Husqvarna R 422 Ts Workshop Manual
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Husqvarna R 422 Ts Workshop Manual

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R 422 Ts
R 422 Ts AWD
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Summary of Contents for Husqvarna R 422 Ts

  • Page 1 Workshop manual R 422 Ts R 422 Ts AWD English...

  • Page 3: Table Of Contents

    Driving ...............27 Removing the BioClip plug (Combi) ....84 Cutting Unit ............28 Electrical system ..........85 Wiring diagram R 422 Ts och R 422 Ts AWD .. 85 Repair Instructions ..........31 Ignition and Starter Lock ........91 Removing the Engine ........31 Hour Meter ............
  • Page 4 Keep the Hydraulic Oil Clean ......96 Working Methods ..........96 Component Locations PR 17, PF 21 ....96 Component Locations R 422 Ts .......97 Component Locations R 422 Ts AWD ....98 Bleeding the Hydraulic System ......99 Power Steering ..........99 Replacing the Lift Cylinder ........99 Valve Assembly ..........100...

  • Page 5: Safety Instructions

    SAFETY INSTRUCTIONS Safety Instructions General Instructions No one may repair the rider unless they have read This workshop manual is written for personnel with and understood the content of this workshop general knowledge about the repair and service of manual. riders.

  • Page 6: Risk Of Sparking

    SAFETY INSTRUCTIONS Risk of sparking Sparking can occur when working with the battery and the thick cables in the starter motor circuit. This can cause the battery to explode, fire or eye injuries. Sparking in the circuit can not occur once the battery's power connection cable (usually the black negative cable) has been disconnected.

  • Page 7: Special Tools

    SPECIAL TOOLS Special Tools The following special tools are used when working on the rider. Special tools for the engine and transmission 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.
  • Page 8 SPECIAL TOOLS 506 66 48-01 506 56 76-01 535 41 32-01 506 89 93-01 The figures show how the special tools are used. English-...

  • Page 9: Laser Tachometer

    SPECIAL TOOLS Laser tachometer Safety • Laser product class 1. • Exercise care when the laser beam is on. • Do not look straight at the beam. Do not aim the beam towards anyone else’s eyes, either people or animals. •...
  • Page 10 SPECIAL TOOLS English-...
  • Page 11 SPECIFICATIONS Specificatons R 422 Ts R 422 Ts AWD Dimensions and weight Length, base machine, mm/ft with tow hook 2 080/6,82 2 080/6,82 Length with Combi 112, mm/ft with tow hook 2 450/8,04 2 450/8,04 Length with Combi 122 2 550/8,37...
  • Page 12 SPECIFICATIONS R 422 Ts R 422 Ts AWD Electrical system Type 12 V, negative grounded 12 V, negative grounded Battery 12 V, 24 Ah 12 V, 24 Ah Main fuse Flat pin, 15 A Flat pin, 15 A Fuse power outlet Flat pin, 7.5 A...
  • Page 13 SPECIFICATIONS Cutting Unit Combi 112 Combi 122 Cutting width, mm/" 1 120/44 1 220/48 Cutting heights, mm/" 25-80/0,98-3,15 25-80/0,98-3,15 Blade length, mm/" 420/16,5 450/17,7 Guaranteed noise level, dB(A) Width, mm/" 1 220/48 1 330/52,4 Weight, kg/lb 56/123,5 64/141 Check List Parallelism, cutting unit with cutting height in position 1: ±...
  • Page 14 SPECIFICATIONS English-...

  • Page 15: Delivery And Dealer Service

    DELIVERY AND DEALER SERVICE Delivery and Dealer Service After the First 8 Hours Change engine oil. Delivery Service Change the oil in the hydraulics and drive system. 1 Charge the battery for 4 hours at max. 3 amp. 25-Hour Service 2 Fit steering wheel, seat and any optional equipment.

  • Page 16: 300-Hour Service

    DELIVERY AND DEALER SERVICE 300-Hour Service At Least Once Each Season Inspect the machine. Come to agreement with Clean the engine’s cooling air intake the customer as to what additional work is to (25 hours). be carried out. Replace the air filter’s paper cartridge Perform the 25-hour service.

  • Page 17: Delivery Procedures

    DELIVERY AND DEALER SERVICE Delivery Procedures To our dealers In conjunction with the delivery, you shall also give A well performed pre delivery service is the first the customer the information required to handle step towards an active after-sales market. and maintain their machine in a safe manner.
  • Page 18 DELIVERY AND DEALER SERVICE Packaging and Unpacking The machine is normally packed using special packaging when delivered from the factory. This packaging is comprised of a wood base with a strong cardboard top section, all held together with plastic wrapping. WARNING! Handle the transport box carefully.

  • Page 19: Battery

    DELIVERY AND DEALER SERVICE Battery WARNING! Actions with acid contact External: Rinse thoroughly with water. Internal: Drink large quantities of water or milk. Contact a doctor as soon as possible. Eyes: Rinse thoroughly with water. Con- tact a doctor as soon as possible. The battery emits explosive gases.

  • Page 20: Towing Eye And Counterweight

    DELIVERY AND DEALER SERVICE Towing Eye and Counterweight Fit the counterweight on the rear bumper when supplied separately. The tow hook is fitted the ”wrong” way at the factory for transport reasons. Fit the tow hook to the back of the bumper as illustrated. Fitting the tow hook Checking the Engine Oil Level Check the oil level in the engine when the...

  • Page 21: Check The Oil Level In The Hydraulic Tank

    Leave the cover removed for now. Transmission cover Check that there is oil in the hydraulic tank. R 422 Ts. Fill if necessary with engine oil SAE 10W/40 (class SF–CC). R 422 Ts AWD. Fill if necessary with engine oil SAE 10W/50 (class SF–CC).

  • Page 22: Checking And Adjusting The Cutting Unit

    DELIVERY AND DEALER SERVICE Checking and Adjusting the Cutting Unit Performed after checking the tyre air pressures. See ”Adjusting the Unit’s Parallelism and Cutting Height” on page 78. Test Running Fill with petrol. The engine should be run on a minimum of 87-octane unleaded petrol (not mixed with oil).

  • Page 23: Engine Speed Regulator

    Engine Speed Regulator Check that the engine’s max. speed is regulated to: R 422 Ts 2900 - 3100 rpm R 422 Ts AWD 2900 - 3100 rpm Hydraulic cutting unit lift Final Inspection Bleed the hydraulic system of excess air after test running.
  • Page 24 DELIVERY AND DEALER SERVICE English-...

  • Page 25: Design And Function

    DESIGN AND FUNCTION Design and Function General This publication describes Husqvarna R 422 Ts All Riders have articulated steering to ease and R 422 Ts AWD. mowing around trees and other obstacles. They also have front-mounted cutting units for controlled Husqvarna Riders are a series of large capacity mowing and the best possible cutting result.

  • Page 26: Cutting Unit

    DESIGN AND FUNCTION Cutting unit R 422 Ts and R 422 Ts AWD can be equipped with two different cutting units. Combi 112 and Combi 122 The Combi-unit, equipped with a BioClip- plug, finely chops the cuttings to fertiliser. Without the BioClip-plug the unit works in the same way as a rear ejection unit.

  • Page 27: Engine

    Model Briggs & Stratton’s engine type R 422 Ts 7220 R 422 Ts AWD 7229 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 lubrication and separate oil filters.

  • Page 28: Steering

    DESIGN AND FUNCTION Steering All mowers in the Rider series have articulated steering. The machines are equipped with hydraulic power steering. The steering force from the steering wheel is transmitted to the rear carriage via a chain and cables. This makes steering the rider both easy and precise. A Rider easily cuts around all obstacles on the lawn.

  • Page 29: Driving

    The hydraulic pump and transmission are assembled as a unit. The transmission cover removed Front axle on R 422 Ts AWD from the top. The axle consists of a hydraulic motor, differential and drive axles. In order to move the machine without the...

  • Page 30: Cutting Unit

    DESIGN AND FUNCTION On the AWD-machines, the power transmission is supplied with pressure by a pump, which is integrated in the transmission. The hydraulic system includes the power steering and the equipment lift. Hydraulic pump Cutting Unit The entire Rider series is equipped with a front-mounted cutting unit in order to mow efficiently even in confined areas.
  • Page 31 DESIGN AND FUNCTION The machines have both a 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.
  • Page 32 DESIGN AND FUNCTION English-...

  • Page 33: Repair Instructions

    REPAIR INSTRUCTIONS Repair Instructions Removing the Engine Remove the engine cover. Loosen the battery’s retaining strap. Remove the protective cover. IMPORTANT INFORMATION Hold the battery cable bolts in place so that the electrodes are not strained. Loosen the battery cable connections. Then lift out the battery.
  • Page 34 REPAIR INSTRUCTIONS 10. Remove the belt guide for the engine belt pulley. On machines with a skid guard the skid guard must be removed. Belt guide 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.

  • Page 35: Fitting The Engine

    REPAIR INSTRUCTIONS Fitting the Engine IMPORTANT INFORMATION When fitting the engine, it is important that the belt pulley’s groove (1) is in such a position that the outgoing shaft’s key (2) fits into the groove (see illustration). Also check that both the spacing tube (3) and key (2) are well fitted to the engine shaft.
  • Page 36 REPAIR INSTRUCTIONS Attach the cover plate over the muffler, two screws on each side of the muffler. The muffler’s protective plate Press the fuel hose into place against the fuel pump and attach the hose clamp. Screw the cable from the starter to the start relay into place.

  • Page 37: Fuel Tank

    REPAIR INSTRUCTIONS Fuel Tank Removal WARNING! Petrol is highly flammable and environmentally hazardous. Exercise caution to avoid fire and spillage. Place a suitable container to collect the petrol. The tank holds about 17 litres (4.5 US Gal). Empty the petrol tank by removing the hose from the connector under the tank.

  • Page 38: Changing The Engine Oil

    REPAIR INSTRUCTIONS Changing the Engine Oil WARNING! The engine oil should be changed the first Engine oil can be very hot if it is time after 8 hours running time. It should then drained directly after stopping the be changed after every 100 hours of running engine.

  • Page 39: Checking And Adjusting The Steering Cables

    REPAIR INSTRUCTIONS Checking and Adjusting the Steering Cables The steering is governed by means of cables. After a period of use these can become stretched, which means the steering setting may have changed. Steering is checked and adjusted as follows: Remove the frame plate by loosening the screws (two on the power steering housing).

  • Page 40: Replacing The Steering Cables

    REPAIR INSTRUCTIONS Power steering and steering cables Replacing the Steering Cables Removing/Fitting the Power Steering Loosen the steering cables’ rear mount (1). Remove the cutting unit. Loosen the steering cables’ rear mount (1). Remove the frame plate. Remove the frame plate. Loosen the steering cables’...

  • Page 41: Removing/Fitting The Cable Pulley

    REPAIR INSTRUCTIONS Steering cables and cable pulley Removing/Fitting the Cable Pulley Remove the frame plate and skid guard under the machine. Loosen the steering cables’ rear mount (1). Remove the screw (2) and remove the cable pulley (5). Remove the bearing’s circlip (3) and tap out the bearing (4).

  • Page 42: Adjusting The Parking Brake R 422 Ts Awd

    REPAIR INSTRUCTIONS Adjusting the Parking Brake R 422 Ts AWD Check that the parking brake is adjusted correctly by placing the machine on a slope with the front and rear axles disengaged. Apply and lock the parking brake. When the...

  • Page 43: Adjusting The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS Tighten the nuts carefully to prevent damaging the adjuster screw. Refit the spring (A). The parking brake should be checked again after the adjustment has been made. WARNING! A poorly adjusted parking brake can result in reduced braking ability.

  • Page 44: Checking And Adjusting The Throttle Cable

    REPAIR INSTRUCTIONS Checking and Adjusting the Throttle Cable 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: Loosen the clamping screw for the cable’s outer casing and move the throttle to the full throttle position.
  • Page 45 REPAIR INSTRUCTIONS Remove the locking spring and loosen the throttle control's link joint locking spring, and remove the cable's bracket from the rear frame and the hydraulic pump's ball joint. Locking spring Clean, see ”Working Methods” on page 106. Mark and remove the hydraulic hoses from the couplings under the machine.

  • Page 46: Removing The Pendulum Shaft

    REPAIR INSTRUCTIONS 11. Remove the inner circlip (1) by the lower bearing (see illustration). The rear carriage is now loose and can be moved. Then loosen the outer circlip (2) and remove the bearings from below. Lower bearings 12. Remove the upper bearings from above; if they are stuck tap them from below.

  • Page 47: Replacing Bushings

    REPAIR INSTRUCTIONS Clean, see ”Working Methods” on page 106. Release the rear hydraulic hose from the rear axle. Hydraulic hose Remove the circlip and washer from the pendulum shaft and pull loose the rear frame. Remove the circlip and washer from the pendulum shaft’s inner mount (1) and pull the shaft out to the rear.

  • Page 48: Drive Axles

    Counterhold using a spanner when releasing and tightening the coupling nuts so that the hoses or angled nipples are not exposed to twisting strain. Front Axle R 422 Ts AWD The equipment frame must not be dismantled. Removal Remove the cutting unit, see ”Removing the Cutting Unit”...
  • Page 49 REPAIR INSTRUCTIONS • Remove the circlip. • Pull off the wheel with hub from the axle. • Take care of the keys, spacers and washers, keep a check of the number of washers, this can vary between sides. Circlip Release the front synchronisation link for speed from the front axle.
  • Page 50 REPAIR INSTRUCTIONS Release the hydraulic pipe from the top 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. Hydraulic pipe, top Release the parking brake cable from the front axle.
  • Page 51 The synchronisation link is fitted in the lower hole on R 422 Ts AWD. (Below the holes for the synchronisation link is a hole for the release control) Grease the axles for protection against corrosion before the wheels are fitted.

  • Page 52: Rear Axle

    REPAIR INSTRUCTIONS Rear Axle Removal Jack up and block the machine Remove the rear wheels. Jacking up • Remove the circlip. • Pull off the wheel with hub from the axle. • Take care of the keys, spacers and washers, keep a check of the number of washers, this can vary between sides.
  • Page 53 REPAIR INSTRUCTIONS Release the hydraulic pipe from the top of the rear axle. Fit the protective plugs. A small amount of oil will leak out even if the rear axle has not been drained. Hydraulic pipe top Remove the 4 screws which hold the rear axle and lower the rear axle.
  • Page 54 The production value can be down to 0.92. Check that the synchronisation link is fitted in the lower hole on the R 422 Ts AWD. Set the steering wheel in the centre 8009-693 Synchronisation link position.

  • Page 55: Seal Replacement, Outgoing Shafts

    REPAIR INSTRUCTIONS Check, with the same steering wheel position as before, that the adjustment gives the desired result. If not, repeat from marking the tyres. 10. When the adjustment has been made, tighten the locking nuts on the adjuster rod. Seal Replacement, Outgoing Shafts Dismantle the circlips holding the wheels and hubs on the axles and remove the...
  • Page 56 REPAIR INSTRUCTIONS Insert a screwdriver between the seal and the shaft and pry off the seal from the shaft housing with a twisting motion. Pry off the seal Wrap insulating tape around the outgoing shaft from the beginning of the key groove and outwards until even the threads of the circlip are covered with tape.
  • Page 57 12. Check that there is oil in the hydraulic tank. R 422 Ts. Fill if necessary with engine oil SAE 10W/40 (class SF–CC). R 422 Ts AWD. Fill if necessary with engine oil SAE 10W/50 (class SF–CC).

  • Page 58: Replacing The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS Replacing the Hydrostatic Transmission Cable Removing the Hydrostatic Transmission Cable Remove the frame plate by loosening the screws (two on the power steering housing). Frame plate Loosen the hydrostatic transmission cable’s forward lock nut a 1/4 turn and remove the locking spring.
  • Page 59 REPAIR INSTRUCTIONS Remove the rear clip of the hydrostatic transmission cable. Cut the plastic tie Remove the spring lock and the hydrostatic transmission cable's rear link joint from the arm on the hydraulic pump. Rear link joint Lift off the link joint and pull out the cable. Lift out the hydrostatic transmission cable and the accompanying link joint.

  • Page 60: Fitting The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS 10. Remove the entire hydrostatic transmission cable. Remove the hydrostatic transmission cable. Fitting the Hydrostatic Transmission Cable Screw in the front link joint on the new hydrostatic transmission cable and tighten the lock nut. Run the cable through the rider so that it follows the same path as the old cable did.
  • Page 61 REPAIR INSTRUCTIONS Tighten the hydrostatic transmission cable clamp. Press the link joint onto its fastener and attach the locking spring. Front clamp Attach the link joint to the rear part of the hydrostatic transmission cable. Screw 10-12 turns so that the link joint has the right length.

  • Page 62: Bleeding The Hydrostatic And Hydraulic Systems, R 422 Ts Awd

    15. Test drive the machine forwards and in reverse. Frame plate Bleeding the Hydrostatic and Hydraulic Systems, R 422 Ts AWD Remove the transmission cover. IMPORTANT INFORMATION Ensure cleanliness. Used oil may not be reused. See ”Hydraulic Hygiene” on page 105.

  • Page 63: Bleeding The Hydrostatic And Hydraulic Systems R 422 Ts

    14. Replace the transmission cover. Hydraulic cutting unit lift Bleeding the Hydrostatic and Hydraulic Systems R 422 Ts Remove the transmission cover. IMPORTANT INFORMATION Ensure cleanliness. Used oil may not be reused. See ”Hydraulic Hygiene” on page 81.

  • Page 64: Transmission Maintenance

    REPAIR INSTRUCTIONS Repeatedly engage and disengage the clutch while alternately depressing the forward and reverse pedals. When the rider begins to move, the throttle should be increased to high engine speed. Repeat quick starts and emergency stops until the transmission responds properly. Turn the steering wheel repeatedly from one extreme position to the other until the steering works without jerks or stops.

  • Page 65: Adjusting The Lever Housing

    fill hole in the hydraulic tank. Bleed the transmission, see ”Bleeding the Hydrostatic and Hydraulic Systems, R 422 Ts AWD” on page 60. Test run the machine and fill with oil to the proper level in the oil tank.
  • Page 66 REPAIR INSTRUCTIONS Make sure that the catch to the hydraulic lift lever has about 2 mm (1/16") of play in relation to its grip on the frame tubing when the lever is in its upper position. Adjust as needed with adjustment screw (1) or (2) on the drive disc.

  • Page 67: Replacing The Rear Drive Belt, R 422 Ts

    (used belt). 13. Check that all lock nuts are tight. 14. Refit the plastic cover. Connecting rod in the belt adjuster Replacing the rear drive belt, R 422 Ts Removal Lift up the cutting unit Remove the transmission cover.
  • Page 68 REPAIR INSTRUCTIONS Pull off the centre belt from the engine's pulley and pull out the rear section. Remove the cooling fan, it is held in place by a nut. Remove the belt from the hydrostatic transmission pulley. Pull the belt off of the engine's pulley and move it under the engine belt pulleys.
  • Page 69 REPAIR INSTRUCTIONS Fit the cooling fan. Check that the centre belt is fitted correctly on its front pulley and fit the centre belt on the engine's pulley. Fit the hose holder in the middle and the belt guide for the centre belt. Refit the spring (A).

  • Page 70: Replacing The Hydraulic Pump's Drive Belt R 422 Ts Awd

    REPAIR INSTRUCTIONS Replacing the Hydraulic Pump's Drive Belt R 422 Ts AWD Removal Remove the transmission cover. Transmission cover Unhook the spring on the belt tensioner. Belt tensioning Remove the belt guide for the centre belt. Belt guide Pull off the centre belt from the engine's pulley and pull out the rear section.
  • Page 71 REPAIR INSTRUCTIONS Remove the nut on the cooling fan. Counter hold using a punch in one of the holes on the underside of the fan when the nut is loosened. Pull the pump belt off of the pump's pulley. Pull the pump belt off of the engine's pulley and move it under the engine belt pulleys.

  • Page 72: Replacing The Centre Belt

    REPAIR INSTRUCTIONS Fit the belt guide for the centre belt. Belt guide Hook the spring on the belt tensioner. Belt tensioner spring Replacing the Centre Belt Remove the hose holder in the middle and the rear belt guide for the centre belt (all machine types).

  • Page 73: Replacing The Front Belt

    If R 422 Ts or R 422 Ts AWD is to be used with an accessory or with the cutting unit CombiTurf 112, the belt...

  • Page 74: Equipment Frame

    REPAIR INSTRUCTIONS Fit the centre belt in position on the centre pulley. Reset the cutting unit in the mowing position. Equipment Frame Removal Remove the cutting unit, see ”Removing Centre gear the Cutting Unit” on page 75. Push down the equipment frame and drop the catch.

  • Page 75: Fitting The Cutting Unit

    REPAIR INSTRUCTIONS 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. Rear guide screw Pull out the equipment frame. Assembly Push in the equipment frame. Make sure that the height adjustment stay is inserted into the equipment frame.
  • Page 76 REPAIR INSTRUCTIONS Remove the drive belt and place it in the belt holder. Push the unit in and put the guide plugs in the grooves on the equipment frame, one on each side. WARNING! Observe caution to avoid trapping your hand. Push the unit in so that the interior plugs touch the bottom of the equipment frame’s grooves.

  • Page 77: Removing The Cutting Unit

    REPAIR INSTRUCTIONS Secure the collet spring. Fit the front cover. Removing the Cutting Unit WARNING! Wear protective glasses when dismantling the cutting unit. The springs which tensions up the belt may break and cause personal injury. Carry out points 1-6 to put the cutting unit in the service position, see Service position for the cutting unit.

  • Page 78: The Cutting Unit's Service Position

    REPAIR INSTRUCTIONS The Cutting Unit’s Service Position 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 Position the machine on flat ground.
  • Page 79 REPAIR INSTRUCTIONS Loosen on the cutting height stay and place in the holder. WARNING! Observe caution to avoid trapping your hand. Remove the drive belt and place it in the belt holder. Grip the front edge of the unit and pull forwards until it stops.

  • Page 80: Restoring From Service Position

    REPAIR INSTRUCTIONS Restoring from service position Grip the front edge of the unit and loosen the lock, fold down and slide in the unit. Replace the cutting height stay and the belt. Tension the belt with the belt adjuster. Fit the front cover. Adjusting the Unit’s Parallelism and Cutting Height When a new cutting unit is attached, you...

  • Page 81: Adjusting The Cutting Height Range

    REPAIR INSTRUCTIONS Adjusting the Cutting Height Range Remove the plastic cover over the hydraulic valve block. Plastic cover Raise or lower the entire cutting range by screwing the nuts up or down. Adjust so that the distance between ground and the cutting unit's edge at the front of the cover is 25 mm.

  • Page 82: Changing The Belt On The Cutting Unit

    REPAIR INSTRUCTIONS Changing the Belt on the Cutting Unit WARNING! Wear gloves to protect your hands when working with the blades. There is a risk of crush injuries when working with the belt. On cutting units with ‘collision-proof’ blades, the blades are driven by a V-belt. Do as follows to replace the V-belt: Remove the cutting unit.

  • Page 83: Removing Blades With Bearings

    REPAIR INSTRUCTIONS Remove the two bolts on the unit frame. Remove the screws on the cutting cover. Lift the unit frame and remove the cutting unit cover. Loosen the spring that tensions the V- belt and pry off the belt. Simply reverse the procedure to fit the new belt.
  • Page 84 REPAIR INSTRUCTIONS 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.
  • Page 85 REPAIR INSTRUCTIONS Mark one end of the shaft. Push out the shaft with a puller. Tap out the bearing and remove the spacer. You can purchase the entire assembly, complete with shaft housing, shaft, spacer, and bearings. 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.

  • Page 86: Sharpening And Balancing Blades

    REPAIR INSTRUCTIONS Sharpening and Balancing Blades WARNING! Protect your hands with gloves when working with the blades. Remove the blades as described in the previous section. Fix the blade in a vice and sharpen it Sharpening blades with a sharpening file. Balance the blade by: •...

  • Page 87: Electrical System

    ELECTRICAL SYSTEM Electrical system Wiring diagram R 422 Ts och R 422 Ts AWD Electrical system: component locations Numbers correspond to: Microswitch, hydrostatic transmission Microswitch, cutting unit Microswitch, seat Ignition lock Counter Start relay Engine connectors Main fuse 15 A Fuse 7.5 A...
  • Page 88 ELECTRICAL SYSTEM English-...
  • Page 89 ELECTRICAL SYSTEM English-...
  • Page 90 ELECTRICAL SYSTEM English-...
  • Page 91 ELECTRICAL SYSTEM English-...
  • Page 92 ELECTRICAL SYSTEM English-...

  • Page 93: Ignition And Starter Lock

    ELECTRICAL SYSTEM Ignition and Starter Lock Remove the right-hand side cover from the lever housing. Release the connector from the ignition lock by pulling it straight down. Remove the ignition key and the rubber seal. Remove the nut and the ignition lock. Assemble the parts in the reverse order.

  • Page 94: Replacing The Light Bulbs

    ELECTRICAL SYSTEM Replacing the Light Bulbs For information about the bulb type, see ”Electrical system” on page 10. Unscrew the two screws holding the cover on the power servo housing. Lift up the cover and turn it around the steering shaft. Unscrew the two screws holding the lamp insert.

  • Page 95: Safety System

    ELECTRICAL SYSTEM Safety System The rider is equipped with a safety system that prevents starting or driving under the following conditions. The engine should only be possible to start when the cutting unit is in its raised position and the parking brake is applied.
  • Page 96 ELECTRICAL SYSTEM Microswitch: Mowing Deck See ”Adjusting the Lever Housing” on page 69 for adjustment instructions. Microswitch: Mowing Deck Microswitch: Seat The microswitch is located on the underside of the seat and can be replaced together with the holder without adjustment. The switch inside the holder cannot be replaced alone as it is glued into place.

  • Page 97: Hydraulic System

    HYDRAULIC SYSTEM Hydraulic System Hydraulic Hygiene Keep the hydraulic system clean. Remember to: • Dirt particles that enter the system include: • Thoroughly clean before the top-up cap is - Contaminants entering when topping up opened or any connector loosened. with oil.

  • Page 98: Keep The Hydraulic Oil Clean

    HYDRAULIC SYSTEM Keep the Hydraulic Oil Clean Working Methods Dirt and contaminants are the greatest enemies of Cleanliness also applies to components that have a hydraulic system. Moreover, long work sessions been removed or are to be installed. Keep in mind at high power are very dependent on whether the that a replaced component should probably be hydraulic oil has been able to retain its condition.

  • Page 99: Component Locations R 422 Ts

    HYDRAULIC SYSTEM Component Locations R 422 Ts Pressure to the hydraulic system is provided by the The hose’s nipple for the cylinder’s piston side is drive system's pump. A pressure limiting valve limits equipped with a throttle. Between the slider and the...

  • Page 100: Component Locations R 422 Ts Awd

    HYDRAULIC SYSTEM Component Locations R 422 Ts AWD Pressure to the hydraulic system is provided by the The hose’s nipple for the cylinder’s piston side is drive system's pump. A pressure limiting valve limits equipped with a throttle. Between the slider and the...

  • Page 101: Bleeding The Hydraulic System

    HYDRAULIC SYSTEM Bleeding the Hydraulic System See ”Bleeding the Hydrostatic and Hydraulic Systems PR 17 AWD, PF 21 AWD” on page 66. Power Steering See ”Removing/Fitting the Power Steering” on page 43. Replacing the Lift Cylinder Lower the cutting unit to the ground. Stop the engine.

  • Page 102: Valve Assembly

    HYDRAULIC SYSTEM Valve Assembly Removing and Refitting Lower the cutting unit to the ground. Stop the engine. Remove the plastic cover from the hydraulic valve block. Clean in accordance with ”Working Methods” on page 96. Hold the valve block nipples in place and loosen the hydraulic connectors from the valve block.
  • Page 103 HYDRAULIC SYSTEM Hydraulic oil filter, change Remove the oil filter. If necessary, use a filter remover. Wipe new, clean engine oil onto the seal for the new filter. Fill the filter with new, clean oil. Mount the filter by hand with + 3/4 turn. Remove the transmission cover and fill the transmission oil tank.
  • Page 104 HYDRAULIC SYSTEM Remove the Allen screws and spacing tubes and remove the control valve from the valve block. Keep track of the two o- rings that are between the control valve and the valve block. When replacing the control valve, move the nipple, including the rubber/steel washer for the forward hose, to the new valve.
  • Page 105 HYDRAULIC SYSTEM Control Valve, Dismantling/Assembly Remove the control valve, see above. Clean in accordance with ”Working Methods” on page 96. Place the valve in the vice. Tighten down on the lower part (under the slider hole). Remove the check valve. Set the tool to the wide wrench setting, 15 mm.
  • Page 106 HYDRAULIC SYSTEM Pull out the slider. Normally, the spring does not need to be removed, but if it does, only the hole in the slider may be used to hold it in place. Slider with spring Remove the steel ring and o-ring from the rear section.

  • Page 107: Pressure Limiting Valve

    HYDRAULIC SYSTEM Pressure Limiting Valve If the hydraulic pressure is too low, it can be due to dirt trapped in the pressure limiting valve. IMPORTANT INFORMATION Incorrect hydraulic pressure is almost never due to an incorrectly adjusted pressure limiting valve. Check the hydraulic system thoroughly for faults before changing the valve setting.
  • Page 108 HYDRAULIC SYSTEM The yellow, blue, green and red hoses should be positioned in two layers. The bottom layer should be made up of the green (left) and yellow (right) hoses. The top layer of the red (left) and blue (right). The black hose is routed to the left between the layers when half of the hose protection has been wound Tightening torque couplings 45 Nm...

  • Page 109: Changing The Hydraulic Oil Cooler, R 422 Ts Awd

    HYDRAULIC SYSTEM Changing the hydraulic oil cooler, R 422 Ts AWD Clean according to work methods. Loosen the hydraulic hoses. Oil from the cooler may flow out. Detach the cables to the cooling fan. Remove the cooling unit by loosening 4 bolts.
  • Page 110 HYDRAULIC SYSTEM English-...
  • Page 111 The engine will not start.
  • Page 112 Engine starts but does not run satisfactorily...
  • Page 113 The motor runs normally, low /no power...
  • Page 114 Low power, abnormal noise...
  • Page 115 Transmission: Overheating, other indications...
  • Page 116 Uneven mowing result, vibrations...
  • Page 118 115 41 73-26 2011W27...

This manual is also suitable for:

R 422 ts awd

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