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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 Pro 18 AWD

Страница 1: ...Workshop manual Rider Pro 18 AWD ProFlex 21 AWD English ...

Страница 2: ......

Страница 3: ...able 47 Replacing the Articulated Steering Bearings 47 Removing the Pendulum Shaft 50 Replacing Bushings 50 Fitting the Pendulum Shaft 51 Pump Unit 52 Drive Axles 55 Front Axle 55 Rear Axle 60 Seal Replacement Outgoing Shafts 64 Replacing the Hydrostatic Transmission Cable 67 Fitting the Hydrostatic Transmission Cable 69 Bleeding the Hydrostatic and Hydraulic Systems 72 Transmission Maintenance 74...

Страница 4: ...c Hygiene 113 Hydraulic Oils 113 Fixing Oil Leaks 113 Keep the Hydraulic Oil Clean 114 Working Methods 114 Component Locations 115 Bleeding the Hydraulic System 116 Power Steering 116 Replacing the Lift Cylinder ProFlex 116 Valve Assembly ProFlex 117 Hose Bundle 122 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 ...

Страница 6: ... disconnected 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 connection cable usually the black negative cable first and connect it last Exercise care with tools so that short cir...

Страница 7: ...ansmission are specified in resp Workshop Manuals 506 66 48 01 Engine belt pulley remover 506 56 76 01 Allen key 5 16 for loosening the engine belt pulley s Allen screw Kawasaki 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 8009 519 ...

Страница 8: ...English 6 SPECIAL TOOLS The figures show how the special tools are used 506 56 76 01 8009 518 8009 517 8009 515 8009 194 ...

Страница 9: ...000mm 3 28 ft Max permitted slope 15 15 Wheels Tyre dimensions 165 60 8 195 65 8 Air pressure front and rear 60 kPa 0 6 bar 9 PSI 60 kPa 0 6 bar 9 PSI Engine Manufacturer Kawasaki Kawasaki V Twin V Twin Model FH531V DS50 FH641V DS50 Power 13 2 kW 18 hp 15 5 kW 21 hp Displacement 494 cm3 30 1 cu in 675 cm3 41 19 cu in Fuel at least 87 octane unleaded at least 87 octane unleaded Tank volume 17 litre...

Страница 10: ...ircuit 45 bar 630 PSI 45 bar 630 PSI Tightening Torques Drive disc steering 5 10 Nm 3 5 7 lbf ft 5 10 Nm 3 5 7 lbf ft Line pulley steering cable 20 30 Nm 14 21 lbf ft 20 30 Nm 14 21 lbf ft Belt pulley 35 40 Nm 25 28 lbf ft 35 40 Nm 25 28 lbf ft Blades M10 bolt 45 50 Nm 32 36 lbf ft 45 50 Nm 32 36 lbf ft Blades M12 bolt 75 80 Nm 53 56 lbf ft 75 80 Nm 53 56 lbf ft Blade bearings 20 25 Nm 14 18 lbf f...

Страница 11: ...mechanical lifting lever 2 mm 1 16 Combi 94XP Combi 103 Cutting width 940 mm 37 1 030 mm 40 5 Cutting heights 30 90 mm 1 19 3 56 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 1 050 mm 41 5 1 115 mm 45 5 Weight 52 kg 115 lb 48 kg 106 lb Combi 112 Combi 122 Cutting width 1 120 mm 44 1 220 mm 48 Cutting heights 40 100 mm 1 57 3 93 40 100 mm 1 57 3 ...

Страница 12: ...English 10 SPECIFICATIONS ...

Страница 13: ... leaving the machine for service every 300 hours The effects of service and maintaining a service journal on the machine s resale value Application areas for mulching 15 Fill in the sales papers etc After the First 8 Hours 1 Change engine oil After the first 50 hours 1 Change the oil in the hydraulics and drive system 25 Hour Service 1 Clean the air filter s pre cleaner foamed plastic Shorter inte...

Страница 14: ...tic 300 hours 3 Replace the air filter s paper cartridge 200 hours 4 Change the engine oil 100 hours 5 Replace the engine oil filter 200 hours 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 plugs 100 hours 10 Change the inline fuel filter 100 hours 11 Clean replace the pulse air...

Страница 15: ...ng the engine oil level 19 Check the fuel pump s air filter Check the safety switch seat 111 Check the safety switch lifting lever 111 Check the safety switch pedal system 111 Check clean the engine s cooling air intake Check the cutting unit 95 Attaching the blades 101 Condition of the blades sharpness shape etc 105 Check the steering cables any play etc 42 Check fastenings screws nuts etc Start ...

Страница 16: ...rake cable Lubricate the throttle Lubricate the choke control Lubricate the guide chain in the frame tunnel Check the steering cables in the frame tunnel 42 Clean the engine s cooling air intake Clean the air filter s pre cleaner foamed plastic Change the engine oil1 41 Clean the air cleaner s filter cartridge 2 paper filter Check adjust the cutting height 96 Check adjust the parking brake 45 Insp...

Страница 17: ...pulse air filter 40 Clean the cooling fins Check the play in the engine valves4 Check whether the oil needs changing in hydraulic system4 5 every 200 hours 72 Replace the suction filter in the hydraulic tank4 every 200 hours 73 Change the air cleaner s pre filter foamed plastic 2 Replace the air filter paper filter 2 every 200 hours Perform the 300 hour service 4 12 Maintenance Page Daily mainte n...

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 t...

Страница 19: ... packaging The machine then stands on the base with the brakes on and is secured with wooden blocks 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 NumberComponent 1...

Страница 20: ...tery 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 Arm Supports In those cases where arm supports are delivered with the machine it is the dealer s responsibility to fit them WARNING Actions with acid contact External...

Страница 21: ...g 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 into place Pull out the dipstick and read the oil level The oil level should be between the markings on the dipstick If the level is approaching the A...

Страница 22: ...ld be 60 kPa 0 6 bar 9 PSI on all wheels Highest permitted pressure 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 8009 603 Transmission cover 8009 702 Sight glass IMPORTANT INFORMATION Check and top up with oil after test running If there are air pockets in the transmission or hydra...

Страница 23: ...ke works Check driving forwards 1 and in reverse 2 Check that the starter does not work when one of the hydrostat pedals is pressed 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 one of the hydrostat pedals is pressed Check that the starter does not work when the cutting unit is in the lowe...

Страница 24: ...specting the Muffler Check that the muffler is fitted securely Temperature variations and vibrations can mean that the tightening torque for the screws drops The screws should be checked to ensure the correct tightening torque The check should be made after test running as any paint will then be burnt off The tightening torque should be approximately 10 Nm 8009 327 Cutting height setting 8009 326 ...

Страница 25: ...ngine 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 fill in the serial number on page 4 in the Operator s manual and to confirm that the delivery service has been performed in the service journal 8009 228 Pre deliv...

Страница 26: ...English 24 DELIVERY AND DEALER SERVICE ...

Страница 27: ...to the largest the Rider 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 tools throughout the year...

Страница 28: ...ION Rider ProFlex is equipped as standard with cutting unit type Combi 112 or Combi 122 Rider Pro 18 can be supplied with Combi 94 Combi 103 or Combi 112 8009 601 Combi 94 8009 288 Combi 103 8009 288 Combi 112 8009 290 Combi 122 ...

Страница 29: ...starter The sticker 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 sticker located on the front of the housing on the left hand drive shaft The type designation is stated above the barcode and starts with the letter K The serial number is stated above the barcode and has the prefix s n The manufactur...

Страница 30: ...below contains the model numbers for the different Rider models These should be stated when ordering manuals Model Kawasaki s engine type Rider Pro 18 AWD FH531V DS50 Rider ProFlex 21 AWD FH641V DS50 It is important that only original spare parts are used to repair the engines If other parts are used the guarantee is invalidated The machines have twin cylinder overhead valve engines with pressure ...

Страница 31: ...m 8 12 depending on model The servo steering obtains its pressure from the pump to the hydrostatic transmission The power steering is mounted in the steering column and its stator section is fitted in the power steering housing which is the front section of the machine s frame The steering servo is in principle a hydraulic torque motor that is controlled by the steering wheel When there is no hydr...

Страница 32: ...flow of the oil It is controlled by the hydrostatic pedals via cables 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 Rear axle on Rider ProFlex AWD from the top Designed in...

Страница 33: ...her drains the differential On the AWD machines pressure is provided to the transmission from an axial piston pump This is built together with the inverted gear pump which feeds the hydraulic system The hydraulic system includes the servo steering and on ProFlex the equipment lift too 8009 631 Oil drainage 8009 615 Hydraulic pump ...

Страница 34: ...while ProFlex AWD has both mechanical and hydraulic lift The cutting unit can be raised or lowered in two different ways with the mechanical lifting lever or with a hydraulic cylinder Both methods work by rotating a shaft When the shaft is rotated the chain attached to a segment inside the end of the shaft will raise or lower the equipment frame When lowering the unit the two connecting rods via t...

Страница 35: ... the top of the cutting unit cover The upper one is coupled between the horizontal connecting rod and the tongue of the forward perpendicular shaft on the top of the cutting unit cover When the shaft is rotated it will raise or lower the cutting unit cover in relation to the protective frame The lower strut the parallel strut is coupled between the tongues on the forward and rear perpendicular sha...

Страница 36: ...English 34 DESIGN AND FUNCTION 8009 400 Cutting height adjustment ProFlex 21 ...

Страница 37: ...e clips holding the throttle and choke cables Unhook the cables from their fasteners in the carburettor The picture shows ProFlex 21 For Pro 18 see Fitting the Engine on page 37 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 ...

Страница 38: ...pe and accompanying pulse air valve 10 Remove the belt guide for the engine belt pulley On machines with a skid guard the skid guard must be removed 11 Push tool no 506 56 76 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 8009 035 Muf...

Страница 39: ... lbf ft The battery s negative cable should be attached to the forward left screw The hydraulic cylinder fixture should be attached to the forward right screw on ProFlex 8009 518 Engine belt pulley remover 8009 192 The engine s fastening screws right side Mount not shown 6019 039 Engine shaft and belt pulley IMPORTANT INFORMATION When fitting the engine it is important that the belt pulley s groov...

Страница 40: ... throttle position Push the cable s outer casing as far to the left 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 The illustration shows Pro 18 For ProFlex 21 see Removing the Engin...

Страница 41: ...st the fuel pump and attach the hose clamp 8 Screw the cable from the starter to the start relay into place Attach the engine s electrical connectors 9 Lift the battery into position and attach the cable connectors and cover tighten the fastening strap 8009 035 The muffler s protective plate 8009 191 Fuel pump 8009 190 The engine s electrical connections IMPORTANT INFORMATION Hold the battery cabl...

Страница 42: ... the fuel filter with the hose clamp Make sure that the hose cannot be chafed or rubbed 2 Place the tank in place on the bracket and attach it with the screws and washers 3 Fit the fuel hose and the hose clamp to the connector under the tank as required Fill with petrol and check that there are no leaks Pulse Air Valve Intake Filter Cleaning the pulse air filter 1 Fold the seat back open the engin...

Страница 43: ... screwed into place Take the dipstick out again and read the oil level The oil level should be between the markings on the dipstick If the level is approaching the ADD mark top up the oil to the FULL mark on the dipstick Never fill above the FULL mark The oil is topped up through the hole the dipstick sits in Use engine oil SAE 30 SAE 10W 30 or 10W 40 class SF SJ over 0 C 32 F Over 20 C 68 F SAE 4...

Страница 44: ...e cables so that 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 ...

Страница 45: ...and unscrewing the stop screw and then lifting the steering wheel and steering rod upwards 5 Remove the power steering housing s protective cover and the rubber bellows 6 Disconnect the electrical cables for the lighting 7 Remove the circlip 5 and the bellows holder 7 on the top of the power steering 8 Clean see Working Methods on page 114 Loosen the hydraulic hoses from the power steering 9 Remov...

Страница 46: ... 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 After mounting the cable tension should be checked see Remove the frame plate by loosening the screws two on the power steering housing on page 42 Ensure that the steering wheel is in the centre position when the rear wheels are centred Re set the chain on the...

Страница 47: ...ve the left hand wing cover 2 Check that the parking brake is not on 3 Adjust the play between the casing and the adjustment screw to 1 mm 0 040 when one pulls the casing This gives play on the pedal of approximately 40 mm 1 5 Adjust using the nuts on the adjustment screw 4 Tighten the nuts moderately to avoid damaging the threads 5 Check that the parking brake works 6 Assemble the left hand wing ...

Страница 48: ...k nut for the socket on the cable Checking and Adjusting the Throttle Cable The picture shows ProFlex 21 For Pro 18 see Fitting the Engine on page 37 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 Loosen the clamping screw for the cable s outer casing and m...

Страница 49: ...uter casing and move the choke lever 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 Engine on page 35 2 Jack up the rider in front of the arti...

Страница 50: ...r part forwards the upper 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 ...

Страница 51: ...Fit the new bearings and mount the articulated steering in the reverse order as set out for dismantling 14 After mounting the cable tension should be checked see Remove the frame plate by loosening the screws two on the power steering housing on page 42 Check that the controls and cables are properly adjusted see Adjusting the Hydrostatic Transmission Cable on page 46 15 Bleed the hydraulic system...

Страница 52: ...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 on page 5 New bushings are fitted with the punch see Special Tools on page 5 Make sure that the bushing grooves are lined up horizontally It is important that the...

Страница 53: ... 4 Roll the rear frame forward and press it onto the pendulum shaft 5 Fit the washer and circlip on the pendulum shaft 1 6 Connect the hydraulic hose to the hydrostatic transmission 7 Fit the pump unit see Pump Unit on page 52 8 Check that the controls and cables are properly adjusted see Adjusting the Hydrostatic Transmission Cable on page 46 9 Check the neutral position contact and adjust if nec...

Страница 54: ...aced without dismantling the pump unit however to gain better access it is recommended that the entire unit is removed When dismantling and assembling separate hydraulic pumps follow this instruction in applicable parts Removal 1 Remove the pump s drive belt from the pump pulley see Replacing the Hydraulic Pump s Drive Belt on page 76 2 Release the external hydraulic hoses from the hydraulic tank ...

Страница 55: ...mp 5 Remove the spring lock and the hydrostatic transmission cable s rear link joint from the arm on the hydraulic pump 6 Remove the mounting bolts for the pump unit and lift up the unit 8009 645 Connections pump 8009 203 Locking spring 8009 646 Link joint 8009 648 Mounting bolts ...

Страница 56: ...nnect the hydraulic hose on the front of the pump 2 Put the pump unit in position 3 Connect the other hydraulic pipes and hoses Do not tighten the couplings 4 Fit the mounting bolts for the pump unit 5 Tighten the hydraulic pipes and hydraulic hoses 8009 647 Hydraulic hose 8009 647 Hydraulic hose 8009 704 Pump unit 8009 648 Mounting bolts ...

Страница 57: ...low the instructions under Hydraulic system Hydraulic Hygiene Counterhold using a spanner when releasing and tightening the coupling nuts so that the hoses or angled nipples are not exposed to twisting strain ProFlex AWD has separate hubs Pro AWD has hubs and rims as a single unit Front Axle The equipment frame on Pro AWD should not be dismantled Removal 1 Remove the cutting unit see Removing the ...

Страница 58: ...se the front synchronisation link for speed from the front axle 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 621 Circlip 8009 693 Synchronisation link 8009 631 Oil drainage 8009 623 Hydraulic pipe ...

Страница 59: ... protective 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 624 Hydraulic pipe top 8009 628 Right front axle mounting 8009 629 Left front axle mounting 8009 630 Rear front axle mounting ...

Страница 60: ...ronisation link is fitted in the upper hole on Pro 18 AWD and in the lower hole on ProFlex 21 AWD Below the holes for the synchronisation link is a hole for the release control 4 Grease the axles for protection against corrosion before the wheels are fitted 5 Fill with oil and vent the entire hydraulic system according to Bleeding the Hydrostatic and Hydraulic Systems on page 71 6 Check and adjust...

Страница 61: ...ys spacers and washers keep a check of the number of washers this can vary between sides 3 Drain out the oil if necessary two plugs 4 Release the hydraulic pipe from the underside of the rear axle Fit the protective plugs A small amount of oil will leak out even if the axle has not been drained 8009 651 Jacking up 8009 621 Circlip 8009 631 Oil drainage 8009 706 Hydraulic pipe underside ...

Страница 62: ...e protective plugs A small amount of oil will leak out even if the rear axle has not been drained 6 Remove the five bolts holding the rear axle and lower the rear axle 8009 644 Hydraulic pipe top 8009 656 Mounting bolts left side 8009 655 Mounting bolts right side 8009 657 Mounting bolt rear axle ...

Страница 63: ...ding the Hydrostatic and Hydraulic Systems on page 71 5 Check and adjust the speed coordination between the front wheels and rear wheels according to the separate instruction Synchronising Front and Rear Wheel Drives The front and rear wheel drives must be synchronised so that when cornering the front wheels run at a higher speed than the rear wheels When driving straight forwards all wheels shoul...

Страница 64: ...t changed during the following test Run the wheels at least 10 revolu tions in one direction and check whether the markings on the wheels still align and that they rotate at the same speed 8 Stop the engine 9 Adjust the synchronisation of the wheel speed on the long horizontal link rod It is designed like a rigging screw and can remain in position when making changes A longer rod gives a higher sp...

Страница 65: ...ft 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 Remove the circlip 5 Insert a screwdriver between the seal and the shaft and pry off the seal from the shaft housing with a twisting motion 8009 621 The hub s circlip IMPORTANT INFORMATION Dirt must not enter the transm...

Страница 66: ...he seal down until it is seated in the bottom of the shaft housing Tap only on the seal s steel casing Move the extender in a circle around the seal so that it is pressed down evenly all around and is tight against the shaft 9 Refit the circlip 10 Remove the insulation tape from the shaft and repeat the entire procedure as needed for the other shaft 11 Replace the washer spacing tube key hub circl...

Страница 67: ...e in the sight glass The machine should stand flat and the oil should have a temperature of approximately 20 C 13 Bleed the hydraulic system of excess air 14 Run the rider and make sure that there are no oil leaks from the new shaft seals 15 Check the oil level after test running and top up as needed 8009 702 Sight glass ...

Страница 68: ...er steering housing 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 4 Remove the transmission cover 8009 340 Frame plate Front locking nut and locking spring 6019 010 8009 203 6019 015 Front clamp 8009 603 Transmission cover ...

Страница 69: ... hydrostatic transmission cable s rear link joint from the arm on the hydraulic pump 7 Lift off the link joint and pull out the cable 8 Lift out the hydrostatic transmission cable and the accompanying link joint 9 Unscrew both link joints from the hydrostatic transmission cable 8009 204 Cut the plastic tie 8009 685 Rear link joint 6019 016 Lift off the link joint 6019 017 Remove the link joints ...

Страница 70: ... 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 On page 36 a view from the right is shown 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 Thre...

Страница 71: ...tic 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 9 Adjust the hydrostatic transmission cable as shown see Adjusting the Hydrostatic Transmission Cable on page 46 6019 023 Forward mount in centre bracket 6019 024 Front cl...

Страница 72: ...ee Micro Switch Pedal Arrangement on page 112 13 Fasten the hydrostatic transmission cables with a plastic tie 14 Screw on the frame plate two screws 15 Test drive the machine forwards and in reverse If the machine drives in neutral the spring s cams may be adjusted incorrectly 8009 203 Locking spring 6019 019 Fastening with a plastic tie 80 8009 340 Frame plate 8009 740 The spring s cams ...

Страница 73: ...ering wheel repeatedly from one extreme position to the other until the steering works without jerks or stops 9 ProFlex run the hydraulic cutting unit between its end positions repeatedly Hold the lever still for 0 5 1 second to ensure that the hydraulic cylinder reaches its end position 10 Close the bypass valves and test drive the machine 11 Finally check the hydrostatic transmission oil level a...

Страница 74: ...nstructions in the hydraulic system chapter Hydrostatic Transmission Front Axle Rear Axle The transmission holds 5 litres 5 2 US qt SAE 10W 40 engine oil class SF CC 1 Drain the hydrostatic transmissions using the two plugs on each axle 2 Refit the drain plugs Fill with oil through the fill hole in the hydraulic tank 3 Bleed the transmission see Bleeding the Hydrostatic and Hydraulic Systems on pa...

Страница 75: ...aulic tank 6 Remove the four screws on the top of the hydraulic tank holding the suction filter unit and lift up the suction filter unit 7 Replace the filter on the suction filter unit 8 Check the inside of the hydraulic tank Use a lamp There must be no visible contamination 9 Guide the seal on the suction filter unit and refit it on the tank Turn the bevelled side towards the filling hole 10 Conn...

Страница 76: ...e so that it is damaged when the unit is lifted It can be loosened if needed and the engine started with bypassed safety circuitry for the next step 4 PF 21 Lift the unit fully with the hydraulic lifting lever Hold the lever still for 0 5 1 second to ensure that the hydraulic cylinder reaches its end position Pro 18 Hold up the unit with the mechanical lifting lever as high as possible 5 Make sure...

Страница 77: ...djust with the adjustment screw 3 against the cylindrical pin so that a distance of 38 2 mm is maintained between the frame structure and the outermost corner of the belt adjuster arm see illustration This measurement applies to new belts and as a starting point for used belts 11 Lower the cutting unit completely to the ground 12 Check that the connecting rod has play along the oblong groove in th...

Страница 78: ...acing the Hydraulic Pump s Drive Belt Removal 1 Remove the transmission cover 2 Unhook the spring on the belt tensioner 3 Remove the belt guide for the centre belt 8009 603 Transmission cover 8009 637 Belt tensioning 8009 727 Belt guide ...

Страница 79: ... the cooling fan Counter hold using a punch in one of the holes on the underside of the fan when the nut is loosened 6 Pull the cooling fan out backwards 7 Pull the pump belt off of the pump s pulley 8 Pull the pump belt off of the engine s pulley and move it under the engine belt pulleys 9 Pull out the pump belt through the opening under the pivot bearing and past the belt tensioner s disc 8009 6...

Страница 80: ...t the cooling fan 14 Tighten the cooling fan nut Counter hold using a punch in one of the holes on the underside of the fan when the nut is tightened 15 Refit the clamp on the hydraulic pipes located under the fan Tighten the pipe connections on the pump 16 Check that the centre belt is fitted correctly on its front pulley and fit the centre belt on the engine s pulley 8009 640 Pump belt under the...

Страница 81: ...the Centre Belt On Rider 21 AWD the spring loaded belt guide under the blade brake on the centre pulley must be pressed in to be moved past the centre belt 1 Remove the rear belt guide for the centre belt 2 Remove the centre belt and mount a new belt 8009 736 Belt guide 8009 637 Belt tensioner spring 8009 737 Rear belt guide ...

Страница 82: ...lt on the engine belt pulley 4 Check and adjust the belt tensioner 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 8009 736 Belt guide 8009 401 Check the belt tensioner ...

Страница 83: ...he service position 2 Pull the 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 6017 227 Service position 8009 684 Belt tightening 8009 596 Runner and te...

Страница 84: ... 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 gear 8009 595 Tongue in the loop 8009 122 Press back ...

Страница 85: ...elt becomes slack when the cutting unit is lifted 4 Press in the spring loaded belt guide under the blade brake on the centre pulley and remove the belt 5 Remove the front belt from the centre pulley in the same way as the centre belt and pull out the front belt forwards Assembly Check before assembling that the new belt is the correct length compare with the old 1 Position the front belt in place...

Страница 86: ...spring loaded belt guide under the blade brake position the centre belt and pull it onto the centre pulley 6 Fit the cutting equipment Equipment Frame Removal 1 Remove the cutting unit see Removing the Cutting Unit Pro 18 on page 89 2 Set the equipment frame in its uppermost position past the stop bracket 8009 689 Tightening the belt 8009 343 Guide plate 8009 616 Equipment frame in uppermost posit...

Страница 87: ...nt from the triangular link 6 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 7 Remove the equipment frame s rear guide screws In order to completely lower the equipment frame on the left hand side it must first be pulled back 8009 635 Control m...

Страница 88: ...verse order in relation to dismantling 4 Adjust the ground pressure see Checking and Adjusting the Ground Pressure on page 97 The Cutting Unit Components ProFlex In the instructions below a cutting unit with a rear ejector is shown but the same principles apply to all cutting units unless otherwise stated The components mentioned are A Catch B Interior plug C Safety catch D Handle E Height adjustm...

Страница 89: ...d on the cutting unit 1 2 Grasp the handle on the front of cutting unit s frame 2 and push the unit in under the Rider Make sure the tongue 3 on the unit mates correctly 3 Fit the screw and secure with a locking pin WARNING Wear protective glasses when assembling the cutting unit The springs that tension the belt can fly off and cause personal injury 1 2 3 6017 159 Cutting Unit 8009 595 Tongue in ...

Страница 90: ...rive belt around the unit s drive pulley 6 Hook in the height adjustment stay 7 Fit the anti scalp rollers in position 8 Fit the front cover 9 Secure the springs on the adjuster pulley 8009 596 Runner and tension wheels WARNING Observe caution to avoid trapping your hand 8009 699 Assembling the pin and belt 8009 439 Support wheels 8009 598 Adjuster pulley s spring ...

Страница 91: ...ing 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 Pro 18 1 Place the machine so it is flat Activate the parking brake A Set the cutting deck to the lowest cutting height and lower the cutting unit B WARNING Wear protective glasses when dismantling the cutting un...

Страница 92: ...er the front cover 4 Fit the two anti scalp rollers on each side of the cutting unit s rear section 5 Loosen the spring on the drive belt s belt idler 6017 219 Dismantling the front cover 6017 220 Support wheels 6017 221 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 8009 ...

Страница 93: ...ont edge to make it easier to loosen the height adjustment stay 7 Secure the height adjustment stay in the holder 8 Lift off the drive belt 1 Now pull out the split pin 2 8009 122 Loosen the height adjustment stay 6017 223 Height adjustment stay WARNING Observe caution to avoid trapping your hand 2 1 6017 225 Drive belt and split pin ...

Страница 94: ...s now holding the cutting unit is removed the cutting unit can be lifted off Releasing the Service Position Pro 18 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 6017 226 Refit the split pin 6017 227 Service position 8009 595 Tongue in the loop ...

Страница 95: ...in the inset position Unit frame mounted on the cutting unit see Dismantling the Equipment Frame ProFlex on page 100 1 Attach the unit to the equipment frame s outer hooks 2 Pull out the catch A and loosen the safety catch by pushing its handle D back 3 Raise the unit by pulling up the mechanical lifting lever located on the driver s right side 4 Push the unit in so that the interior plugs B touch...

Страница 96: ...he front belt pulley A new belt is short Turn the forward pulley as needed with a spanner on the central bolt 7 Re attach the belt tensioner spring Belt Sketch 1 Drive belt 2 Forward pulley 3 Belt idler 4 Belt tensioner spring 8 Attach the nose cover E 8009 168 Height adjustment handle WARNING Watch your fingers Do not turn the blades or the belt 8009 008 Belt tensioner spring IMPORTANT INFORMATIO...

Страница 97: ...sm Always start by adjusting the parallelism 1 Loosen the two nuts on the strut 2 Measure the distance between the ground and the front and back edges of the unit s cover 3 Place a spanner over the bevel in the middle of the strut and tighten so that the cutting unit s rear edge is 2 4 mm 1 8 higher than its front edge Screw out extend the strut to raise the rear edge of the cover Screw in shorten...

Страница 98: ...ribed in the next section 6 Attach the nose cover Adjusting the Cutting Height Range 1 Remove the plastic cover over the hydraulic valve block on ProFlex 21 or the plastic cover between the seat and the lever housing on Pro 18 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 r...

Страница 99: ...d be between 12 and 15 kg 26 5 33 lb and the springs evenly tensioned The Cutting Unit s Service Position ProFlex In order to provide good accessibility 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 ProFlex 1 Place the unit so that it hangs on the o...

Страница 100: ...ing unit with the mechanical lifting lever 4 Remove the nose cover 5 Loosen the belt tensioner spring 6 Remove the belt from the front pulley 7 Re attach the belt tensioner spring 8 Hang the belt around the handle 8009 328 Lock the brake WARNING Exercise caution Risk of crush injuries 8009 007 Mechanical lifting lever and nose cover 8009 008 Belt tensioner spring 8009 009 Placement of the belt ...

Страница 101: ...as come out a bit 11 Pull out the unit so that it catches on the outer hooks In this position the unit can be set in the service position when required 12 Lower the unit with the mechanical lifting lever 13 Pull the handle D so that the safety catch locks Check that the catch A is in the inset position 14 Remove the unit from the machine 8009 169 Height adjustment strut 8009 170 Pull forward 8009 ...

Страница 102: ... Combi 94 103 112 122 On cutting units with collision proof blades the blades are driven by a V belt Do as follows to replace the V belt 1 Loosen the equipment frame 1 on ProFlex bolt on the parallel strut 2 and the two screws on the cover 3 Lift off the cutting unit cover 2 Loosen the spring 4 that tensions the V belt and pull the belt off Attach a new belt in the reverse order Position the belt ...

Страница 103: ...ulley 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 and remove the blade bolt washer and blade 5 Loosen the four screws that hold the blade bearing and remove the entire bearing assembly from the cut...

Страница 104: ...ngs Fit in the reverse order to removal Make sure that the shaft is mounted in the same direction as when it was removed otherwise the keys will not fit the grooves Tighten the blade bearings with a torque of 20 25 Nm 14 18 lbf ft Tighten the blade bearings with a torque of 45 50 Nm 32 36 lbf ft 6012 084 Removing the hub 6012 085 Removing the protective washer 6012 086 Removing the shaft 6012 087 ...

Страница 105: ...he nuts which hold the bearing housing in position from the top of the cover Make sure that the unit is positioned with the belt pulley against the unit s cover 5 Place a wooden block under the unit cover so that the blade is free from the supporting surface Knock on the screws to remove the belt pulley Do not knock hard enough to deform the cover If the belt pulley is stuck heat it with a hot air...

Страница 106: ...rwise the keys will not fit the grooves Blade bearings are tightened with a torque of 20 25 Nm 14 17 lbf ft Tighten the belt pulley with a torque of 45 Nm 32 lbf ft Tighten the blade bearings with a torque of 75 80 Nm 53 56 lbf ft An oil filter wrench for example can be used to hold the pulley in place when the screw is tightened 8009 295 Removing blades 8009 296 Removing the hub IMPORTANT INFORMA...

Страница 107: ...a cutting unit with rear ejection remove the BioClip plug which is located under the unit attached with three screws 1 Put the cutting unit in the service position see The Cutting Unit s Service Position ProFlex on page 97 and page 89 for Pro 18 2 Remove the three screws holding the BioClip plug and remove the plug 3 Tip Fit three full thread screws M8x15 mm in the screw holes to protect the threa...

Страница 108: ...English 106 REPAIR INSTRUCTIONS ...

Страница 109: ... 2 Microswitch cutting unit 3 Microswitch seat 4 Ignition lock 5 Chronometer 6 Start relay 7 Starter 8 Fuse 15 A 9 Fuse power outlet 10 Mains switch power outlet 11 Power outlet 12 Mains switch lighting 13 Headlight 14 Headlight 15 Generator 16 Fuel valve 17 Charge regulator Key for colour abbreviations in wiring diagram RD Red BL Blue VT White SV Black GL Yellow GR Grey BR Brown ...

Страница 110: ...English 108 ELECTRICAL SYSTEM 8009 679 Wiring diagram AWD ...

Страница 111: ...The chronometer may be attached with nuts bolts and spring washers if suitable rivets are unavailable 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 The fuse for the power outlet is placed under the ignition switch behind the side plate on the control panel Type Flat pin 7 5 A Do not use any other type of fuse when rep...

Страница 112: ...sing Lift up the cover and turn it around the steering shaft 2 Unscrew the two screws holding the lamp insert Lift out the lamp insert 3 Disconnect the cables from the bulbs 4 Lift out the bulbs from the insert 5 Insert the new bulbs Make sure you use your thumb to support the front 6 Refit the cables lamp insert and the cover on the power servo housing 8009 511 8009 512 8009 513 8009 522 ...

Страница 113: ...ing 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 or the hydrostat pedals are not in the neutral pos...

Страница 114: ... Pedal Arrangement 1 Remove the transmission cover 2 Check the hydrostatic cable adjustment See Adjusting the Hydrostatic Transmission Cable on page 46 3 Remove the cover from the frame tunnel 4 Adjust the microswitch so that it clicks when the parking brake pedal is pressed down approximately 40 mm 1 5 Note The spring on the parking brake cable can be unhooked to improve accessibility 5 Replace t...

Страница 115: ...from the system which are due to the oil 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 ins...

Страница 116: ...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 117: ...purities The control valve on the ProFlex is a gate valve The lever is found in the lever housing to the rear and is connected to the slider Pressure supply and exhaust takes place via the valve block Hydraulic oil for the lift cylinder is provided via two hoses The hose s nipple for the cylinder s piston side is equipped with a throttle Between the slider and the throttle there is a mechanically ...

Страница 118: ...to the forward mounting A washer is placed on each side of the cylinder ear in the fork Secure the cylinder bolt 7 Connect the hydraulic connectors Counter the angled nipples Twist the hoses so that they do not chafe against any sharp edges The front hose on the cylinder shall run to the upper connector on the valve block 8 Attach the hydraulic cylinder to the rear mounting A washer is placed on e...

Страница 119: ...ove the valve block in a downwards direction 6 Hold the valve block in place and attach the fastening screws 7 Connect the hydraulic connectors Twist the hoses so that they do not chafe against any sharp edges The upper hose on the valve shall run to the forward cylinder connector and be pointed forwards so that it is free from the cover 8 Remove the transmission cover and top up with transmission...

Страница 120: ...sion top up if necessary The oil filter holds 0 3 litres 0 3 US qt of oil 7 Replace the transmission cover Control Valve Replacement ProFlex 1 Lower the cutting unit to the ground Stop the engine 2 Remove the plastic cover from the hydraulic valve block 3 Clean see Working Methods on page 114 4 Hold the valve block nipples in place and loosen the hydraulic connectors from the control valve A small...

Страница 121: ... screws fitted with spacing tubes 9 Refit the nipple without the throttle with the washer in the connector for the upper hose 10 Connect the hydraulic connectors Twist the hoses so that they do not chafe against any sharp edges The upper hose on the valve shall run to the forward cylinder connector and be pointed forwards so that it is free from the cover 11 Remove the transmission cover and top u...

Страница 122: ...on the lower part under the slider hole 4 Remove the check valve Set the tool to the wide wrench setting 15 mm 5 Remove lever housing and lever By lifting the lever housing and twisting the lever backwards it can be unhooked from the hole in the slider 6 Remove the plastic plug and unscrew the spring holder with a 12 mm Allen key 8009 389 Check valve 8009 390 Lever housing with lever 8009 391 Spri...

Страница 123: ...ken apart for cleaning if necessary 11 Lubricate and place the o ring in its position in the front section Check that it is properly seated 12 Thread on the spacing ring length 7mm 0 28 on the slider 13 Make sure that the o ring is not damaged by lubricating the slider and coaxing the slider into place Insert the slider completely into the valve housing 14 Fit the spring holder and plastic plug 15...

Страница 124: ...machine are collected into a hose bundle This is held together by means of a plastic hose protection which is wound around the hoses When manufactured the hoses are colour coded but this may wear off or be damaged It is then possible to identify the hoses by the punched part numbers 1 Yellow 535 47 85 01 2 Blue 535 48 84 01 3 Green 535 48 78 01 4 Black 535 48 77 01 5 Red 544 01 71 01 8009 390 Asse...

Страница 125: ...oned correctly lengthwise in the bundle Green is connected to the rear connection on the hydrostatic motor Red blue and yellow are connected to the front of the pump 2 Collect the hoses in two layers green yellow and red blue in their pipe holders 3 Guide the end of the hose protection between the two layers and wind the protection 4 turns 4 Insert the black hose on the left hand side of the bundl...

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

Страница 127: ...g Replace 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 Cl...

Страница 128: ... 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 diffuser jets Too ...

Страница 129: ...shaft s pulley slips 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 The suction filter in the tank is blocked 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 wrong...

Страница 130: ... an object Belt worn Coordination 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 driv...

Страница 131: ...Overheating other indications Overheated transmission Poor air circulation Damaged or loose fan Replace or tighten the fan Fill with engine oil to the correct 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 to wrong port Move t...

Страница 132: ... the belt 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 Cutti...

Страница 133: ...2005W14 115 00 64 26 ...

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