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9 Troubleshooting

9.1 Troubleshooting schedule

Fault

Possible

cause

Steps

Troubleshooting

Action

The start motor does not

start when the key

switch is turned to

START.

Cutting deck

lowered.

Make sure that the lift lever is in the

top position.

Parking brake

not applied.

Do a check of parking brake.

Apply parking brake.

Low battery

voltage.

Make sure that the 15A fuse is not

damaged.

Replace the fuse.

Measure the battery voltage, >12.0V. Charge the battery.

Measure the voltage of the red cable

connected to the ignition switch. The

voltage must be equal to the battery

voltage.

Repair the cable or re-

place the wiring.

Starter relay

malfunction.

Do a check of of the thin brown cable

between ignition switch and the start-

er relay.

Repair the cable or re-

place the wiring.

Do a check of the black cable be-

tween the starter relay and the nega-

tive terminal on the battery (-).

Repair the cable or re-

place the wiring.

Measure the voltage of the thin brown

cable to the starter relay. When the

key switch is turned to START, there

must be the same voltage in the ca-

ble as in the battery.

Replace the ignition

switch.

Measure the resistance of the relay. It

must be 3.7-4.2 Ω.

Replace the starter re-

lay.

Parking brake

microswitch

malfunction.

Do a check of the parking brake mi-

croswitch.

Replace the micro-

switch.

Lift lever mi-

croswitch mal-

function.

Do a check that the microswitch

changes the position when the lift lev-

er is lifted.

Replace the micro-

switch.

Wiring fault.

Measure the resistance between the

thin black cable to the starter relay

and the negative battery terminal. If

the parking brake is applied and lift

the lever in the top position, the re-

sistance must be low.

Go to next step.

Measure the resistance between the

black cable to the starter relay and

the connector to the wiring to the ped-

al plate 1 pin. The resistance must be

low.

Repair the cable or re-

place the wiring.

Measure the resistance between the

wiring to the pedal plate pin 5 and the

negative battery terminal. The resist-

ance must be low.

Repair the cable or re-

place the wiring.

50 - Troubleshooting

659 - 001 - 11.04.2018

Содержание FR 2213 MA

Страница 1: ...Workshop manual FR 2213MA FR 2216MA FR 2216MA 4x4 English 659 001 11 04 2018 ...

Страница 2: ...evel 7 3 9 To do a check of the transmission oil level 8 3 10 To fill fuel 8 4 Function test 4 1 To do a check of the safety system 9 4 2 Seat safety switch 9 5 Servicing schedule 6 Servicing tools 6 1 Servicing tools 12 6 2 Optical tachometer 12 7 Function overview 7 1 Product overview 13 7 2 Serial numbers on the product 13 7 3 Engine 13 7 4 Transmission 14 7 5 Steering 14 7 6 Cutting deck 15 8 ...

Страница 3: ...air and do servicing All personnel that do repair or do servicing on the product must read and understand the manual 1 4 Safety WARNING All personnel that repair or do servicing on the product must read and understand the safety instructions in this workshop manual 1 5 Revisions Changes to the product can cause changes to the maintenance work and spare parts Separate information is sent out for ea...

Страница 4: ...rotective gloves when you do work on or near the blades The blades are sharp and can give cut injuries Use eye protection when you do work on the cutting deck The belt tension spring can break and cause injury Use eye protection when you do work on the battery with the caps removed If battery acid gets into your eyes or onto your skin clean immediately with much water and get medical aid Explosive...

Страница 5: ...sion to the environment according to the European Community s Directive The product s emission is specified in the Technical data chapter and on the label Always use approved hearing protection Stop the engine Start the engine Engine speed fast Engine speed slow Fuel Max ethanol 10 Cutting height Servicing position for the cutting height lever The blades are engaged The blades are disengaged Servi...

Страница 6: ...own in the illustration 3 4 Hitch The hitch is assembled the wrong way during transport from the factory Remove the hitch and attach it to the bumper as shown in the illustration 3 5 Wheels Note Different tire pressure in the front wheels makes the blades cut the grass at different heights The recommended tire pressure is 0 6 bar 8 5 PSI on all wheels 3 6 To remove and attach the cutting deck 1 Pa...

Страница 7: ...ge of the cutting deck with two hands and pull it out 12 Remove the wooden block 13 Attach the cutting deck in opposite sequence 3 7 To do a check of the parallelism of the cutting deck 1 Make sure that the air pressure in the tires is 60 kPa 0 6 bar 9 0 PSI 2 Park the product on a level surface 3 Lower the cutting deck to mow position 4 Set the cutting height lever to the middle position 5 Measur...

Страница 8: ...ol Note All models do not have a transmission oil tank 1 Remove the screws one on each side and remove the transmission cover 2 Make sure that the oil level in the transmission oil tank is between the 2 horizontal lines on the tank Max Min 3 Fill with engine oil if the oil level is below the lower line but do not fill above the top line See Technical data on page 52 for recommended oil 3 10 To fil...

Страница 9: ...d the parking brake is not applied and the operator lifts from the seat To do a check of the safety circuit try to start the engine with one of the conditions above not met Change the conditions and try again 4 2 Seat safety switch The seat safety switch starts the safety circuit when the operator lifts from the seat The engine and the drive to the blades stop if the blades are engaged or the park...

Страница 10: ...s not blocked X Make sure that the safety devices are not defective X Examine and do a test of the brakes Do a check of the engine oil level O Do a check of the oil level in the transmission O Do a check of the steering cables O Examine the blades in the cutting deck X Clean the cutting deck below the belt covers and below the cutting deck X Make sure that the tire pressure is correct O O Do a che...

Страница 11: ...nce be fore operation Maintenance interval in hours 25 50 100 200 Do a check of the battery O Do a check of the fuel hose Replace it if necessary O Change the oil in the transmission O O 659 001 11 04 2018 Servicing schedule 11 ...

Страница 12: ... Clean the surface to be measured before attaching the reflection tape 3 Put a small piece of reflection tape approximately 1x1 cm on the object to be measured 4 Put the switch to the RPM position for measuring rpm or TOT for measuring the number of revolutions 5 Press and hold the measuring button on the side of the instrument Point the measuring laser beam at the object and the reflection tape T...

Страница 13: ...rial numbers on the product The engine serial number A is found on the left side of the engine The transmission serial number B is found behind the wheels on the left side of the product The product serial number C is found on the printed type plate at the front below the seat From the top the type plate gives the designation the type number from the manufacturer and the serial number s n of the p...

Страница 14: ...lve is operated with a lever adjacent to the front left wheel The bypass valve must be closed when operating or the front transmission will be drained of oil The illustration shows the rear transmission from above To move the product without the rear transmission operation engaged there is a hydraulic bypass valve The bypass valve is operated with a control behind the rear left wheel The hydraulic...

Страница 15: ...in small spaces because of the front attached cutting deck The Combi Deck works almost the same as a BioClip deck when a BioClip plug is attached When the BioClip plug is removed the cutting deck ejects rearward 659 001 11 04 2018 Function overview 15 ...

Страница 16: ...everse pedal A to remove it 2 Remove the 3 screws B and remove the footrest plate A B B B 8 1 1 4 To remove the left footrest plate Remove the 3 screws and remove the footrest plate 8 1 1 5 To remove the transmission cover Remove the 2 screws and remove the transmission cover 8 1 1 6 To remove the frame tunnel cover 1 Remove the 2 screws and remove the frame tunnel cover 8 1 2 Throttle cable 8 1 2...

Страница 17: ... the product on a slope with a hard surface Note Do not park the product on a grass slope when you do a check of the parking brake 2 Press the parking brake pedal 1 down 1 2 3 Press and hold the lock button 2 4 Release the parking brake pedal while the lock button 2 is pressed 5 If the product moves adjust the parking brake 8 1 4 2 To adjust the parking brake on AWD products 1 Remove the left foot...

Страница 18: ...r axle 8 1 6 1 To disassemble the pivoting rear axle 1 Put supports below the product in front of the articulated steering 2 Make marks on the hydraulic hoses to make it easier to connect them correctly when the pivoting rear axle is assembled 3 Disconnect the hydraulic hoses from the couplings below the product 4 Remove the idler spring 5 Remove the hydrostatic transmission cable from the arm and...

Страница 19: ...ls on page 12 2 Attach the new bushings with a drift Make sure that the grooves in the bushings run horizontally 3 Align the outer edges of the bushings with the outer edge of the hole 4 Lubricate the bushings with a lithium based grease 8 1 6 3 To assemble the pivoting rear axle 1 Put the axle into the bushings Note Make sure that the hole on the axle points rearward 2 Attach the washer and circl...

Страница 20: ... and belt guide 4 Remove the drive belt from the engine belt pulley 5 Remove the lock spring on the ball joint for the speed control A B 6 Remove the ball joint for the speed control A A B 7 Remove the clamp on the speed control cable B from the rear frame 8 Make marks on and disconnect the hydraulic hoses from the couplings below the product 9 Loosen the steering cables A and remove the steering ...

Страница 21: ...ables are correctly adjusted See To replace the hydrostat cable on page 36 21 Do a function test of the product 22 Bleed the hydraulic system and fill the transmission oil tank with oil See To bleed the drive system on page 30 8 2 Propulsion system 8 2 1 To remove and install the engine 1 Remove the engine cover See To remove the covers on page 16 2 Disconnect and remove the battery 3 Disconnect t...

Страница 22: ...d and remove the Allen screw that holds the belt pulley and engine together See Servicing tools on page 12 11 Remove the belt pulley from the engine shaft Use a puller if it is necessary See Servicing tools on page 12 12 Remove the 4 engine fixtures 13 Lift the engine to remove it 14 Install the engine in the opposite sequence Note The belt pulley groove must align with the output shaft key Make s...

Страница 23: ...tick correctly before you start the engine Start and idle the engine for approximately 30 seconds Stop the engine Wait 30 seconds and do a check of the oil level again 8 2 3 To replace the engine oil and oil filter If the engine is cold start the engine for 1 2 minutes before you drain the engine oil This makes the engine oil warm and easier to drain WARNING Do not operate the engine for more than...

Страница 24: ...sion oil tank 1 Remove the screws one on each side and remove the transmission cover 2 Make sure that the oil level in the transmission oil tank is between the 2 horizontal lines on the tank Max Min 3 Fill with engine oil if the oil level is below the lower line but do not fill above the top line See Technical data on page 52 for recommended oil 8 2 5 To clean and change the air filter 1 Open the ...

Страница 25: ...eck 0 95 1 1 Make sure the adjustment rod behind the left front wheel is attached to the top hole of the front transmission arm 2 Put the product on the adjustment tool for wheel speed A See Servicing tools on page 12 To prevent measuring faults 2 of the wheels must touch the ground A B C D 3 Put the steering wheel in a central position 659 001 11 04 2018 Repair instructions 25 ...

Страница 26: ...t full speed Then measure the speed of the front wheel it must be between 0 5 lower than the rear wheel speed 7 Stop the engine 8 Adjust the turning speed of the wheels with the adjusting rod First loosen the locknuts A B a A longer rod gives the front wheels a higher speed b A shorter rod gives the rear wheels a higher speed 9 Do a check that the adjustment is correct If not do step 6 8 again 10 ...

Страница 27: ...holder 5 Assemble in opposite sequence 8 3 4 To adjust the microswitch for the parking brake pedal 1 Remove the transmission cover See To remove the covers on page 16 2 Do a check of the adjustment of the hydrostatic transmission cable See To adjust the hydrostatic transmission cable on page 37 3 Remove the frame tunnel cover See To remove the covers on page 16 4 Adjust the microswitch until it cl...

Страница 28: ...e and spill 1 Remove the fender above the fuel tank See To remove the covers on page 16 2 Put a container below the fuel tank to collect the gasoline For information about fuel tank capacity see Technical data on page 52 3 Compress the fuel tank hose to prevent leakage 4 Disconnect the fuel tank hose from the lower connection of the fuel filter 5 Pull the hose through the frame 6 Put the end of th...

Страница 29: ...ith white spirit To only clean the parts that are disassembled is not sufficient Tools and areas from where dirt can fall onto the point of entry while work is in progress must be cleaned Clean the work area with an applicable brush use a cloth to dry the work area If it is necessary clean the work area again Before you disassemble spray the hose connections and the area on the product with white ...

Страница 30: ... of the package 5 Wind the hose protection around all 3 hoses until 80 100 mm from the sleeve on the black hose 6 Connect the front end of the hoses to their pipes 8 5 8 To bleed the drive system CAUTION Read To keep the hydraulic system clean on page 29 before the hydraulic system is repaired CAUTION Air can go into the system Do not run the transmission oil tank empty while you bleed the drive s...

Страница 31: ...mediately 16 Move the product on the adjustment tool for wheel speed and do a test 17 Fill the transmission oil tank again 18 Replace the transmission cover 8 5 9 Drive shafts 8 5 9 1 To disassemble the front transmission Do not disassemble the tool frame Obey the instructions in To keep the hydraulic system clean on page 29 CAUTION Hold the connection nut with a wrench to prevent damage from twis...

Страница 32: ...on 11 Loosen the 2 stop screws and remove the bearing on the right side 8 5 9 2 To assemble the front transmission Obey the instructions in To keep the hydraulic system clean on page 29 CAUTION Hold the connection nut with a wrench to prevent damage from twisting forces to the pipes or elbow nipples 1 Assemble the front transmission in opposite sequence See To disassemble the front transmission on...

Страница 33: ...of and adjust speed coordination between the front wheels and rear wheels See To adjust the wheel speed on page 24 8 5 9 3 To disassemble the rear transmission Obey the directions in To keep the hydraulic system clean on page 29 CAUTION Hold the connection nut with a wrench to prevent damage to the pipes or elbow nipples Note A small quantity of oil can leak although the transmission is drained 1 ...

Страница 34: ...els have different lengths Left 36 3 mm washer Right 45 5 mm no washer Do not mix up with the front axle spacer sleeves 3 Lightly lubricate the pipe couplings before you assemble 4 Fill with oil and bleed the hydraulic system See To bleed the drive system on page 30 5 Do a check of and adjust speed coordination between the front wheels and rear wheels See To adjust the wheel speed on page 24 8 5 1...

Страница 35: ...ase the lifetime of the hydrostatic transmission 1 Remove the wheel See To disassemble and assemble the wheels on page 17 2 Clean all the dirt and corrosion from the input shaft and the area around the seal 3 Put a screwdriver between the seal and the shaft and remove the seal out of the shaft housing A small quantity of oil can leak out 4 Wind insulating tape around the input shaft to prevent daa...

Страница 36: ...nsmission cable 1 Remove the frame tunnel cover See To remove the covers on page 16 2 Loosen the cable locknut for the front hydrostatic transmission turn and remove the locking spring A B 3 Remove the cable clamp for the front hydrostatic transmission that is attached below the tunnel cover 4 Remove the transmission cover See To remove the covers on page 16 5 Remove the locking spring and the bal...

Страница 37: ... correctly above the ball on the lever arm Note Make sure the that locking spring goes through the two holes in the ball socket 7 Turn the ball socket two more times 8 Assemble the ball joint and the locking spring for the ball joint 9 Tighten the locknut for the ball socket on the cable 10 Attach the transmission cover 8 5 11 3 To install the hydrostatic transmission cable 1 Attach the front link...

Страница 38: ... monoxide Attach an exhaust hose before you start the engine indoors 1 Bleed the hydraulic system See To bleed the drive system on page 30 2 Put the product on the adjustment tool for wheel speed See Servicing tools on page 12 3 Turn the adjustment shaft on the transmission to adjust the neutral position A B 4 Start the engine and give it full throttle 5 Loosen the locknut A on the transmission ad...

Страница 39: ...sion oil is dangerous to your skin Clean spills with soap and water WARNING Used oil and filters are dangerous to the environment Discard used chemicals at an applicable disposal location CAUTION Do not tighten the filter lid to much The filter lid is made of plastic This filter is behind the rear transmission and must be changed when the oil is changed Obey the instructions in To keep the hydraul...

Страница 40: ...ation about the position of the drive belt is found on the inner surface of the cutting deck cover 6 Put the tension spring back in its position to apply tension to the drive belt C 7 Attach the front cover 8 Move the cutting height lever from the servicing position to one of the positions with a number 8 6 3 To examine and adjust the ground pressure from the cutting deck A correct ground pressure...

Страница 41: ...e belt shield and tighten the screws 8 Attach the right footrest plate and the front cover 8 6 5 To adjust the cutting height 1 Make sure the cutting height stay is attached to the cutting deck 2 Put the cutting height lever in the lowest cutting height position 3 Remove the right footrest plate See To remove the covers on page 16 4 Adjust the stay for the cutting height adjustment until there is ...

Страница 42: ...des given in Technical data on page 52 5 Attach the blade the washer and the bolt Tighten the bolt with a tightening torque of 45 50 Nm 8 6 7 To disassemble the blade bearings 1 Remove the covers on the cutting deck 2 Remove the belts 3 Remove the screws that hold the pulley Lock the blade with a wooden block 4 Remove the pulley Use a puller if it is necessary 5 Loosen the 4 screws that hold the b...

Страница 43: ... 8 7 Equipment frame 8 7 1 To remove the equipment frame 1 Remove the cutting deck See To remove and attach the cutting deck on page 6 2 Measure the adjustment screw positions Make a note of the values and use them as initial values when assembling 3 Remove the adjustment screws to release the springs 4 Put a small screwdriver through the chain to prevent that the chain goes into the frame 5 Loose...

Страница 44: ...cables do not twist 2 Remove the tunnel cover See To remove the covers on page 16 3 Disconnect the steering cable front connection B at the steering chain C 4 Attach the new cable to the used cable if the used cables are not cut 5 Pull out the used cables from the frame to put the new cables in the frame 6 Make sure that the steering wheel is in the center position when the rear wheels are in cent...

Страница 45: ... 9 Belts 8 9 1 Belts overview Belt 1 Transmission belt Engine pulley to transmission pul ley Belt 2 Main belt Engine pulley to intermediate pul ley Belt 3 Equipment belt Intermediate pul ley to cutting deck 8 9 2 To lubricate the belt adjuster The belt adjuster must be lubricated regularly with a good quality molybdenum disulphide grease 659 001 11 04 2018 Repair instructions 45 ...

Страница 46: ...n belt 1 Lift up the cutting deck 2 Remove the transmission cover See To remove the covers on page 16 3 Remove the cooling fan nut and the cooling fan 4 Disengage the spring on the belt tensioner 5 Remove the transmission belt from the hydrostatic transmission pulley with a screwdriver and a wrench 6 Remove the engine pulley covers on the left and right side of the product 7 Remove the belt guide ...

Страница 47: ...l the transmission belt below the engine belt pulley and put it on the engine belt pulley 3 Put the transmission belt on the hydrostatic transmission pulley 4 Attach the cooling fan 5 Do a check that the main belt is installed correctly on the front pulley 6 Attach the main belt on the engine pulley 7 Attach the belt guide for the main belt 8 Attach the spring 8 9 5 To remove and attach the main b...

Страница 48: ... into servicing position 2 Pull the center belt off the center pulley The tension of the equipment belt loosens when the cutting deck is in servicing position 3 Remove the equipment belt from the center pulley 8 9 7 To install the equipment belt 1 Put the equipment belt between the impeller and the idler pulley 2 Put the equipment belt in the top groove and the center belt in the bottom groove of ...

Страница 49: ...lt for the tie rod and the 2 screws on the cover and remove the cutting unit cover 3 Loosen the belt tension spring and pull off the belt 4 Attach the new belt in reverse sequence Note A decal on the inner side of the cover shows how to put the belt 659 001 11 04 2018 Repair instructions 49 ...

Страница 50: ...wn cable to the starter relay When the key switch is turned to START there must be the same voltage in the ca ble as in the battery Replace the ignition switch 9 Measure the resistance of the relay It must be 3 7 4 2 Ω Replace the starter re lay Parking brake microswitch malfunction 10 Do a check of the parking brake mi croswitch Replace the micro switch Lift lever mi croswitch mal function 11 Do ...

Страница 51: ... an operator in the seat the resistance must be low The resist ance must be high when there is an operator in the seat Do a check of the seat microswitch and connec tor replace if necessary The product stops when the operator lifts from the seat with the parking brake applied Lift lever in lowered posi tion 1 Do a check that the microswitch changes the position when the lift lev er is lifted Repla...

Страница 52: ...e 91 91 91 Fuel tank volume litres 10 10 10 Oil Class SF SG SH or SJ SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Class SF SG SH or SJ SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Class SF SG SH or SJ SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Oil tank volume litres 1 4 1 4 1 4 Start motor Electric start 12V Electric start 12V Electric start 12V Transmission Brand Tuff Torq Tuff Torq Tuff Torq Mode...

Страница 53: ...10 Nm 3 5 7 lb ft 5 10 Nm 3 5 7 lb ft 5 10 Nm 3 5 7 lb ft Steering cable pulley 20 30 Nm 14 21 lb ft 20 30 Nm 14 21 lb ft 20 30 Nm 14 21 lb ft Belt pulley 45 50 Nm 32 36 lb ft 45 50 Nm 32 36 lb ft 45 50 Nm 32 36 lb ft Blades M10 bolt 45 50 Nm 32 36 lb ft 45 50 Nm 32 36 lb ft 45 50 Nm 32 36 lb ft Blade bearings 20 25 Nm 14 18 lb ft 20 25 Nm 14 18 lb ft 20 25 Nm 14 18 lb ft Belt tensioner 15 25 Nm 1...

Страница 54: ...54 Technical data 659 001 11 04 2018 ...

Страница 55: ...659 001 11 04 2018 Technical data 55 ...

Страница 56: ...www jonsered com 1159918 26 2018 07 05 ...

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