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English-

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SAFETY INSTRUCTIONS

Safety Instructions

General Instructions

This workshop manual is written for personnel with
general knowledge about the repair and service of
riders.

The workshop where the rider is to be repaired
must be equipped with safety equipment in
accordance with local bylaws.

No one may repair the rider unless they have read
and understood the content of this workshop
manual.

The machine is tested and approved only with the
equipment originally provided or recommended by
the manufacturer.

This workshop manual contains the following
boxes in relevant places.

Special Instructions

The fuel used in the rider has the following
hazardous properties:

•

The ﬂuid and its vapour are poisonous.

•

Can cause eye and skin irritation.

•

Can cause breathing problems.

•

Is highly inﬂammable.

When using compressed air, do not direct the jet
towards the body. Air can penetrate into the blood
circulation system, which entails mortal danger.

Use eye protection when working with tensioned
springs.

Wear protective earplugs or earmuffs when test
running.

After test running, do not touch the mufﬂer until it
has cooled. Risk of burns. This is especially true if
the rider is equipped with a catalytic converter. The
coatings on and in the catalytic converter element
are hazardous to ingest. Use protective gloves
when working with the converter/mufﬂer.

The blades are sharp and can cause cuts and
gashes. Use protective gloves when handling the
blades.

Use eye protection when working with the cutting
unit. The belt tensioning spring can break, ﬂy off,
and could cause personal injury.

Use eye protection when working with the battery
with the plugs removed. Be especially careful
when handling battery acid. Acid on the skin can
cause serious corrosive injuries. In the event of
spillage on the skin wash immediately with water.

Acid in the eyes can cause blindness; contact a
doctor immediately.

Be careful when servicing the battery. Explosive
gases form in the battery. Never perform
maintenance on the battery while smoking or in
the vicinity of open ﬂames or sparks. This can
cause the battery to explode and cause serious
injuries.

WARNING!

The warning box warns of the risk
of personal injury if the
instructions are not followed.

IMPORTANT INFORMATION

This box warns of material damage if the
instructions are not followed.

!

IMPORTANT INFORMATION

Waste oil and old filters shall be handled
as hazardous waste.

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Содержание Rider 13 AWD

Страница 1: ...Workshop manual Rider 13 AWD Rider 175 AWD Rider 15V2 AWD English ...

Страница 2: ......

Страница 3: ...ting the parking brake Rider AWD machines 55 Adjusting of the Hydrostatic Transmission Cable 56 Checking and adjusting the throttle cable Kawasaki 56 Adjusting the throttle cable Briggs Stratton 57 Checking and adjusting the choke cable Kawasaki 58 Replacing the Articulated Steering Bearings 58 Removing the Pendulum Shaft 61 Replacing Bushings 62 Fitting the Pendulum Shaft 63 Drive axles 63 Front ...

Страница 4: ...r 175 AWD 115 Ignition and Starter Lock 117 Main fuses 117 Safety System 118 Hydraulic System 120 Hydraulic Hygiene 120 Hydraulic Oils 120 Fixing Oil Leaks 120 Keep the hydraulic oil clean 121 Working Methods 121 Hydraulic system AWD 122 Hose bundle 123 Appendix Trouble Shooting Guide ...

Страница 5: ...il it has cooled Risk of burns This is especially true if the rider is equipped with a catalytic converter The coatings on and in the catalytic converter element are hazardous to ingest Use protective gloves when working with the converter mufﬂer The blades are sharp and can cause cuts and gashes Use protective gloves when handling the blades Use eye protection when working with the cutting unit T...

Страница 6: ...isconnected Avoid sparking and its consequences by Wearing protective glasses Make sure that the fuel cap is ﬁtted and that no ﬂammable liquids are stored in an open container Do not work on the starter motor circuit in the vicinity of spilt fuel Disconnect the battery s power connec tion cable usually the black negative cable ﬁrst and connect it last Exercise care with tools so that short circuit...

Страница 7: ...over 506 56 76 01 Allen key 5 16 for loosening the engine belt pulley s Allen screw Kawasaki 506 79 06 01 Allen key 3 8 for loosening the engine belt pulley allen screw Briggs Stratton 506 89 92 01 Counter to aid removing the engine belt pulley 506 89 93 01 Tool for the centre spring 535 41 32 01 Punch kit for pendulum shaft bushings 6021 034 506 66 48 01 506 56 76 01 506 79 06 01 506 89 92 01 506...

Страница 8: ...English 6 SPECIAL TOOLS The ﬁgures show how the special tools are used 506 66 48 01 506 89 93 01 535 41 32 01 506 56 76 01 506 79 06 01 8009 518 8009 517 8009 515 6021 035 ...

Страница 9: ...ﬂective tape The display will come on after 1 2 seconds 4 Hold the measurement button down during the entire measurement The instrument switches off when the measurement button is released Read the last highest and lowest values The instrument automatically saves the last highest and lowest measurement values during a measurement i e as long as the measurement button is held down Press and hold do...

Страница 10: ... Manufacturer Briggs Stratton Kawasaki Briggs Stratton V Twin Model 219907011E1 FH430V 316777 Power 9 2 kW 12 5 hp 11 2 kW 15 hp 11 4 kW 15 5 hp Displacement 465 cm3 28 4 cu in 431 cm3 26 3 cu in 426 cm3 26 cu in Fuel at least 85 octane unleaded at least 87 octane unleaded at least 87 octane unleaded Tank volume 7 litres 1 8 US Gal 7 litres 1 8 US Gal 7 litres 1 8 US Gal Oil SAE 5W 30 10W 30 SAE 1...

Страница 11: ... ft Line pulley steering cable 20 30 Nm 14 21 lb ft 20 30 Nm 14 21 lb ft Belt pulley 35 40 Nm 25 28 lb ft 35 40 Nm 25 28 lb ft Blades M10 bolt 45 50 Nm 32 36 lb ft 45 50 Nm 32 36 lb ft Blades M12 bolt 75 80 Nm 53 56 lb ft 75 80 Nm 53 56 lb ft Blade bearings 20 25 Nm 14 18 lb ft 20 25 Nm 14 18 lb ft Belt tensioning wheel 15 25 Nm 10 18 lb ft 15 25 Nm 10 18 lb ft Fitting screws engine 20 25 Nm 14 18...

Страница 12: ...aged unit 17 5 mm 7 16 3 16 Play Brake cable 1 mm 0 040 Cable hydrostatic pedals 0 mm Combi 94 Combi 103 Cutting width 940 mm 37 1030 mm 40 5 Cutting heights 45 95 mm 1 75 3 75 45 95 mm 1 75 3 75 Blade length 360 mm 14 410 mm 16 Guaranteed noise level 100 dB A 100 dB A Width 1080 mm 3 54 ft 1115 mm 3 66 ft Weight 46 kg 102 lb 48 kg 106 lb Combi 112 Cutting width 1120 mm 44 Cutting heights 40 100 m...

Страница 13: ...ning a service journal on the machine s resale value Application areas for mulching 14 Fill in the sales papers etc After the first 5 resp 8 hours Briggs Stratton after 5 hours and Kawasaki after 8 hours 1 Change engine oil After the first 50 hours 1 Change the oil and ﬁlter in the transmission 25 Hour Service 1 Clean the air ﬁlter s pre cleaner foamed plastic Shorter intervals for dusty operating...

Страница 14: ... Replace the air cleaner s pre ﬁlter foamed plastic 300 hours 3 Replace the air ﬁlter s paper cartridge 200 hours 4 Change the engine oil 100 hours Briggs Stratton 50 hours 5 Replace the engine oil ﬁlter 200 hours Not Briggs Stratton 6 Adjust the cutting height 50 hours 7 Adjust the parking brake 50 hours 8 Inspect the ﬂame prooﬁng spark arrestor extra equipment 50 hours 9 Clean replace the spark ...

Страница 15: ...Checking the Engine Oil Level 19 Check the fuel pump s air ﬁlter Check the safety switch seat 119 Check the safety switch lifting lever 119 Check the safety switch pedal system 119 Check clean the engine s cooling air intake Check the cutting unit 105 Attaching the blades 108 Condition of the blades sharpness shape etc 112 Check the steering cables any play etc 52 Check fastenings screws nuts etc ...

Страница 16: ...ine s cooling air intake Clean the air ﬁlter s pre cleaner foamed plastic Change the engine oil1 Kawasaki 51 Change the engine oil1 Briggs Stratton 48 Clean the air cleaner s ﬁlter cartridge 2 paper ﬁlter Check adjust the cutting height 106 Check adjust the parking brake 55 Inspect the ﬂame prooﬁng spark arrestor extra equipment Replace the engine oil ﬁlter every 200 hours Not Rider 13 AWD Clean r...

Страница 17: ... s manual Check the play in the engine valves4 Check whether the oil needs to be changed in the transmission 4 5 every 200 hours 83 Change the ﬁlter in the transmission4 every 200 hours 84 Replace the air ﬁlter s pre cleaner foamed plastic 2 Replace the air ﬁlter paper ﬁlter 2 every 200 hours Perform the 300 hour service 4 12 Maintenance Page Daily mainte nance before Daily mainte nance after Week...

Страница 18: ...a customer register so that in the future you can see which machine the customer owns as well as the appropriate serial numbers The register is of beneﬁt when you order spare parts and during future marketing activities In conjunction with the delivery you shall also give the customer the information required to handle and maintain their machine in a safe manner Remember in particular to inform th...

Страница 19: ...e then stands on the base with the brakes on and secured using wheel chocks Check that the machine has not been damaged during transport when the packaging is opened Any damage should be reported to the transport company as per routine The packaging shall not be returned Lifts from the short side see illustration require long pallet forks Packed components Number Component 1 pc Steering wheel with...

Страница 20: ...e 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 chafe against anything Fit the cover on the battery and tighten the strap WARNING Actions with acid contact External Rinse thoroughly with water Internal Drink large quantities of...

Страница 21: ...strated Checking the Engine Oil Level Check the oil level in the engine when the Rider stands horizontal with the engine switched off Open the engine cover Loosen the dipstick and pull it out Wipe off the dipstick and ﬁt it again The dipstick shall not be screwed down on Kawasaki The dipstick should be screwed down Briggs Stratton Pull out the dipstick and read the oil level The oil level should b...

Страница 22: ...PSI on all wheels Highest permitted pressure is 100 kPa 1 0 bar 14 PSI Skid guard In those cases where the front and rear skid guards are delivered with the machine it is the dealer s responsibility to ﬁt them 6021 030 Transmission cover 6012 048 Hydraulic tank IMPORTANT INFORMATION Check and top up with oil after test running If there are air pockets in the transmission or hydraulic system the oi...

Страница 23: ...released Check that the parking brake works Check driving forwards 1 and in reverse 2 Check that the starter motor does not work when the parking brake pedal is not actuated Check that the engine stops if the driver stands from the seat when the parking brake pedal is unactuated Check that the starter does not work when the cutting unit is in the lower position 8042 017 Fuel tank WARNING Petrol is...

Страница 24: ...ed the hydraulic system of excess air after test running Check the oil level in the hydraulic tank and top up if necessary Check that there are no leaks including engine oil and fuel leaks Replace the transmission cover Clean the machine if necessary wipe up spilled oil ﬁnger marks on steering wheel and controls dust etc Administration Fill in the sales papers customer register etc Don t forget to...

Страница 25: ...English 23 DELIVERY AND DEALER SERVICE ...

Страница 26: ...om the smallest the Rider 11 to the largest the ProFlex 21 AWD All Riders have articulated steering to ease mowing around trees and other obstacles They also have front mounted cutting units for controlled mowing and the best possible cutting result In addition the Husqvarna Riders can also be equipped with various accessories such as moss rakes and snow blades which makes them ﬂexible working too...

Страница 27: ...N AND FUNCTION Rider 13 AWD is equipped as standard with cutting unit type Combi 94 Rider 15V2 AWD and Rider 175 AWD can be delivered with Combi 103 or Combi 112 6021 025 Combi 94 8009 288 Combi 103 8009 288 Combi 112 ...

Страница 28: ...s found on a barcode decal This is placed on the left side of the crankcase in front of the starter The decal states The engine s serial number E NO Code Please state these when ordering spare parts The transmission s serial number is found on the barcode decal located on the front of the housing on the left hand drive shaft The serial number is stated above the barcode and has the preﬁx s n The m...

Страница 29: ...bout adjusting and repairing the engines These manuals can be ordered from an authorised service workshop The table below contains the model numbers for the different Rider models These should be stated when ordering manuals Model Engine type Rider Pro 13 AWD B S 219907011E1 Rider 175 AWD B S 316777 Rider 15V2 AWD Kawasaki FH430V It is important that only original spare parts are used to repair th...

Страница 30: ... rider both easy and precise A Rider easily cuts around all obstacles on the lawn A mechanical linkage gives the front wheels a higher speed when cornering The turning circle is very small thanks to the articulated steering the uncut circle with full lock is only 20 30 cm 8 12 depending on model 6011 008 Outline diagram of the articulated steering function 6019 007 The Rider machines have steering...

Страница 31: ...rear axle The hydraulic tank is separate and is located above the rear axle Front axle on Rider AWD from the top The axle consists of a hydraulic motor differential and drive axles In order to move the machine without the front axle s drive engaged there is a mechanical bypass valve that is operated by a control on the inside of the left hand wheel The bypass valve must be closed with all driving ...

Страница 32: ...nglish 30 DESIGN AND FUNCTION The oil is drained using two plugs on the underside One plug drains the hydraulic motor and the other drains the differential 8009 832 Oil drainage 8009 856 Drive system AWD ...

Страница 33: ...ed with cutting unit Combi 94 Rider 15V2 AWD and Rider 175 AWD are supplied with cutting unit Combi 103 or Combi 112 The Combi unit functions as a BioClip unit when a BioClip plug is ﬁtted but can be changed to rear ejection by removing the BioClip plug 6021 023 Removing the BioClip plug Combi 94 6021 025 Combi 94 8009 289 Removing the BioClip plug Combi 103 112 8009 288 Combi 103 112 ...

Страница 34: ...t to the service position Other wise when dismantling the rear of the attachment would fall directly to the ground when the lug on the rear axle releases its grip The mowing height is adjusted using the lever which has a catch for the different mowing height positions The setting for the mowing height range is located on the same axle see Adjustment of the mowing height range Two connecting rods v...

Страница 35: ...English 33 DESIGN AND FUNCTION ...

Страница 36: ... cover and loosen the cable connections Then lift out the battery 3 Remove the cable connecting the starter relay to the starter 4 Pull apart the connector for the engine s electrical cables 5 Remove the clip holding the throttle and choke cables Release the cable from its mounting 8009 427 IMPORTANT INFORMATION Hold the bolts so that the poles are not put under strain 8009 426 8009 421 8009 402 ...

Страница 37: ... higher than the fuel tank level 7 Loosen the exhaust pipe clamp Then remove the exhaust pipe Loosen the mufﬂer s mounting bolts if necessary 8 Remove the belt guide for the engine belt pulley On machines with a skid guard the skid guard must be removed 9 Pry off the pump belt from the belt adjuster 8009 425 8042 15 8009 736 8009 839 ...

Страница 38: ...terhold Loosen the belt pulley from the engine shaft 11 Use the puller part number 506 66 48 01 if necessary 12 Remove the engine s ﬁxtures two on each side of the engine Watch where the battery s negative cable is connected Disconnect it from the engine if necessary Lift the engine out of the mower take care of the key and spacer tube located on the engine shaft 6012 008 506 66 48 01 8009 518 800...

Страница 39: ...ft Connect the negative cable as shown in the ﬁgure 2 Fit the belt pulley with tool part number 506 79 06 01 and tighten with a torque of 70 80 Nm 50 56 lbft Use tool part number 506 89 92 01 to counterhold Place both belts in place on the belt pulley 6019 039 IMPORTANT INFORMATION Hold the bolts so that the poles are not put under strain 8009 419 8009 420 506 79 06 01 506 89 92 01 6012 008 ...

Страница 40: ... the skid guard if used 5 Attach the throttle cable to the carburet tor and ﬁt the cable clip without tighten ing it 6 Move the accelerator to the full choke position Pull the cable s outer 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 8009 839 8009 737 8009 402 8009 403 ...

Страница 41: ...t the exhaust pipe and tighten the mounting bolts on the exhaust ﬂange and mufﬂer and ﬁnally the pipe clamp 9 Firmly ﬁt the fuel hose to the fuel pump and attach the hose clamp 10 Attach the engine s electrical connectors 8009 404 8042 115 8009 425 8009 421 ...

Страница 42: ...40 REPAIR INSTRUCTIONS 11 Screw into place the cable from the start relay to the starter 12 Lift the battery into position and attach the cable connectors and cover tighten the fastening strap 8009 426 8009 427 ...

Страница 43: ...ve the engine s electrical connectors 6 Remove the clips holding the throttle and choke cables Unhook the cables from their fasteners in the carburettor 7 Remove the hose clamp on the fuel hose by the fuel pump and pull the fuel hose downwards Place the hose so that the fuel does not leak out 8009 526 Battery installation IMPORTANT INFORMATION Hold the battery cable bolts in place so that the elec...

Страница 44: ...exhaust pipe Loosen the mufﬂer s mounting bolts if necessary 9 Push in the belt adjuster and pry off the pump belt 10 Remove the belt guide for the engine belt pulley On machines with a skid guard the skid guard must be removed 8042 115 Exhaust system 8009 839 8009 736 Belt guide ...

Страница 45: ...en the belt pulley from the engine shaft 12 Use the 506 66 00 48 01 puller if necessary 13 Remove the engine ﬁxtures two on each side of the engine and remove the engine from the rider The ﬁgure shows the right hand side For the left side see the illustration under Assembling 8009 194 Engine belt pulley 506 56 76 01 506 66 48 01 8009 518 Engine belt pulley remover 8009 192 The engine s fastening s...

Страница 46: ...506 89 92 01 to counterhold Place both belts in position on the belt pulley 3 Press in the belt adjuster and align the pump belt in position 6019 039 Engine shaft and belt pulley 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 the spacing tu...

Страница 47: ...eft as possible and tighten the cable clip Attach the choke cable to the carburettor and ﬁt the cable clip without tightening it Move the choke control to the full choke position Pull the cable s outer casing as far to the right as possible and tighten the cable clip 6 Press the fuel hose into place against the fuel pump and attach the hose clamp 7 Screw the cable from the starter to the start rel...

Страница 48: ... position and attach the cable connectors and cover tighten the fastening strap 9 Fit the engine cover and transmission cover IMPORTANT INFORMATION Hold the battery cable bolts in place so that the electrodes are not strained 8009 427 Battery installation ...

Страница 49: ...mark top up the oil to the FULL mark on the dipstick The oil is topped up through the hole the dipstick sits in Fill the oil slowly Tighten the dipstick correctly before starting the engine Start and run the engine at idling speed for approx 30 seconds Turn off the engine Wait 30 seconds and check the oil level If necessary ﬁll so that the oil comes up to the FULL mark on the dipstick First and fo...

Страница 50: ...ighten it 5 Fill with oil up to the FULL mark on the dipstick Oil is ﬁlled using the same hole as the dipstick See Checking the engine s oil level above for ﬁlling instructions The engine holds 1 4 litres 1 5 USqt of oil 6 Run the engine warm then check that there is no leakage from the oil plug WARNING Engine oil can be very hot if it is drained directly after stopping the engine Allow the engine...

Страница 51: ...hole the dipstick sits in Fill the oil slowly Tighten the dipstick correctly before starting the engine Start and run the engine at idling speed for approx 30 seconds Turn off the engine Wait 30 seconds and check the oil level If necessary ﬁll so that the oil comes up to the FULL mark on the dipstick The following oil classes are recommended API Service Class SF SG SH and SJ Choose an oil with vis...

Страница 52: ... Remove the two screws that ﬁx the tank to the bracket Lower the tank and pull out the hose through the frame of the machine if it has been loosened by the fuel ﬁlter Fitting 1 It is easier to work if you empty the tank before ﬁtting Insert the hose into place and attach it to the fuel ﬁlter with the hose clamp Make sure that the hose cannot be chafed or rubbed 2 Position the tank in the bracket a...

Страница 53: ...t 5 Then replace the oil drain plug and tighten it 6 Replace the oil ﬁlter if necessary 7 Fill with new engine oil 8 Starting the engine run for a few sec onds Check the oil level and top up if necessary WARNING Engine oil can be very hot if it is drained directly after stopping the engine Allow the engine to cool somewhat first 8009 529 Engine oil drainage IMPORTANT INFORMATION Used engine oil is...

Страница 54: ...hat the distance between them is half the size without using too much force Change the cable if it has a damaged strand causing loose threads to protrude 3 If necessary the cables can be adjusted by ﬁrst loosening the lock nut and then tightening the adjustment nut one cable on each side of the machine Hold the cable with for example an adjustable wrench so that it does not twist If the adjustment...

Страница 55: ...s will then automatically sit in the proper position The steering cable s chain coupling should be ﬁtted with the spring lock upwards Hold the cables with for example a wrench when mounting so that they do not twist Ensure that the steering wheel is in the centre position when the rear wheels are centred Re set the chain on the power steering sprocket or adjust the rear ﬁxture for the steering cab...

Страница 56: ...ame and the cable pulley Ensure that the cables are properly situ ated under the steering cable rollers 7 in the frame tunnel Hold the cables with for example an adjustable wrench when mounting so that they do not twist Ensure that the steering wheel is in the centre position when the rear wheels are centred Re set the chain on the power steering sprocket or adjust the rear ﬁxture for the steering...

Страница 57: ...not stand still the parking brake should be adjusted according to the following 1 Remove the left hand wing cover 2 Loosen the locking nuts 1 3 Tension the cable using the adjuster screw 2 until the play in the cable is taken up 4 Tighten the locking nuts 1 5 The brake should be checked again after the adjustment has been made 6 Assemble the left hand wing cover 8042 017 6021 031 WARNING A poorly ...

Страница 58: ...rn 8 Assemble the ball joint 9 Put the ball joint s locking spring in place 10 Tighten the lock nut for the socket on the cable 11 Fit the transmission cover Checking and adjusting the throttle cable Kawasaki Check that the engine responds to throttle increases and that a good engine speed is attained at full throttle If adjustments are necessary they can be made as follows for the lower cable 1 L...

Страница 59: ... black smoke or maximum revs are not reached 1 Loosen the clamping screw by the arrow and slide the throttle to the choke position 2 Pull the throttle wire s casing as far as possible to the right and check that the choke is fully actuated 3 Tighten the clamping screw 4 Pull back the throttle to the full throttle position and check that the choke is no longer actuated 8009 402 8009 403 8009 404 ...

Страница 60: ...ver to the full choke position 2 Check that the choke cable is mounted in the upper lever see illustration 3 Pull the choke cable s outer casing as far to the right as possible and tighten the clamping screw Replacing the Articulated Steering Bearings 1 Remove the engine as previously described Removing the Kawasaki engine 2 Jack up the rider in front of the articulated steering 3 Remove the belt ...

Страница 61: ...pper part backwards and force the pulley out 9 Loosen the centre spring This spring is under high tension and the load should be relieved with the help of tool number 506 89 93 01 10 Remove the screw for the centre spring s rear mounting after the load on the spring has been relieved 8009 203 Locking spring 8009 367 Steering cables and belt pulley WARNING The centre spring is under extremely high ...

Страница 62: ...re stuck tap them from below 13 Fit the new bearings and mount the articulated steering in the reverse order that it was removed 14 After mounting the cable tension should be checked see Checking and Adjusting the Steering Cables Check that the controls and cables are properly adjusted see Adjusting of the Hydrostatic Transmission Cable 15 Bleed the hydraulic system of excess air Top up the oil af...

Страница 63: ... Shaft 1 Jack up the rider in front of the rear frame 2 Clean see Working Methods 3 Mark and remove the hydraulic hoses from the couplings under the machine 4 Loosen the idler s spring 6012 029 Jacking up 8009 820 Hydraulic hoses 8009 821 Idler s spring ...

Страница 64: ...e a sledgehammer or puller if needed If the dust cover 2 is damaged it should be replaced with a new one Replacing Bushings Once the pendulum shaft is removed replace the bushings in the rear frame Remove these with a punch see Special Tools New bushings are ﬁtted with the punch see Special Tools Make sure that the bushing grooves are lined up horizontally It is important that the outer bushing s ...

Страница 65: ...c transmission s fan 9 Fit the hydrostatic transmission cable Check that it is adjusted correctly see Adjusting of the Hydrostatic Transmission Cable 10 Fit the idler s spring 11 Fill and bleed the hydraulic system of excess air Top up as needed after test running 12 Fit the transmission cover Drive axles Remember cleanliness follow the instructions under Hydraulic system Hydraulic Hygiene Counter...

Страница 66: ...peed from the front axle Check in which hole the synchronisation link is ﬁtted normally over the hole 5 Drain out the oil if necessary two plugs 6 Release the hydraulic pipe from the underside of the front axle Fit the protective plugs A small amount of oil will leak out even if the front axle has not been drained 7 Remove the left front wing 8009 825 Circlip 8042 121 Synchronisation link 8009 631...

Страница 67: ...ctive plugs A small amount of oil will leak out even if the front axle has not been drained 9 Remove the ﬁve bolts holding the front axle and lower the front axle 8009 826 Hydraulic pipe top 8009 827 Right outer front axle mounting 8009 830 Right inner front axle mounting 8009 828 Left front axle mounting ...

Страница 68: ...hten the left side bearing before the right bearing 2 The stop screws for the bearing on right hand side are tightened after the ﬁve screws holding the front axle have been tightened 3 The synchronisation link is ﬁtted in upper the hole Below the holes for the synchronisation link is a hole for the release control 8009 829 Rear front axle mounting 8009 691 Parking Brake Cable 8009 625 Right front ...

Страница 69: ...d bleed the complete hydraulic system according to Bleeding the drive system 8 Check and adjust the parking brake cable 9 Check and adjust the speed coordination between the front wheels and rear wheels according to the separate instruction Rear axle Removal 1 Jack up and block the machine 2 Remove the rear wheels Remove the protective cover Remove the circlip Pull off the wheel with hub from the ...

Страница 70: ...e of the rear axle Fit the protective plugs A small amount of oil will leak out even if the axle has not been drained 5 Release the return hose from the hydraulic tank Open the clamp for the suction hose under the tank and remove the hydraulic tank 8009 832 Oil drainage 8009 833 Hydraulic hoses underside 8009 834 Opening the clamp ...

Страница 71: ...utch control 8 Pry off the rear V belt from the fan pulley Place the belt over the groove on the crankshaft belt pulley and move it between the fan blades 9 Remove the ﬁve bolts holding the rear axle and lower the rear axle 8009 835 Mounting bolts left side 8009 837 Mounting bolts right side 8009 836 Mounting bolt rear axle ...

Страница 72: ... between the front wheels and rear wheels according to the separate instruction Synchronising front and rear wheel drives The front and rear wheel drive must be synchronised so that the speed between the front and rear wheels is correct when cornering In order to avoid measurement error due to rollback on the differential wheels two of the machine s wheel must make contact with the ground Ensure t...

Страница 73: ...the steering wheel position has not changed during the following test Start the engine and run warm at full speed until the wheel speed has stabilized Check with tachometer 7 Stop the engine 8 Adjust the synchronisation of the wheel speed using the adjuster rod First loosen the locking nuts A longer rod gives a higher speed on the front wheels A shorter rod gives a higher speed on the rear wheels ...

Страница 74: ...aft and pry off the seal from the shaft housing with a twisting motion 2 Wind the insulating tape around the ingoing shaft in order to protect the new seal from damage from splines and grooves Begin winding from the bottom and continue upwards along the shaft until the entire shaft is wound in tape Lubricate the shaft and the inside of the new seal with lubricant so that the seal slips on smoothly...

Страница 75: ...lip Seal Replacement Outgoing Shafts 1 Remove the circlips that hold the wheels onto the shafts and remove the wheels by pulling them outwards Do not lose the key that sits between the wheel and the shaft 2 Remove the spacers and washers Keep count of the number of washers this can vary between sides 3 Clean the outgoing shaft and the area around the seal from all dirt and rust 4 Insert a screwdri...

Страница 76: ...ing Move the extender in a circle around the seal so that it is pressed down evenly all around and is tight against the shaft 8 Remove the insulation tape from the shaft and repeat the entire procedure as needed for the other shaft 9 Reﬁt the large washer spacer sleeve key rear wheel small washer circlip and hub cap 10 Fill engine oil SAE 10W 40 class SF CC or higher in the transmission oil tank u...

Страница 77: ...as needed Replacing the Hydrostatic Transmission Cable Removing the Hydrostatic Transmission Cable 1 Remove the frame plate by loosening the screws 2 Loosen the hydrostatic transmission cable s forward lock nut a 1 4 turn and remove the locking spring 3 Remove the hydrostatic transmission cable s forward clamp which is attached inside the centre bracket 8042 039 Frame plate Front locking nut and l...

Страница 78: ...om the arm Remove the rear clamp 6 Lift off the front link joint and pull out the cable 7 Lift out the hydrostatic transmission cable and the accompanying link joint 8 Unscrew both link joints from the hydrostatic transmission cable 6021 030 Transmission cover 8009 214 Rear link joint 6019 016 Lift off the link joint 6019 017 Remove the link joints ...

Страница 79: ... through the rider so that it follows the same path as the old cable did 3 Make sure that the cable is routed under the articulated steering bearing as shown in the picture The placement of the cable is important otherwise the pump stroke can be affected when you turn in either direction 6019 009 Remove the hydrostatic transmission cable 6019 018 Front link joint 6019 022 Threading the cable 8009 ...

Страница 80: ... transmission cable Screw 10 12 turns so that the link joint has the right length 7 Run the hydrostatic transmission cable along with the other cables 8 Position the hydrostatic transmission cable in the casing s rear bracket and ﬁt the rear clamp 9 Adjust the hydrostatic transmission cable as shown see Adjusting of the Hydrostatic Transmission Cable 6019 023 Forward mount in centre bracket 6019 0...

Страница 81: ...ONS 10 Connect the rear link joint and attach the locking spring 11 Tighten the rear link joint s lock nut 12 Screw on the frame plate 13 Test drive the machine forwards and in reverse 8009 203 Locking spring 8042 119 Frame plate ...

Страница 82: ...oap and water in case of spillage See Hydraulic Hygiene on page 120 IMPORTANT INFORMATION The tank must never be run empty while work is underway Fill the tank completely when filling Risk of air penetration into the system IMPORTANT INFORMATION When the controls for the release valves bypass valves in the front or the rear axles are extended and the engine is running the drive pedals must not be ...

Страница 83: ...rating speed and actuate the forward and reverse pedals 4 x 5 seconds top up 10 Lower the engine speed to idling no actuation of the pedals 11 Open both the clutch control valves for a few seconds and close them 12 Increase the engine speed to operating speed and actuate the forward and reverse pedals Check that the wheels react without delay 13 Lower and test drive the machine 14 Adjust the level...

Страница 84: ...p rotating backwards and make a mark on the transmission housing RS Turn the shaft slowly counter clockwise until the drive shafts begin rotating forwards Turn the shaft slowly clockwise until the drive shafts stop rotating forwards and make a mark on the transmission housing FS Turn the shaft clockwise 1 3 of the distance between the two marked stop points Hold the shaft still N 8 and tighten the...

Страница 85: ...meowners with gardens do not have the tools or experience needed to change the transmission oil The transmission probably has a longer life than the rider itself which means that being able to change the oil is not of major concern to the average consumer The lifespan of the transmission increases however if the oil is changed When the rider is used commercially we recommend changing the oil ﬁrst ...

Страница 86: ...he drain plugs Fill with oil through the ﬁll hole in the hydraulic tank 4 Bleed the transmission see Bleeding the drive system on page 80 5 Test run the machine and ﬁll with oil to the proper level in the oil tank Replacing the hydrostatic transmission filter The ﬁlter is placed at the rear of the rear axle and should be replaced with each oil change 1 Drain the oil from the rear axle approximatel...

Страница 87: ...e right position 4 Fit the cover Adjusting the lever housing The lever housing on these types of machine only has two settings Adjuster nuts for the cutting unit s mowing height range See Adjusting the Cuttin Height Range Adjuster screw for the belt adjuster s home position See Replacing the Centre Belt 6020 003 Hydrostatic transmission filter IMPORTANT INFORMATION The cover is made of plastic Do ...

Страница 88: ...4 Pull off the centre belt from the engine s pulley and pull out the rear section Used belt can be pulled downwards When the belt is new the centre belt must be pulled off of its front pulley whereupon it can be moved downwards from the engine pulley so that the rear part can be pulled out 6021 030 Transmission cover 8009 839 Belt tensioning 8009 736 Belt guide 8009 638 Rear part of the front belt...

Страница 89: ...d on the inside past the belt adjuster s disc 10 Fit the pump belt on the engine pulley guide it under the engine belt pulleys and place up its groove 11 Fit the belt on the pump pulley between the fan blades 12 Fit the pump belt in its groove on the engine pulley 13 Press in the belt adjuster and align the pump belt in position on the belt adjuster s belt pulley 14 Check that the centre belt is ﬁ...

Страница 90: ...y 4 Check and adjust the belt adjuster This is especially important when ﬁtting a new belt since stretching of the old belt may have been compensated for by changing the setting of the belt adjuster The distance between the belt adjuster and the belt guide should be 17 5 mm Adjust using the adjuster screw by the lever housing 8009 737 Rear belt guide 8009 736 Belt guide 8009 842 Check the belt adj...

Страница 91: ...e centre belt off of the centre pulley The belt becomes slack when the cutting unit is lifted 3 Take off the front belt from the centre pulley and remove the belt Assembly 1 Position the belt from the front Pull the belt on the outside of the runner pulley and on the inside of the adjuster pulley Position it in the centre pulley s upper groove 6017 227 Service position 8009 684 Belt tightening 800...

Страница 92: ...eset the cutting unit in the mowing position Make sure that the tongue 3 mates with the loop on the underside of the machine 4 The belt is ﬁtted on the cutting unit s drive pulley once the unit has been pushed back into its rear position 8009 695 Centre pulley 8009 595 Tongue in the loop 8009 122 Press back ...

Страница 93: ...he link for the height adjustment from the triangular link 4 Lower the equipment frame with the mechanical lever Insert a small screwdriver or the like through the chain so that it can not slide into the frame tunnel and release the chain from the equipment frame 5 Remove the equipment frame s rear guide screws 8009 845 Adjuster nuts 8009 844 Link height setting 8009 701 Chain bracket 8009 846 Rea...

Страница 94: ...lts in the bracket Make the basic setting with the locking nuts so that the eyebolts protrude 45 mm Final setting is dependent on the weight of the cutting unit 7 Fit the stay for the mowing height adjust ment Risk for incorrect assembly turn the stay so that the split pin is on the inside of the triangle link 8 Fit the front wings 9 Fit the cutting unit 10 Adjust the ground pressure see Checking ...

Страница 95: ...a locking pin 4 Place the belt over the runner pulley and behind the adjuster pulley 5 Press down the frame and secure with the split pin Fit the drive belt around the unit s drive pulley 6 Hook in the height adjustment stay 8009 595 Tongue in the loop 6017 120 Bolt in the front bracket 8009 831 Runner and tension wheels WARNING Observe caution to avoid trapping your hand 8009 699 Assembling the p...

Страница 96: ... Combi 112 1 Follow The cutting unit s service position points 1 9 to put the cutting unit in the service position 2 Remove the bolt 3 and lift off the cutting unit 8009 439 Support wheels 8009 598 Adjuster pulley s spring WARNING Wear protective glasses when dismantling the cutting unit The springs that tension the belt can fly off and cause personal injury 8009 674 Bolt ...

Страница 97: ...machine on ﬂat ground Apply and lock the parking brake Set the cutting height control in the lowest position and lift up the cutting unit 2 Remove the front hood by removing the pin 3 Loosen the spring on the drive belt s belt idler by loosening the handle 8042 047 8042 035 8042 048 ...

Страница 98: ... 96 REPAIR INSTRUCTIONS 4 Place the handle on the frame arch 5 Lift off the drive belt and hang on the load relieving hook 6 Loosen on the cutting height stay and place in the holder 8042 049 8042 050 8042 051 ...

Страница 99: ...ccessibility for cleaning repair and servicing the unit can be set in the service position The service position means that the unit is raised and locked in the vertical position Placing in the Service Position Combi 103 Combi 112 1 Place the machine so it is ﬂat Activate the parking brake 1 Set the cutting deck to the lowest cutting height and lower the cutting unit 8042 052 8042 118 8042 047 Prep...

Страница 100: ...cover by loosening the split pin Complete instructions for the service position can be found on the inside of the front cover 3 Loosen the two anti scalp rollers located under the front cover 8042 096 Dismantling the front cover 8042 084 Support wheels ...

Страница 101: ...it s front edge to make it easier to loosen the height adjustment stay 7 Secure the height adjustment stay in the holder 8042 086 Placement of the anti scalp rollers WARNING Wear protective glasses when dismantling the cutting unit The springs that tension the belt can fly off and cause personal injury 8042 087 Spring on belt idler 8042 088 Loosen the height adjustment stay 8009 438 Height adjustm...

Страница 102: ... bolt which is now holding the cutting unit is removed the cutting unit can be lifted off Releasing the Service Position To leave the service position reverse the procedures set out in Placing in the service position Make sure that the cutting unit s tongue 3 enters the loop correctly on the underside of the machine 8042 086 Drive belt and split pin 8042 087 Refit the split pin 1 2 8042 088 Servic...

Страница 103: ...he machine on ﬂat ground Apply and lock the parking brake Set the cutting height control in the lowest position and lift up the cutting unit 2 Remove the front hood by removing the pin 3 Loosen the spring on the drive belt s belt idler by loosening the handle 8042 047 8042 035 8042 048 ...

Страница 104: ...102 REPAIR INSTRUCTIONS 4 Place the handle on the frame arch 5 Lift off the drive belt and hang on the load relieving hook 6 Loosen on the cutting height stay and place in the holder 8042 049 8042 050 8042 051 ...

Страница 105: ...NSTRUCTIONS 7 Grip the front edge of the unit and pull forwards until it stops 8 Lift the unit until it stops and a clicking sound is heard 9 The unit locks automatically in the vertical position 8042 052 8042 053 8042 054 ...

Страница 106: ...he front edge of the unit and loosen the lock fold down and slide in the unit 2 Replace the cutting height stay and the belt Tension the belt with the belt adjuster 3 Fit the front cover 4 Set the cutting height control to one of the positions 1 7 8042 054 8042 055 8042 056 ...

Страница 107: ...ld have a slight slant with the rear edge 2 4 mm 1 8 higher than the front edge 1 Check the air pressure in the tyres 60 kPa 0 6 kp cm2 8 5 PSI 2 Remove the front cover and the right hand wing cover 3 Loosen the parallelism stay s nuts 4 Screw out extend the strut to raise the rear edge of the cover Screw in shorten the strut to lower the rear edge of the cover 5 Tighten the nuts after adjustment ...

Страница 108: ...tting unit s ground pressure as described in the next section 6 Attach the nose cover Adjusting the Cutting Height Range 1 Remove the right hand wing cover 2 Raise or lower the entire cutting range by screwing the nuts up or down If the highest cutting height is raised by 5 mm 3 16 the other ﬁxed cutting heights will also be raised by the same amount 8009 028 8009 556 Adjusting the cutting height ...

Страница 109: ...eces sary a block can be placed between the frame and the scales so that the anti scalp rollers do not support any weight 5 Adjust the cutting unit s ground pressure by screwing the adjuster screws which are located behind the front wheels on both sides in or out The ground pressure should be between 12 and 15 kg 26 5 33 lb and the springs evenly tensioned Belt Replacement the Combi 94 Combi 103 C...

Страница 110: ... Replacement the Combi 94 Combi 103 Combi 112 2 Loosen the spring 1 that tensions the V belt and pull the belt off 3 Remove the screws holding the pulley 2 Lock the blade with a wooden block or hold the belt pulley in place with an oil ﬁlter wrench for example Do not lose the key that sits between the pulley and the shaft Remove the pulley A puller may be required for this 4 Loosen the blade bolt ...

Страница 111: ...move the hub using a puller Do not lose the key that sits between the hub and the shaft 7 Remove the protective metal washer 8 Mark one end of the shaft Push out the shaft with a puller Tap out the bearing and remove the spacer 6012 083 Screws blade bearing 6012 084 Removing the hub 6012 085 Removing the protective washer 6012 086 Removing the shaft ...

Страница 112: ...ing housing is located on the underside of the cutting unit s cover 1 Remove the cutting unit s upper cover see Belt Replacement the Combi 94 Combi 103 Combi 112 2 Loosen the spring 1 that tensions the V belt and pull the belt off 3 Loosen the screw that holds the belt pulley 2 a few turns Lock the blade with a wooden block or hold the belt pulley in place with an oil ﬁlter wrench for example 6012...

Страница 113: ...earing housing in a vice and remove the blade and washers 7 Replace the blade bolt in the shaft Screw it in a few turns and tap or press down the hub Do not lose the key that sits between the hub and the shaft 8 Mark one end of the shaft Press or tap out the shaft 9 Tap out the bearing and remove the spacer Fit in the reverse order Make sure that the shaft is mounted in the same direction as when ...

Страница 114: ...he punch 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 Fit in the reverse order IMPORTANT INFORMATION When tightening the blade shaft screws the transmission side should always be tight ened first and then the blade screws The belt pulley can be turned the wrong way the t...

Страница 115: ...e BioClip plug and remove the plug 3 Combi 103 112 Tip Fit three full thread screws M8 x 15 mm in the screw holes to protect the threads 4 Combi 94 Remove the wing nut and BioClip plug 5 Return the unit to the normal position Fit the BioClip plug in the reverse order WARNING If the blades are cracked whether caused by poor repair or other damage they could break while being used The risk increases...

Страница 116: ...English 114 REPAIR INSTRUCTIONS ...

Страница 117: ...nent locations 1 Microswitch seat 2 Ignition and Starter Lock 3 Microswitch lifting lever 4 Microswitch pedal arrangement 5 Main fuse 15 A 6 Start relay 7 Engine Charging 8 Engine Stop 9 Fuel valve not Rider 13 AWD 10 Starter 11 Battery Key for colour abbreviations in wiring diagram RD Red BL Blue VT White SV Black GL Yellow GR Grey BR Brown ...

Страница 118: ...English 116 ELECTRICAL SYSTEM 8009 679 Wiring diagram AWD ...

Страница 119: ...ector ends up in the proper position click lock Main fuses The main fuse is placed in a detachable holder under the battery case s cover in front of the battery Type Flat pin 15 A Do not use any other type of fuse when replacing A blown fuse is indicated by a burnt connec tor Pull the fuse from the holder when replac ing The fuse is there to protect the electrical sys tem If it blows again shortly...

Страница 120: ...raised position and the parking brake is applied The driver does not need to be seated in the driver s seat Check daily 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 Check that the engine stops if you temporarily move out of the driver s seat while the cutting unit is lowered Starter Ignition syste...

Страница 121: ...in the fasteners and remove the microswitch from the holder Assembling is done in the reverse order without setting Micro switch pedal arrangement 1 Remove the transmission cover 2 Check the hydrostatic cable adjustment See Adjusting of the Hydrostatid Transmission Cable 3 Remove the cover from the frame tunnel 4 Adjust the microswitch so that it clicks when the parking brake pedal is pressed down...

Страница 122: ...not being changed in time and containing water and other aggressive substances Dirt particles that enter the system include Contaminants entering when topping up with oil Dust particles from the workshop Gasket and thread sealants from assembly Dirt from storage and handling before assembly Fibres from rags ﬁlters etc Dirt from maintenance areas due to insufﬁcient cleaning before disassembly Dirt ...

Страница 123: ...irty It can also be so that the submitted component is not faulty and is therefore returned without action The following points should be gone through routinely when working with the hydraulic system 1 Clean as necessary 2 Protect the area where the work is to be done against dust and other impurities in the air Plastic sheets and the like may be used 3 Clean thoroughly with white spirit or equiva...

Страница 124: ...English 122 HYDRAULIC SYSTEM Hydraulic system AWD 1 Hydraulic tank 2 Filter 3 Hydraulic pump variable 4 Hydraulic motor fixed 5 Control arm displacement 6 Hydraulic motor variable 8009 857 ...

Страница 125: ...tion on the hydrostatic motor Red to the rear and black to the tank 2 Collect the hoses green and black 3 Start to wind the hose protection 115 20 mm from the centre of the green hose s connection on the hydrostatic transmission Guide the end of the hose protection between the two hoses and wind the protection 4 5 turns 4 Insert the red hose on the left hand side of the bundle 5 Wind the hose prot...

Страница 126: ...English 124 HYDRAULIC SYSTEM ...

Страница 127: ...eplace the spark plug guard Replace the spark plug Change the ignition coil Fill with fuel No current to the valve the solenoid is defective Channel from fuel stop valve blocked Fuel ﬁlter clogged Tank ventilator blocked Check cable connection or the replace valve Clean the channel with compressed air Change the ﬁlter Clean or replace the fuel cap Pump diaphragm faulty Change the diaphragm Clean t...

Страница 128: ...n cover Spark plug defective Ignition setting incorrect Faulty ignition module sensor Too little fuel in tank Soiled fuel ﬁlter Dirt in fuel pipe Pinched or blocked hose Faulty carburettor Tank ventilator blocked Clogged air ﬁlter Spark plug has wrong thermal value Pre ignition incorrect Faulty ignition module sensor Incorrect setting Partially or completely blocked needles and dif fuser jets Too ...

Страница 129: ...ps on the axle Wheel hub wheel axle slips Belt pulley slips on the input shaft hydraulic pump Inner leakage hydraulic pump Defective hydraulic motor or differential parts Filter in the rear axle clogged Low oil level in the tank Air in the hydraulic system The lever for the bypass valve is partly extended Defective accelerator Internal damage transverse axle Brake wrongly adjusted or jamming The p...

Страница 130: ...oordination linkage damaged Faultly front or rear axle Engine fault Transmission fault The drive belt Hydraulic pump s cooling fan Belt pulley on the pump s input shaft Pump unit Front and rear axle not synchronised The machine slows down under heavy loads Abnormal noise from the transmission Overloading Change driving style Abnormal noise from the cutting unit Check the drive belts runner and gui...

Страница 131: ...be towed or pushed Transmission Overheating other indications Overheated transmission Poor air circulation Damaged or loose fan Replace or tighten the fan Fill the oil to the right level Oil level too low Clean off contamination Dirt grass or leaves on the cooling ﬁns Partial braking Check and adjust the parking brake Replace the hydrostatic transmission or damaged internal parts Throttling ﬁtted ...

Страница 132: ...elt Lubricate the bearing or replace the belt adjuster Check the belt tensioning mechanism Machine fault Uneven mowing results Loose blade Coating on blades Imbalanced blades Belt pulley loose Worn blade bearing Check friction washers Tighten blades Clean blades and underside of cover Balance or replace blades Check hub and axle Tighten belt pulley Repair worn bearings check the others Cutting uni...

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Страница 134: ...2008W12 115 03 16 26 ...

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