Jonsered FR 13 Workshop Manual Download

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108 88 61-26

Workshop Manual

Summary of Contents for FR 13

Page 1: ...108 88 61 26 Workshop Manual ...

Page 2: ...Svenska 31 Sve 5 225 232 235 Bruk 97 11 25 08 46 31 ...

Page 3: ...ticulated Steering Bearings 31 Removing the Pendulum Shaft 33 Replacing Bushings 33 Fitting the Pendulum Shaft 34 Removing Fitting the Gearbox 35 Removing Fitting the Hydrostatic Transmission 35 Replacing the Hydrostatic Transmission Shaft Seals 36 Seal Replacement Ingoing Shaft 36 Seal Replacement Outgoing Axles 37 Replacing the Hydrostatic Transmission Cable 37 Airing the Hydrostatic Transmissio...

Page 4: ...muffs earplugs when test running After test running do not touch the muffler until it has cooled Risk for burns This applies especially if the rider is fitted with a catalyser The coatings on the inside and outside of the catalyser element are harmful if ingested Used protective gloves when working with the catalyser muffler The blades are sharp and can cause cuts and gashes Used protective gloves...

Page 5: ... for loosening the engine belt pulley Allen screw Briggs Stratton 506 89 92 01 Stop for when removing the engine belt pulley 506 89 93 01 Tool for removing the steering return spring 535 41 32 01 Mandrel for bushings in pendulum shaft The following special tools are used when working with the rider Special Tools ...

Page 6: ...ement 362 cm3 465 cm3 465 cm3 Fuel min 85 octane min 85 octane min 85 octane unleaded unleaded unleaded Tank volume 7 2 litres 7 litres 7 2 litres Oil SAE 30 or SAE 30 or SAE 30 or 10W 30 class SF CC 10W 30 class SF CC 10W 30 class SF CC Oil volume 1 4 litres 1 4 litres 1 4 litres Starter Electric start Electric start Electric start Transmission FR 2111 FR 13 FR 2113 A Manufacturer Peerless MST 20...

Page 7: ...min 85 octane min 85 octane min 85 octane unleaded unleaded unleaded Tank volume 7 2 litres 7 litres 7 2 litres Oil SAE 30 or SAE 30 or SAE 30 or 10W 30 class SF CC 10W 30 class SF CC 10W 30 class SF CC Oil volume 1 4 litres 1 4 litres 1 4 litres Starter Electric start Electric start Electric start Transmission FR 2113 MA FRM 13 A FR 2115 MA Manufacturer Tuff Torq K 46 Tuff Torq K 46 Tuff Torq K 4...

Page 8: ...111 0 1 mm Belt pulley 35 40 Nm Brake lever arm FR 13 FR 2111 7 9 mm Blades 45 50 Nm Brake cable 1 mm Blade bearings 20 25 Nm Cable hydrostatic transmission pedals 0 mm Belt tensioning wheel 15 25 Nm Fitting screws engine 20 25 Nm Fitting screws gearbox 20 25 Nm Engine belt pulley 70 80 Nm Wheel axle nuts 100 150 Nm Cutting Unit FR 2111 FR 13 FR 2113 A Cutting width 850 mm 850 mm 850 mm Cutting he...

Page 9: ... 4 Check that the right amount of oil is in the engine 5 Check that the right amount of oil is in the transmission not FR 13 FR 2111 6 Check and adjust the air pressure in the tyres 60 kPa 0 6 bar 7 Connect the battery 8 Fill the fuel tank and start the engine 9 Check that the machine does not move in neutral Not FR 13 FR 2111 10 Check Driving forwards Reversing Engaging the blades The safety swit...

Page 10: ... spark extinguisher extra equipment 100 Hour Service 1 Perform the 25 hour service as detailed above 2 Perform the 50 hour service as detailed above 3 Replace the air cleaner s pre filter and paper filter 4 Change the inline fuel filter 5 Clean replace the spark plug Delivery and Dealer Service 300 Hour Service 1 Inspect the machine Reach agreement with the customer with regard to what additional ...

Page 11: ...th daily use the rider should be lubricated twice weekly 4 Performed by an authorised service workshop Check the engine oil level 12 Check the engine s cooling air intake Check the fuel pump s air filter Check the steering cables 26 Check the brakes 29 Check the battery 11 Check the safety system 59 Check nuts and bolts Check for any fuel or oil leakage Change the engine oil 1 26 Clean the air fil...

Page 12: ...leaving their machine for regular service Which fuel is to be used Mowing tips to attain good results Application areas for mulching The accessories available for the customer s type of machine Guarantee rules Your company and whom the customer should approach if problems arise Packaging and Unpacking The machine is normally packed using special packaging when delivered from the factory This packa...

Page 13: ... container Fit the battery Connect the battery with the nuts and bolts that are attached to the battery Counter the bolts when fitting so that the electrodes are not strained The black cable connects to The red cable connects to Ensure that the cables do not rub against anything Fit the cover on the battery and tighten the strap WARNING Actions following contact with acid External Rinse thoroughly...

Page 14: ... back of the bumper as illustrated Checking the Engine Oil Level Check the oil level in the engine when the rider stands horizontal Fold up the engine cover Loosen the dipstick and pull it out Wipe off the dipstick and fit it again The dipstick should be completely screwed down Now loosen the dipstick and pull it out again Read the oil level The oil level should be between the markings on the dips...

Page 15: ...2 Checking the Oil Level in the Transmission Not FR 13 FR 2111 Remove the transmission cover Loosen both screws one on each side and lift off the transmis sion cover Checking and Adjusting the Cutting Unit s Ground Pressure and Parallelism Performed after checking the tyre air pressures See the appropriate sections in this workshop manual Delivery Procedures IMPORTANT INFORMATION Check and top up ...

Page 16: ...ne Check that the machine is in neutral and is standing still on flat ground when the parking brake is re leased Not FR 13 FR 2111 Check that the parking brake works Check driving forwards 1 and in reverse 2 Check that the starter does not work when one of the hydrostatic transmission pedals is pressed hydrostatic machines or the gear stick is not in neutral FR 13 FR 2111 Check that the engine sto...

Page 17: ...13 FR 2111 40 90 mm cutting height Mulching unit 45 95 mm cutting height Engine Speed Regulator Check that the engine s max speed is regulated to 2 900 3 100 rpm Administration Fill in the sales papers customer register etc Don t forget to fill in the serial number on page 3 and to confirm that the delivery service has been performed in the operator s manual Delivery Procedures ...

Page 18: ...hine s serial number can be found on the printed plate attached to the front on the left hand side under the seat Stated on the plate from the top are The machine s type designation The manufacturer s type number The machine s serial number Please state the type designation and serial number when ordering spare parts The engine number is punched on a plate that is riveted to the fan cover The plat...

Page 19: ...ingle cylinder air cooled engines from Briggs Stratton Major engine repairs are not described in this workshop manual Such information can be found in Briggs Stratton s own manuals which include detailed information about engine adjustments and repairs These manuals can be ordered from an authorised workshop The transmission s serial number is stated on the barcode decal located on the front of th...

Page 20: ...ering The force from the steering wheel is transferred to the rear wagon via cables and a chain This makes steering the rider both easy and very precise It easily mows around all obstacles on the lawn The FR machines have steering columns with bearings 1 The turning circle is very small due to the articulated steering the uncut circle with full lock is only 20 30 cm ...

Page 21: ...ull driving control The speed is continuously regulated with the foot pedals both forward and reverse Manual gearbox Hydrostatic transmission The FR 13 and FR 2111 have manual gearboxes with five forward gears neutral and one reverse gear This gearbox is a so called inline type which means that changes can be made directly from neutral to fifth without stopping at each intermediate gear ...

Page 22: ...ow efficiently even in confined areas The FR 13 FR 2111 and FR 2113 A have cutting units with rear ejectors and cutting widths of 850 mm The FRM 13 A and FR 2113 MA have cutting units with a mulching function and cutting widths of 900 mm The FR 2115 MA has a mulching unit with a cutting width of 1 030 mm Cutting unit with rear ejector 850 mm Cutting unit with mulching 1 030 mm ...

Page 23: ...tery s retaining strap Remove the protective cover and loosen the cable connections Then lift out the battery Remove the clip holding the throttle and choke cables Release the cable from the mounting Mark and remove the engine s electrical connectors Remove the cable connecting the starter relay to the starter ...

Page 24: ... Use flat nosed pliers to grip the cable holder under the engine belt pulley and pull the cable holder downwards Push tool no 506 79 06 01 into the centre of the engine belt pulley Loosen and remove the Allen screw that holds the belt pulley and engine shaft together Use tool no 506 89 92 01 to counter Loosen the belt pulley from the engine shaft Remove the engine fixtures two on each side of the ...

Page 25: ...ssion cable lies lowest on machines with a hydrostatic transmission Attach the throttle cable to the throttle and fit the cable clip without tightening it Repair Instructions Fitting the Engine IMPORTANT INFORMATION When fitting the engine it is important that the belt pulley s groove 1 is in such a position that the outgoing shaft s key 2 fits into the groove see illustration Also check that both...

Page 26: ...er casing as far to the right as possible and tighten the clamping screw Pull back the throttle to the full throttle position and check that the choke is no longer activated Fit the exhaust pipe and tighten the fixing screws and clamps Firmly fit the fuel hose to the fuel pump and attach the hose clamp Attach the engine s electrical connectors ...

Page 27: ...welding pliers and then remove the hose and hose clamp from the fuel filter s lower connector You must then be sure to keep the hose opening higher than the fuel level in the tank Remove the two screws that hold the tank on the console Lower the tank and pull out the hose through the frame of the machine if it has been loosened at the fuel filter Fitting It is easier to work if you empty the tank ...

Page 28: ...hanged after every 50 hours of running 25 hours when run under heavy operat ing conditions WARNING Engine oil can be very hot if it is drained directly after stopping the engine Allow the engine to cool somewhat first Drainage plug for engine oil Tip When draining the engine oil fold a piece of cardboard and use it to guide the oil into the drainage container Place a container under the engine s d...

Page 29: ...n should be checked see Checking and Adjusting the Steering Cables Removing Fitting the Steering Shaft 1 Loosen the steering cables rear fixture 1 Remove the frame plate 2 Remove the steering wheel and steering rod by loosening the lock nut and unscrewing the stop screw and then lifting the steering wheel and steering rod upwards 3 Remove the steering column s two drive discs 4 4 Unscrew the screw...

Page 30: ...e bushing 6 is to be placed between the frame and the cable pulley Repair Instructions Ensure that the cables are properly situated under the steering cable pulleys 7 in the frame tunnel Ensure that the steering wheel is in the centre position when the rear wheels are centred Re set the chain on the steering column s sprocket or adjust the rear fixture 1 for the steering cables 1 as needed Hold th...

Page 31: ...hen the brake cable is adjusted you should make sure that the brake lever does not have too much play If the range of movement of the lever arm exceeds 9 mm it should be adjusted by tightening the nut on the brake lever arm 1 Loosen the lock nuts 1 2 Tension the cable using the adjuster screw 2 until the play in the cable disappears 3 Tighten the lock nuts 1 4 The brakes should be checked again af...

Page 32: ... until the proper adjustment is achieved 4 Lock the adjustment in place with the lock nut 1 and push the locking spring 2 into place IMPORTANT INFORMATION Make sure that the locking spring goes through the hole in the socket Checking and Adjusting the Gear Control FR 13 FR 2111 3 2 1 There should be about 8 10 mm of play A be tween the cable nipple and the lever arm Adjust the clutch cable as foll...

Page 33: ...ugh for the socket 3 to be lifted from the ball on the lever arm 4 3 Depress the accelerator pedal completely and use a screwdriver to move the lever arm 4 forward as far as possible 4 Adjust the socket 3 position on the draw bar 5 so that it fits exactly over the ball on the lever arm Fit the socket on the ball 5 Lock the adjustment in place with the lock nut 1 and push the locking spring 2 into ...

Page 34: ...es if it flies off Wear protective eyewear and gloves when removing or fitting the spring 6 5 Remove the inner catch circlip 1 by the lower bearing see illustration The rear carriage is now loose and can be moved Then loosen the outer circlip 2 and remove the bearings from below Remove the upper bearings from above if they are stuck tap them from below Fit the new bearings and the articulated stee...

Page 35: ...nstructions Removing the Pendulum Shaft Jack up the rider in front of the rear frame Remove the transmission gear box cover Loosen the idler s spring 1 and the clutch cable 2 Remove the idler s arm 3 from the rear frame and force the belt from the gearbox pulley Loosen the gear and brake cables 4 and 5 and remove the cables mounting plates 6 Remove the circlip and washer from the pendu lum shaft 7...

Page 36: ...nd its casing 2 4 Attach the cable to the neutral position contact 5 Fit the rear belt 8 Attach the brake cable to the arm under the tank and the casing fixture on the rear frame 6 Fit the idler s spring 1 Fit the hydrostatic transmission s fan and the circlip 7 3 FR 13 FR 2111 Fit the washer and circlip on the pendulum shaft 1 Attach the cables mounting plates 2 and the gear and brake cables 3 an...

Page 37: ...rame and remove the rear wheels Remove the transmission cover Repair Instructions Removing Fitting the Gearbox FR 13 FR 2111 Jack up the machine in front of the rear frame and remove the rear wheels Remove the cover over the gearbox Loosen the idler s spring 1 Loosen the clutch cable 2 and wiggle the belt from the gearbox pulley Remove the clutch and brake cables 3 and 4 Place a garage jack under ...

Page 38: ... Shaft Remove the cooling fan held in place by a circlip Remove the pulley from the ingoing shaft by pulling it upwards and then removing the circlip under the pulley Clean the ingoing shaft and the area around the seal from all dirt and rust Insert a screwdriver between the seal and the shaft and pry off the seal from the shaft housing with a twisting motion IMPORTANT INFORMATION The area around ...

Page 39: ...p Fit the fan and the washer and the upper circlip Clean the outgoing axle and the area around the seal from all dirt and rust Insert a screwdriver between the seal and the axle and pry off the seal from the axle housing with a twisting motion IMPORTANT INFORMATION Dirt must not enter the transmission since this will shorten the transmission s life Wrap insulating tape around the outgoing axle fro...

Page 40: ...t the entire procedure as needed for the other axle Replace the washer spacing tube key and rear wheel on the axle Fit the circlip that holds the wheel and the plastic cap over the end of the axle Fill the transmission s oil container with SAE 10W 30 engine oil until the level reaches the MAX mark Air the transmission as described in Airing the Hydrostatic Transmission s Oil System Run the rider s...

Page 41: ...move the transmission cover Lift off the link joint and pull out the cable Lift out the hydrostatic transmission cable and the accompanying link joint Follow the hydrostatic transmission cable back wards towards the hydrostatic transmission and cut the plastic binding around the cable Remove the spring lock by the hydrostatic trans mission cable s rear link joint Loosen the bracket that holds the ...

Page 42: ...ck nut Run the cable through the rider so that it follows the same path as the old cable did Press in the cable casing in the forward fastener in the centre console Tighten the hydrostatic transmission cable in place Press the link joint onto its fastener and attach the spring lock Attach the link joint to the lower part of the hydro static transmission cable Screw 10 12 turns so that the link joi...

Page 43: ...rostatic transmission cable along with the other cables Place the hydrostatic transmission cable on the bottom in the cable bracket under the articulated steering s bearing Place the hydrostatic transmission cable in place and screw the casing on with the rear bracket Adjust the hydrostatic transmission cable as shown see Checking and Adjusting the Accelerator Connect the rear link joint and attac...

Page 44: ... adjusted by turning the hexagonal shaft on the transmission see illustra tion Start the engine and turn the throttle to full Loosen the lock nut on the hexagonal shaft and turn the shaft clockwise until the drive axles begin to rotate backwards Make a mark on the top of the shaft Adjusting the Transmission s Neutral Position 1 Air the hydrostatic transmission s oil system 2 Lift the rear of the r...

Page 45: ...neutral position is to be adjusted in the following manner Turn the shaft slowly counter clockwise until the drive axles begin rotating forwards Turn the shaft slowly clockwise until the drive axles stop rotating forwards and make a mark on the transmission housing FS and shaft Turn the shaft clockwise 8 from the mark on the transmission housing Hold the shaft still N 8 and tighten the lock nut N ...

Page 46: ...emoval instructions in the reverse order Changing the Oil in Hydrostatic Machines Empty the hydrostatic transmission by means of the two 14 mm plugs the other screws are smaller in size Fill the oil tank with oil Air the transmission as described in Airing the Hydrostatic Transmission s Oil System Fill with oil as needed during airing Test run the machine and check the oil level IMPORTANT INFORMAT...

Page 47: ...ure in the tyres 60 kPa Place the rider on a level surface and measure the distance between the ground and the edge of the cutting unit at the front and rear of the housing The cutting unit should have a slight slant with the rear edge 2 4 mm higher than the front edge Remove the front cover and the right hand wing cover Adjustment of the cutting unit is carried out using the adjuster nuts at the ...

Page 48: ...p and tighten the nut after adjustment The parallelism of the cutting unit should be checked again after the adjustment has been made Attach the front cover and the right hand wing cover Adjustment of FR 2115 MA Remove the front cover and the right hand wing cover Loosen the nuts on the parallel strut Screw the strut counter clockwise to lower the cover s rear edge clockwise to raise the cover s r...

Page 49: ...the nut on the height adjustment strut Adjust so that the distance between the stop for lowest height setting and the protective frame is 5 mm Tighten the nut Recheck that the parallelism has not changed If so the parallelism must be readjusted Check and if necessary adjust the cutting unit s ground pressure see Checking and Adjusting the Cutting Unit s ground pressure Attach the nose cover IMPORT...

Page 50: ...NING Wear protective glasses when dismantling the cutting unit The springs that tension the belt can break and cause personal injury Fit the two support wheels on each side of the cutting unit s rear section Put your foot on the front edge of the cutting unit next to the wheel and lift the cutting unit s front edge to make it easier to loosen the height adjust ment strut Secure the strut in the ho...

Page 51: ...which is now holding the cutting unit is removed the cutting unit can be lifted off Releasing the Service Position To release the service position reverse the proce dures set out in Placing in the Service Position Make sure that the cutting unit s lug enters the loop correctly on the underside of the machine see illustration Grasp the cutting unit s front edge pull out and lift up into the service...

Page 52: ...transport position by pulling the lifting lever Wiggle the belt off from the cutting unit s rear pulley Lower the cutting unit to the cutting position by using the lifting lever Set the lowest cutting height with the cutting height lever Remove the hairpin spring that holds the lifting chain in the cutting unit Remove the locking pins of safety pin type on both sides of the rear of the cutting uni...

Page 53: ...ift off the hood Tip Mark the position of the blades on respec tive belts with a felt tip pen IMPORTANT INFORMATION The blades on the mulching unit should be positioned at 90 angles to each other Otherwise the blades can go against each other and damage the cutting unit 4 Loosen the nuts on the eccentric plate and twist this round Remove the four nuts see illustration holding the outer blade beari...

Page 54: ...nsion to the belt Check the posi tion of the blades again adjust as needed by re setting the belt Tighten the three bolts to 45 Nm Replacing the Cutting Unit s Belts Belt Replacement on FRM 2115 A The 103 mulching unit has a toothed drive belt The drive belt powers and synchronises the rotation of the blades The belt is located under the cover on top of the cutting unit 1 Dismantle the cutting uni...

Page 55: ...each blade bolt The washer must always be replaced with a new washer when replacing the shear pin Otherwise the shear pin can break causing the blades to collide Only use original spare parts A set containing a blade shear pin and friction washer can be purchased from your dealer 1 Put the unit in the service position see Remov ing the Cutting unit 2 Remove the blade 2A by removing the blade bolt ...

Page 56: ...se the entire assembly complete with axle housing axle spacer and bearings Assemble in the reverse order as described for dismantling IMPORTANT INFORMATION When tightening the blade axle screws the transmission side should always be tightened first and then the blade screws When the blades on the mulching unit have been removed the friction disc located between the blade and nut must be replaced M...

Page 57: ...xample horizontally in the vice as shown Thread the hole in the centre of the blade over the mandrel and make sure that the blade is equally weighted The illustration shows a blade that needs to be adjusted it must be filed more so as to attain the right balance at the arrow Assemble in the reverse order as described for dismantling IMPORTANT INFORMATION When the blades on the mulching unit have b...

Page 58: ...m FR 13 FR 2111 1 Microswitch seat 2 Ignition lock 3 Microswitch lifting lever 4 Microswitch gear 5 Fuse 15A 6 Start relay 7 Engine charging 8 Engine stop Key for colour abbreviations in wiring diagram SV Black RD Red BR Brown BL Blue VT White GR Green GL Yellow ...

Page 59: ...trical System 1 Microswitch seat 2 Ignition lock 3 Microswitch lifting lever 4 Microswitch hydrostatic transmission 5 Fuse 15A 6 Start relay 7 Engine charging 8 Engine stop Key for colour abbreviations in wiring diagram SV Black RD Red BR Brown BL Blue VT White GL Yellow ...

Page 60: ...hydrostat pedals are in the neutral position The driver does not need to be seated in the driver s seat Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met Change the conditions and try again Works Does not work Starter Ignition System Electrical System Check that the engine stops if you temporarily move out of the d...

Page 61: ...lace valve Clean channel with compressed air Fuel filter blocked Change filter Tank ventilator blocked Clean or replace fuel cap Fuel pump not working Pump diaphragm broken Impulse channel blocked Fuel hoses blocked or constricted Clean or replace fuel hoses Needles and diffuser jets blocked Clean carburettor with compressed air Replace diaphragm Blow channel clear with compressed air Poor contact...

Page 62: ...mal value Pre ignition incorrect Diode failure V twin engine Incorrect setting Partially or completely blocked needles and diffuser jets Too little or no oil in the engine Blocked cooling fins or air intake Cooling fan damaged Extremely worn or blocked Incorrect thermal value Incorrect electrode gap Incorrect pre ignition position Fill fuel tank Change filter Clean or replace fuel hose Incorrect s...

Page 63: ...de transmission shaft No drive to machine in either direction Brake on Brake wrongly adjusted or jamming Key on transmission shaft broken Clean or replace drive belt Spring off Replace Lever arm jamming Lubricate Replace key Inspect shaft and belt wheel for damage Replace key Inspect shaft and belt wheel for damage Repair or replace transmission shaft Repair or replace transmission shaft Repair or...

Page 64: ...t worn Fan blades damaged or moving against foreign objects The wheel is loose or damaged Oil level too low Oil filter blocked Noise from transmission Repair the engine Belt worn or oily Clean or replace belt Adjust belt tension Stop and allow the transmission to cool Clean the cooling fins Fill with engine oil SAE 10W 30 to right level Repair Lubricate bearing or replace belt tensioning device Re...

Page 65: ...fault for example gear shaft Wrongly adjusted or jamming Oil level too low Internal fault for example gear shaft Wrongly adjusted or jamming Replace linkage and adjust to right setting Replace brake pad Repair or replace hydrostatic transmission Lubricate and adjust Fill with engine oil SAE 10W 30 to right level Lubricate and adjust Bypass valve only partly activated Linkage damaged or jamming Int...

Page 66: ...Svenska 31 Sve 5 225 232 235 Bruk 97 11 25 08 46 31 ...

Page 67: ...Svenska 31 Sve 5 225 232 235 Bruk 97 11 25 08 46 31 ...

Page 68: ...Svenska 31 Sve 5 225 232 235 Bruk 97 11 25 08 46 31 ...

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Summary of Contents for FR 13

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Jonsered FR 13, Workshop Manual

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Summary of Contents for FR 13

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