Workshop manual ZTH English
Svenska – Sve-5 225/232/235 Bruk 31 97-11-25, 08.
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 ......................
English-2
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 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.
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.
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.
TECHNICAL DATA Technical Data Model ZTH5223 Model part number 968 99 91 60 Engine (spec. number) Kawasaki (FH680V-AS15) Kawasaki (FH721V-AS04) Cylinder diameter 75.2 mm (2.96 in.) 75.2 mm (2.96 in.) Cylinder stroke 76 mm (2.99 in.) 76 mm (2.99 in.) Cylinder volume 675 cc (41.19 cu.in.) 675 cc (41.19 cu.in.) Power 23 hp 25 hp Engine RPM 2,950 RPM 2,950 RPM Idle RPM 1,550 RPM 1,550 RPM Spark plugs (2) NGK BPR4ES NGK BRR1550 Oil capacity, engine (total) 1.8 litres (3.
TECHNICAL DATA Model ZTH5223 ZTH6125 Displacement 10.2 cc/r (0.623 cu. in./rev) 10.2 cc/r (0.623 cu. in./rev) Nominal working pressure 70 bars (1000 PSI) 70 bars (1000 PSI) Max. hydraulic pressure 145 bars (2,100 PSI) 145 bars (2,100 PSI) Max. hydraulic oil temp 110°C (230°F) 110°C (230°F) Weight, hydraulic pump 3.6 kg (8 lbs) 3.6 kg (8 lbs) Hydraulic motors (2) Parker Ross Parker Ross Tightening torque, wheel motor hub nut 122 Nm (90 ft/lb) 122 Nm (90 ft/lb) Hydraulic oil 1.
TECHNICAL DATA Model ZTH5223 ZTH6125 7/16" 70 Nm (52 ft/lb) 70 Nm (52 ft/lb) 1/2" 110 Nm (80 ft/lb) 110 Nm (80 ft/lb) BioClip adapter Optional Optional Foot controlled mower deck lift Optional Optional Deluxe seat Optional Optional Accessories English-9
TECHNICAL DATA English-10
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.
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.
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).
DELIVERY AND DEALER SERVICE At Least Once a Year 1. Clean the engine’s cold air intake (25 hours). 2. Change the air cleaner’s pre-filter (Oilfoam). 3. Change the paper cartridge in the air filter (200 hours). 4. Change the engine oil (100 hours). 5. Change the engine’s oil filter (200 hours). 6. Change the oil and the filter in the hydraulic system. 7. Check/adjust the cutting height regulator. 8. Check/adjust the park brake (50 hours). 9. Clean/change the spark plugs (100 hours). 10.
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 Maintenance Page Pre- After use use Check for fuel and oil leaks. - ❍ Check the park brake. - ● 21 ● Check engine oil level (every fueling). - Check the safety systems. - Check/clean the engine’s cold air intake. - ▼ 38 ● Check fasteners (bolts, nuts, etc.).
DELIVERY AND DEALER SERVICE Daily Maintenance Weekly Page Pre- After use use At Maintenance intervals in hours least once 25 50 100 300 a year 38 ● - ▼ - ▼ 22 ● 56 ● Change the engine’s oil filter (every 200 hours). - ▼ ▼ Clean/change the spark plugs. - ❍ ❍ Change the fuel filter in the fuel line. - ▼ ▼ Clean the cooling fins. - ❍ ❍ Check the play in the engine valves 4) . - ❍ ❍ Change the air cleaner’s pre-filter (Oil-foam).
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.
DELIVERY AND DEALER SERVICE English-18
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.
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.
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.
DELIVERY SERVICING The oil level must be between the markings on the dipstick. If the level is near the “ADD” mark, top up with oil to the “FULL” mark. ADD Oil is topped up via the hole in which the dipstick sits. FULL Use grade SC-SH engine oil with a viscosity as per the chart below. The engine (excluding oil filter) holds 1.5 litres of oil.
DELIVERY SERVICING WARNING! Gasoline is highly flammable. Take great care. 12. Fill the gasoline tanks (unleaded gasoline with no oil and a minimum octane rating of 87). Environment-friendly, acrylate gas , e.g. Aspen, can be used to good advantage. 8011-550 Fueling 13. Select tank by moving the selector to the appropriate position. 8011-506 WARNING! Never run the engine indoors in confined or poorly ventilated areas. Exhaust fumes contain carbon monoxide (poisonous).
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.
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.
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.
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.
DESIGN AND FUNCTION Mower Deck WARNING! The engine must not be started if the operator’s floor plate or any of the guards for the mower deck’s belt is/are not securely in position. The blades are driven by a V-belt from the engine crankshaft (1). The crankshaft has an electromagnetic clutch. This locks the deck pulley to the shaft when current is applied to the clutch (i.e. when the appropriate control panel switch is operated).
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. 8.
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.
REPAIRS inlet. 14. Connect and adjust the gas and choke wires (see below). 15. Check that the oil drain valve is closed and fill the engine with oil (see Delivery Servicing\Delivery Service). 16. Connect the positive cable (red) to the battery’s positive terminal. 17. Open the fuel valve. Dismantling and Assembling Adjustments and Specific Repairs See the Kawasaki Service Manual for the engine and auxiliary systems. Troubleshooting See section 8 of the Kawasaki Service Manual.
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.
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.
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.
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.
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.
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.
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. 5.
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.
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.
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.
REPAIRS English-42
ELECTRICAL SYSTEM Electrical System Troubleshooting See the “Troubleshooting” section towards the back of this manual. Wiring Assembly The diagram below shows the structure of the electrical system. A. To the engine ground bolt B. To the solenoid C. To the electric clutch D. To the pigtail E. To the park brake F. To motion control lever G. To the seat H. Console harness J. Frame harness 8011-584 ZTH electrical system To connect the engine to the frame harness (13), there is a pigtail.
ELECTRICAL SYSTEM The console harness (1) connects the console controls to the frame harness.
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.
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 flames. Never smoke in the vicinity of the battery.
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 Pull relays directly upwards. If necessary, carefully work a screwdriver under the relay and lever upwards.
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.
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.
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.
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.
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.
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.
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.
HYDRAULIC SYSTEM ZTH Hydraulic System 8011-588 ZTH hydraulic system The hydraulic pumps are controlled (via mechanical links) by the motion control levers.
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. 3.
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 SYSTEM Fitting IMPORTANT INFORMATION Pipes between hydraulic pumps and hydraulic motors must not be subjected to bending or compression. To avoid pipe fatigue and the resultant leaks and fractures, the fitting procedures below must be observed. 1. Clean the surfaces mating pumps and motors to their mounts. 2. Bolt the hydraulic pump loosely into place - it must still be possible to move the pump. 3. Bolt the hydraulic motor loosely into place - it must still be possible to move the motor. 4.
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.
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.
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.
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.
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 Ω. CMS-200 (271 Nm) = 1.74 - 1.93 Ω. 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 Ω.
TROUBLESHOOTING Problem Possible causes Solution • Low coil resistance. Replace with new MagStop unit. • Defective battery. Replace. • Faulty charging system. Repair or replace. • Bad wiring or connections, PTO switch Repair or replace. • Defective battery. Replace. • Faulty charging system. Repair or replace. • Bad wiring or connectors, PTO switch. Repair or replace. Incorrect coil resistance. • Damaged coil. Replace with new MagStop unit.
TROUBLESHOOTING faulty. Repair or replace. Overloaded clutch. • Clogged deck, faulty spindle, etc. Remove excess grass. Replace spindle. Contaminated friction surfaces. • Engine oil leak on clutch. Repair leak. Replace with new MagStop unit. • 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 against anti-rotation pin. • Some noise is normal.
TROUBLESHOOTING Hydraulic Pump In most cases, problems with the drive system are not due to a defective pump but to slipping drive belts, partially engaged bypass valves, loose or damaged control linkages, etc. Be sure to check all of these before assuming a pump is faulty.The troubleshooting checklist below is designed to help determine the cause of problems. WARNING! Do not attempt any servicing or adjustments with the engine running.
TROUBLESHOOTING Unit operating hot. External oil leak • Bypass loose. Tighten the bypass. • Inlet leak. Check all connections and hoses for leaks. • Clogged/damaged hydraulic filter. Replace hydraulic filter. • Defective hydraulic pump. Replace pump. • 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. Fill to proper level or change oil.
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