
ZTH console harness  
English-44  
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ELECTRICAL SYSTEM  
There are two connectors connecting the frame harness (13) to the console harness (1).  
Blk = Black  
Blu = Blue  
Gra = Gray  
Grn = Green  
Pur = Purple  
Wht = White  
Yel = Yellow  
8011-628  
ZTH frame harness  
The engine pigtail (page 43) plugs into the “Engine Pigtail” socket of the frame harness.  
English-45  
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ELECTRICAL SYSTEM  
Battery  
The battery is maintenance-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  
ames. 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  
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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 plugged into any of the  
sockets in the holder.  
Relay function (working along the holder from  
right to left) is:  
Brake relay  
Run relay  
Start relay  
Removing  
8011-597  
Pull relays directly upwards. If necessary,  
carefully work a screwdriver under the relay  
and lever upwards.  
Relays  
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  
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ELECTRICAL SYSTEM  
Ignition and Start Switch  
Refer to the “ZTH electrical system” diagram.  
Changing  
1. Free the control console and pull  
forwards.  
2. Disconnect the wires at the back of the  
ignition switch (10).  
3. Remove the ignition key and the rubber  
cap (20).  
4. Remove the nut (19) and the ignition  
switch (10).  
5. 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.  
8011-599  
Freeing the control console  
6. 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.  
7. Remove the key and fit the rubber cap  
(20). Reinsert the key.  
8. Reconnect the wires at the back of the  
ignition switch.  
9. Refit the control console.  
Hour Meter  
Refer to the “ZTH electrical system” diagram.  
Changing  
1. Free the control console and pull forwards.  
2. Disconnect the wires at the back of the hour meter (12).  
3. Prise the catches apart and remove the hour meter’s locking plate.  
4. Pull the hour meter out of the console panel.  
5. 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.  
6. Fit the locking frame (push in manually and check that the catches have fastened).  
7. Connect the two violet wires to the right pin and the black to the left.  
8. Refit the control console.  
English-48  
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ELECTRICAL SYSTEM  
Blade Switch  
Refer to the “ZTH electrical system” diagram.  
Changing  
1. Free the control console and pull forwards.  
2. Disconnect the wires at the back of the switch (11).  
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.  
5. Reconnect the wires at the back of the switch.  
6. 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.  
8011-592  
Deck clutch  
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  
8011-6022  
(6).  
Loosen the deck belt  
English-49  
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ELECTRICAL SYSTEM  
Fitting  
The fitting procerdure is the reverse of the removal procedure.  
Pay particular attention to the following:  
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. If necessary, adjust/twist the tie down.  
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  
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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 (11).  
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  
1. Disengage the park brake.  
2. Drop the deck to its lowest position.  
3. Remove the bolts (9). The tapped plate  
(8) is freed when the switch is loosened.  
4. Separate the connector from the switch  
(7). Pull it directly upwards.  
5. Push the connector onto the new switch  
(there is only one way for the parts to  
mate).  
6. Using the bolts (9) and tapped plate (8),  
fasten the switch securely to its bracket.  
8011-600  
Park brake interlock switch  
7. Check that the start interlock functions  
correctly.  
English-51  
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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  
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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. Filters 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 µm and upwards (1 µm  
= 0.001 mm). It should be noted that a particle measuring 40 µm can only just be seen by the naked eye.  
The main impurities generated in system operation are:  
Wear particles (mainly from components with moving parts, e.g. pumps and hydraulic motors).  
Dust entering the hydraulic oil tank via air vents.  
Water formed by condensation (water vapor enters with air from outside).  
Particles of dirt entering the system via moving piston rods, etc.  
Sediments, etc. produced by the breaking down of the hydraulic oil.  
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.  
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, filters, 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-53  
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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.  
Contamination 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 for 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.  
English-54  
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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  
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HYDRAULIC SYSTEM  
Hydraulic Tank  
Draining  
1. 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.  
2. 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  
3. 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 (25) 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  
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HYDRAULIC SYSTEM  
The Cooler for the Hydraulic System  
Removing  
1. Remove the right rear wheel.  
2. To eliminate any excess pressure, remove then replace the hydraulic tank cap.  
3. Loosen the hose clamps (16) but leave the hoses attached to the cooler.  
4. Remove the bolts (14), spacers (15) and nuts (12).  
5. 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 until 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-57  
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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 tting  
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 bolts.  
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.  
2. Raise the mower and support on blocks or jack stands.  
3. Remove the rear wheel on the side with the faulty pump.  
4. 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”).  
5. Loosen the two lock screws holding the pump pulley and remove it from its shaft.  
6. Clean as set out in the instructions.  
7. Remove the hydraulic lines (21, 22 or 23, 24) and “O” rings (34) from both pump and motor.  
8. 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:  
Fit hydraulic pipes as per the instructions under “Hydraulic Lines”.  
English-58  
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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. Remove the seat rod so that the seat can swing down onto the frame.  
2. 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.  
3. 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.  
4. 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.  
5. Release the park brake so that the rear wheels can rotate.  
6. 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. Turn  
these nuts far enough to just stop the wheel rotating.  
7. 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.  
8. 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.  
9. Tighten the jam nuts directly behind each ball joint (10, 32).  
10. Adjust the linkage on the other side in the same way.  
11. Reattach the seat rod to the seat.  
Reverse Spring Detent Adjustment  
1. Stop the engine and remove the key.  
2. 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).  
3. 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.  
4. Sufficient to allow the bolt to slide in its slot, loosen the nut (27) fastening the spring (17) to its  
upper mount.  
5. 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-59  
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HYDRAULIC SYSTEM  
6. Holding the lever, adjust the spring by sliding the bolt (37) in the slot to remove all the slop.  
Retighten the bolt.  
7. Check the adjustment by pulling the motion control lever back to the reverse position and  
releasing it.  
8. If necessary, make the same adjustment on the other side.  
9. Reattach the seat rod to the seat frame.  
Hydraulic Motors  
Removing  
1. Drain the hydraulic tank as per the instructions given above.  
2. Raise the mower and support on blocks or jack stands.  
3. Remove the rear wheel on the side with the faulty motor.  
4. Remove the cotter pin and hub nut. Using an extractor if necessary, pull the hub off the axle.  
5. Remove the park brake as a single unit.  
6. Clean as set out in the instructions.  
7. Disconnect the hydraulic lines (21, 22 or 23, 24) and “O” rings from both the pump and the motor.  
8. Remove the hydraulic motor from its bracket.  
Dismantling and Assembling  
TM  
Refer to Parker Hydraulics Torqlink 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  
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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  
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.  
Symptom: The starter motor does not work.  
Suggested procedure:  
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 in a  
cable connector may be damaged or a switch broken/incorrectly set.  
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 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-61  
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TROUBLESHOOTING  
to RUN?  
2. 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.  
3. 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.  
4. 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.  
5. 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.  
6. 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 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  
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TROUBLESHOOTING  
Clutch  
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.  
4. Connect the meter leads to the clutch.  
5. Check the meter reading.  
CMS-175 (237 Nm) = 2.45 - 2.71 .  
CMS-200 (271 Nm) = 1.74 - 1.93 .  
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.  
1. Connector  
. Ohmmeter  
8011-567  
Measuring resistance  
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.  
4. Ensure that the wires will not become  
entangled in the rotating parts of the  
clutch.  
5. Start the engine and engage the PTO  
switch.  
1. Connector  
V. Voltmeter  
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.  
8011-568  
Voltage measurement  
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.  
English-63  
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TROUBLESHOOTING  
Problem  
Possible causes  
Solution  
Clutch will not engage  
Blown fuse.  
Low coil resistance.  
Defective battery.  
Replace with new MagStop unit.  
Replace.  
Faulty charging system.  
Repair or replace.  
Bad wiring or connections,  
PTO switch  
Repair or replace.  
Low voltage supply.  
Defective battery.  
Replace.  
Faulty charging system.  
Repair or replace.  
Repair or replace.  
Bad wiring or connectors,  
PTO switch.  
Incorrect coil resistance.  
Inadequate current supply  
Damaged coil.  
Replace with new MagStop unit.  
Repair.  
Broken clutch lead wire.  
Faulty electrical system.  
Measure coil resistance and supply  
voltage at the clutch. If both are  
correct, electrical system is faulty.  
Repair or replace.  
Rotor/armature air gap too  
large (more than  
Rotor/armature wear. End of  
useful life.  
Replace with new MagStop unit.  
0.125"/3.18 mm)  
Brake will not engage  
Armature/brake poles  
worn out.  
End of useful life.  
Replace with new MagStop unit.  
Contaminated friction  
surfaces.  
Engine oil leak on brake.  
Repair leak.  
Replace with new MagStop unit.  
Clutch slips  
Low voltage supply.  
Defective battery.  
Replace.  
Faulty charging system.  
Repair or replace.  
Repair.  
Bad wiring or connectors,  
PTO switch  
Inadequate  
current supply.  
Broken clutch lead wire.  
Faulty electrical system.  
Repair.  
Measure clutch coil resistance and  
supply voltage at the clutch. If both  
are correct, electrical system is  
English-64  
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TROUBLESHOOTING  
faulty. Repair or replace.  
Overloaded clutch.  
Clogged deck, faulty spindle, etc.  
Engine oil leak on clutch.  
Remove excess grass.  
Replace spindle.  
Contaminated friction  
surfaces.  
Repair leak.  
Replace with new MagStop unit.  
Noisy clutch/vibrations  
Failed bearing.  
Loose mounting (bolt not tightened  
to the correct torque).  
Replace, tighten to specification.  
Insufficient play at the adapter plate Check, clean, adjust.  
Adapter plate rattles  
Some noise is normal.  
If noise is excessive, repair or  
against anti-rotation pin.  
replace anti-rotation pin device.  
Clutch loose on shaft  
Loose mounting (bolt not tightened  
to the correct torque).  
Tighten mounting bolt to  
specification.  
Mounting bolt too long and  
bottoms on the crankshaft before  
the clutch bites.  
Use correct length bolt.  
Mounting washer too thin and  
deforms when bolt is tightened.  
Use correct washer.  
Shaft bottoms on the clutch.  
Use proper spacer, at least1/4"  
thick  
.
Clutch not mounted square. • Ground drive spacer mounting  
shoulder not square.  
Replace.  
Clutch integral key hitting  
end of keyway in engine shaft.  
Space clutch away from radius  
in shaft keyway.  
Incorrect or no chamfer on ground  
drive spacer.  
Increase chamfer on ground drive  
spacer.  
Broken spring.  
Loose mounting.  
Replace clutch.  
WARNING!  
A clutch with broken rivets or springs may separate from the shaft and  
cause personal injury.  
English-65  
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TROUBLESHOOTING  
Hydraulic Pump  
WARNING!  
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  
Do not attempt any servicing or  
adjustments with the engine  
running.Take great care when  
inspecting drive belts, pulleys and  
motion control lever linkages!  
troubleshooting checklist below is designed to  
help determine the cause of problems.  
Troubleshooting Checklist, Hydraulic  
Pump  
Problem  
Cause  
Corrective action  
Vehicle does not drive/track straight.  
Vehicle tires improperly inflated.  
Adjust to proper pressure.  
Pump linkage bent, loose or  
incorrectly adjusted.  
Repair, adjust or replace the  
linkages on both sides.  
Bypass loose.  
Inlet leak.  
Tighten the bypass.  
Check all connections and  
hoses for leaks.  
Unit is noisy.  
Engine RPM high.  
Adjust the speed regulator.  
Oil level low or oil contaminated.  
Excessive loading (long grass).  
Fill to proper level or change oil.  
Raise the cutting height, drive  
more slowly.  
Air trapped in the hydraulic system. Aerate the system.  
Bypass loose.  
Inlet leak.  
Tighten bypass.  
Check all connections and  
hoses for leaks.  
Clogged/damaged hydraulic filter.  
Replace filter.  
Unit has no/low power.  
Engine RPM low.  
Adjust the speed regulator.  
Repair or adjust the linkages  
Pump linkage bent, loose or  
incorrectly adjusted linkage system. on both sides.  
Drive belt slipping or pulley  
damaged.  
Repair/clean or replace drive belt.  
Oil level low or oil contaminated.  
Excessive loading (long grass).  
Fill to proper level or change oil.  
Raise the cutting height, drive more  
slowly.  
Air trapped in the hydraulic system. Aerate the system.  
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TROUBLESHOOTING  
Bypass loose.  
Inlet leak.  
Tighten the bypass.  
Check all connections and  
hoses for leaks.  
Clogged/damaged hydraulic filter.  
Defective hydraulic pump.  
Replace hydraulic filter.  
Replace pump.  
Unit operating hot.  
Build-up of of grass cuttings.  
Clean the exterior of the mower,  
especially the cooler.  
Hydraulic cooler clogged or  
damaged.  
Replace hydraulic cooler.  
Oil level low or oil contaminated.  
Excessive loading (long grass).  
Fill to proper level or change oil.  
Raise the cutting height, drive  
more slowly.  
Air trapped in the hydraulic system. Aerate the system.  
Inlet leak.  
Check all connections and  
hoses for leaks.  
External oil leak  
Loose connection/seal.  
Damaged seal or gasket.  
Tighten, clean, test run.  
Replace seal, test run.  
Replace seal and gasket.  
Hose leaking but oil reaching  
the pump.  
Replace hose, seal and gasket.  
English-67  
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114 00 80-26  
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