Husqvarna P 520D Workshop Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Lawn Mower
  5. P 520D With cabin
  6. Workshop manual

Husqvarna P 520D Workshop Manual

Hide thumbs Also See for P 520D:
Table of Contents

Advertisement

Quick Links

Workshop Manual
P 520D
P 525D
English

Advertisement

Table of Contents
loading

Related Manuals for Husqvarna P 520D

Summary of Contents for Husqvarna P 520D

  • Page 1 Workshop Manual P 520D P 525D English...

  • Page 2: Table Of Contents

    Workshop Manual P 520D, P 525D Contents Introduction ............2 Fuel System ............35 Safety Instructions ..........3 Fuel Tank, Assembly and Dismantling ... 35 General Safety Instructions ......3 Bleeding the Fuel System ......36 Special Safety Directions ......... 3 Electrical System ..........

  • Page 3: Introduction

    Operator's manuals from the following sub- contractors are included with the machine. Kubota Diesel Engine Operator’s manual D905 (P 520D)/D1105 (P 525D). Bondioli & Pavesi Propeller shaft service manual. – English...

  • Page 4: Safety Instructions

    Safety Instructions Safety During Repair Work the type of diesel but is normally higher than +50°C (120°F). This Workshop Manual contains the following You must be attentive to ensure spillage does not warning boxes in relevant places. occur when you open a system that contains oil or fuel. WARNING! Avoid spillage, use a funnel and fill carefully.

  • Page 5: Special Tools

    Special Tools Laser Tachometer The machine is designed so that the number of special tools is kept to a minimum. The following special tools are used when working on the ride-on IMPORTANT! mower. Special tools for engine and transmission can be found in the respective workshop manual. To avoid incorrect readings, the laser meter must be held at right angles to the rim at a •...

  • Page 6: Measure Rpm

    Measure rpm Read the Last, Highest and Lowest Values 1. Put the switch to RPM position for measuring The instrument will automatically save the last, rpm or TOT for measuring the number of highest and lowest readings for a measurement (i.e. revolutions.

  • Page 7: Serial Number

    Serial Number Serial Number The serial number can be found on the printed plate attached to the right-hand frame member. The plate includes the following information: • Manufacturer • Machine type designation. • Manufacturer type number • Weight • Machine serial number (s/n). Please provide the type designation and serial number when ordering spare parts.

  • Page 8: Screw Fasteners

    Screw Fasteners Metric threads are used on the machine. Some bolt fasteners are locked with screws treated ® with Eslok Nylon 180°. The screw threads have a red coating. These screws can be refitted three times before having to be replaced. Always torque tighten screw unions to the specified torque table unless specified otherwise in the text.

  • Page 9: Chassis

    Chassis Repair Instructions CHASSIS Changing Throttle Cable Removing Driver's Seat Tools Dimension Quantity Socket wrench 10 mm WARNING! Combination 13 mm The seat is heavy and can fall if let wrench go. Secure it from falling. Risk of Torx personal injury. Snipe nose pliers Tools Dimension...

  • Page 10: Changing Parking Brake Cable

    Chassis Dismantle two screws (1) for the parking brake Changing Parking Brake Cable bracket (2). Carefully bend the bracket out from Tools Dimension Quantity the overlying frame section to expose the cable fastening. Combination 13 mm wrench Remove the cable eye (4) from the spring (5). Torx T 30 Refit the new cable in reverse order.

  • Page 11: Dismantling Wheel Hub

    Chassis Dismantling Wheel Hub Changing Wheel Hub Bearing Tools Dimension Quantity Tools Dimension Quantity Circlip pliers SGH 45° Circlip pliers Socket wrench 15 mm Circlip pliers Socket wrench 15 mm Remove the wheel hub. See Removing Hub. Loosen the wheel nuts on the wheel in question Put the hub on a work bench.

  • Page 12: Changing Pedal Bracket Bushings

    Chassis Lower the lifting arms. Changing Pedal Bracket Bushings Turn off the machine and make sure it can not Tools Dimension Quantity be restarted. Groove joint Dismantle the pedal cable (2) split pin (4) and pliers clevis pin (3). Combination 13 mm wrench Combination...
  • Page 13 Chassis Remove five screws (1) so that the base plate 11. Press out the pedal shaft (9) and dismantle one (2) can be loosened from the front edge. pedal arm at a time. Lift up the base plate to allow the reverse pedal to pass. Screw Base plate 10.

  • Page 14: Changing Lifting Arms And Bushings

    Chassis Press bushings (1), (3) out of the lift arms (2). Changing Lifting Arms and Bushings Tools Dimension Quantity Combination 13 mm wrench Combination 16 mm wrench Combination 18 mm wrench Socket wrench 13 mm Circlip pliers WARNING! Heavy objects are released when dismantling the lift arms.

  • Page 15: Changing Link Stay

    Chassis Assembling Changing Link Stay Clean and lubricate with grease before Tools Dimension Quantity assembling new bushings. Torx Hold the lift arm (6) in place and fit the threaded Combination 15 mm bolt (3) and washers (4), (7), and nylon spacer (5). wrench Combination 17 mm...
  • Page 16 Chassis Note how the link stay grease nipples are turned 13. Assemble in the reverse order. The front link for refitting. stay grease nipple must point to the right. Turn the steering wheel to full right lock to prepare 14. Torque tighten as below. the space for dismantling the link stay (1).

  • Page 17: Changing Joint Bearing In Articulated Unit

    Chassis Changing Joint Bearing in Articulated Unit Connecting rod Joint bearing Control cylinder Link stay Rear transmission Tools Dimension Quantity WARNING! Combination 13 mm Heavy objects are released when wrench dismantling the lift arms. Combination 15 mm wrench Combination 16 mm wrench WARNING! Never insert hands or fingers as...
  • Page 18 Chassis 6. Loosen the front end of the connecting rod (1). Dismantling Remove the flanged nut (2), screw (3) and Jack up and block the machine under the frame washer (4). as illustrated. IMPORTANT! Make sure not to place the trestle so that the connecting rod is damaged or parts of the articulated unit are blocked.
  • Page 19 Chassis Dismantle the protective cover (1) over the 12. Loosen the steering cylinder (3) from the rear steering joint. fastening by dismantling the shaft with the locking lug (1). IMPORTANT! 13. Turn the steering wheel so that the cylinder goes to front end position (fully contracted). Check that the protective cover is intact.
  • Page 20 Chassis 18. The rear carriage is now free, but can not be Assembling lowered without reversing first. Support the rear It is essential the screw is tightened to the correct carriage and lower it slightly as illustrated. Do torque for fastening the ball in the joint bearing. not lower too much, avoid the positions with crosses in the illustration.
  • Page 21 Chassis Put the rear carriage in place over the pin (6). Location Screw Articulated unit 52 ft/lb (85 Nm) 52 ft/lb (47 Nm) IMPORTANT! Rear link stay. 52 ft/lb (47 Nm) 52 ft/lb (24 Nm) Make sure the hydraulic hoses are routed correctly. Assemble the link stay (1) with sleeve (2), screw (3), washer (5) and lock nut (4).
  • Page 22 Chassis 11. Lubricate the link stay through the grease nipples. 12. Torque tighten as specified in the table. 13. Assemble the steering cylinder (3) to the rear bracket. 14. Assemble the shaft with locking lug (1) with the screw (2). Shaft with locking lug Control cylinder Screw...

  • Page 23: Propulsion

    Propulsion PROPULSION Intake Drive shaft belt pulley 11. Engine cradle Engine Solenoid clutch 12. Wheels Hydraulic pump drive shaft Drive shaft (PTO shaft) 13. Exhaust system PTO belts Spline joint to propeller shaft Hydraulic belt coupling 10. Belt pulley cradle Air Filter, Dismantling and Assembly Tools Dimension...

  • Page 24: Drive Shaft For Hydraulic Pump, Dismantling And Assembling

    Propulsion Loosen the drive shaft from the engine flywheel. Drive Shaft for Hydraulic Pump, Dismantling The drive shaft for the hydraulic pump should be and Assembling secured with some form of tool, e.g. a large combination wrench or chisel to prevent rotation Tools Dimension Quantity...

  • Page 25: Changing Solenoid Clutch

    Propulsion Changing Solenoid Clutch Hydraulic pump drive shaft Belt pulley cradle Solenoid clutch PTO belts PTO shaft WARNING! Never insert hands or fingers as heavy components are unstably supported. Use tools that reach. Risk of crush injuries. Tools Dimension Quantity Snipe nose pliers Combination 15 mm...
  • Page 26 Propulsion Ensure that the engine cannot start. Secure the shaft package on a workbench. Unplug the connector (10) for the solenoid 10. Loosen the PTO shaft (1) from the clutch by clutch cable (11). unscrewing four screws (2). Release the spring tension on the belt adjuster (7). Dismantle the front bearing mount (1) on the PTO shaft.
  • Page 27 12. Dismantle the front center screw (4) together PTO shaft must be prevented from turning with two washers (5) and sleeve (3). when undoing. Husqvarna provides a special tools for this. See illustration. Alternatively, the 13. Remove the shaft (2), sleeve (3) and retain propeller shaft can be used as a counterhold.
  • Page 28 Propulsion Assembling 10. Belt pulley Front bearing Screw, 114 Nm PTO shaft Solenoid clutch Washers 11. Axle Sleeve Rear storage bearing Screw, 114 Nm The illustration above shows assembling the solenoid clutch in section. Slide the solenoid clutch (1) half way onto the shaft (2).
  • Page 29 IMPORTANT! High torque (assembly torque 114 Nm)! The PTO shaft must be prevented from turning when undoing. Husqvarna provides a special tools for this. See illustration. Alternatively, the propeller shaft can be used as a counterhold. – English...

  • Page 30: Engine, Dismantling, Assembling

    Propulsion Engine, Dismantling, Assembling Radiator Intake with air filter Drive axle Exhaust system Battery Engine Dismantling Tools Dimension Quantity Socket wrench 7 mm Socket wrench 15 mm Socket wrench 17 mm Socket wrench 18 mm Combination wrench 10 mm Combination wrench 13 mm Torx Torx...
  • Page 31 Propulsion Remove the exhaust system by loosening Dismantling the fastening screws (1), (2). Dismantle the engine hood. Remove the battery. See Replacing the Battery. To make room to remove the engine, either the Loosen the hose clip (3) on the battery box. radiator or the drive shaft for the hydraulic pump must be removed.
  • Page 32 Propulsion 14. Dismantle the cable bridge (1). Start by 20. Dismantle the engine cushion M12 screws (1) loosening the cables (2) from the bridge clamps through (4). and the clamp for the fuel line (3). Then dismantle the cable bridge. Note the location of any cable ties before cutting them.

  • Page 33: Cooling System

    Cooling system COOLING SYSTEM Input cooler hose Water Radiator Incoming hydraulic hose Hydraulic fluid cooler Outgoing coolant hose Air duct Engine cover seal Outgoing hydraulic hose WARNING! Do not open the radiator cap quickly when the engine is hot, first release the overpressure with the cap partially slackened off.

  • Page 34: Replacing The Cooler

    Cooling system Loosen the incoming hydraulic connection (6) Replacing the Cooler from the radiator. Use a counterhold. Tools Dimension Quantity Fit protective plugs in all hydraulic connections. Socket wrench 7 mm 10. Extract the air hose (5). Socket wrench 13 mm 11.

  • Page 35: Pressure Testing The Radiator

    Cooling system 20. Fill with coolant. 21. Fill the hydraulic system with oil. 22. Warm up the engine and top up with coolant and oil as necessary. 23. Check for leakage after running warm. Pressure Testing the Radiator The radiator must be disconnected from the remainder of the cooling system when testing at the pressure below.

  • Page 36: Fuel System

    Fuel system FUEL SYSTEM Fuel tank Fuel cap Prefilter Hand pump Fuel gage Suction Hose Main filter Return hose Fuel Tank, Assembly and Dismantling IMPORTANT! Fuel can leak out. If the level of fuel in the tank is higher than the suction line, the suction line must first be carefully pinched with self-locking pliers or similar.

  • Page 37: Bleeding The Fuel System

    Fuel system Loosen the front mounting (3) from the tank. Bleeding the Fuel System Keep the washers safe for refitting. Tools Dimension Quantity Loosen the rear mounting (4), move the Combination 10 mm mounting away and lift away the tank. wrench Tightening torque, mountings 12 Nm.

  • Page 38: Electrical System

    Electrical System ELECTRICAL SYSTEM Battery 12. Temperature gage Main Fuse 13. Warning lamp panel Electric outlet switch 14. Headlights Power outlet 15. Hour meter Temperature sensor 16. Parking brake sensor Supply fuse 17. Fuse box Control for cutting deck drive 18.

  • Page 39: Battery, Changing

    Electrical System Battery, Changing IMPORTANT! Tools Dimension Quantity Hold the bolts so that the battery terminals are not Combination 10 mm put under strain. wrench Combination 13 mm Loosen and lift off the positive terminal cable lug wrench (1), which is located under the fuse holder. Socket wrench 10 mm Dismantle the battery bridge (2) with two screws.

  • Page 40: Circuit Board, Changing

    Electrical System Loosen all connections from the circuit board. Circuit Board, Changing Use bent round nosed pliers to press in the plastic catches holding the connections. IMPORTANT! It is important to check the circuit outside of the circuit board first, to ensure this is correct, before replacing the circuit board.

  • Page 41: Parking Brake Sensor, Changing

    Electrical System Dismantle the starter module (6) from the circuit Parking Brake Sensor, Changing board (8). Tools Dimension Quantity Release all cables by loosening their rubber Combination 17 mm seals from the ends of the distribution box. wrench Dismantle the screws (7) holding the circuit board. Torx Carefully remove the circuit board.

  • Page 42: Ignition Switch, Changing

    Electrical System Make sure the two clip nuts (4) are not lost. IMPORTANT! Dismantle the nut (3) and seal from the ignition The sensor has a thin wall with a fine thread switch (1). and the thread strip if tightened too tight. Remove the ignition switch through the steering wheel console.

  • Page 43: Hour Meter, Changing

    Electrical System Hour Meter, Changing Temperature Gage, Changing Dismantle the front cover of the steering wheel Tools Dimension Quantity console (2). Torx Loosen the headlight insert (1) and move out of the way. Make sure the two clip nuts are not lost. Dismantle the front cover (2) from the steering wheel console.

  • Page 44: Hydraulic System

    Hydraulic System HYDRAULIC SYSTEM Hydraulic Hygiene Keep the hydraulic system clean. Remember to: • Clean thoroughly before opening the filler cap or disconnecting anything. • Use clean vessels with topping up oil. • Use only clean oil that has been stored in sealed containers. •...

  • Page 45: Hydraulic Couplings, Pipes And Hoses

    Hydraulic System Hydraulic Couplings, Pipes and Hoses Aluminum hydraulic pipes must always be loosened at both ends when dismantling. It is essential to use two tools, of which one is used as a counterhold, both when loosening and tightening hoses, so that the hose is not exerted to tensional stress or rotation when tightening. Elbow nipples can fail or cracks occur when loosening or tightening without counterhold.

  • Page 46: Suction Filter, Changing

    Hydraulic System Suction Filter, Changing Tools Dimension Quantity Socket wrench 8 mm Torque wrench U-grip for 32 mm torque wrench Tilt the seat back. Release the hydraulic line (1) from its connection to the tank (3). Remove the screws (2) and lift up the connection. Remove the suction filter (5) from its connection.

  • Page 47: Hydraulic Pump, Changing

    Hydraulic System Hydraulic Pump, Changing Drive axle Hydraulic pump Hex screws Pump arm Tools Dimension Quantity Allen Key 8 mm Combination 13 mm wrench Combination 16 mm wrench Combination 22 mm wrench Combination 27 mm wrench Combination 32 mm wrench Socket wrench 19 mm Socket wrench...
  • Page 48 Hydraulic System Loosen the pump arm (6) from the pump with Dismantling two screws (7). Dismantle the driver's seat. See Removing Dismantle the hydraulic pipes (2), (5) to the Driver's Seat. hydraulic pump and plug the hole and Dismantle the protective cover under the seat. connections.
  • Page 49 Hydraulic System Place the pump in its location and position it. Torque tighten the two retaining screws (2) holding the pump to the partition wall to 47 Nm. Turn the drive shaft so that two hex screws (1) are visible in the belt pulley mounting and tighten them.

  • Page 50: Rear Transmission, Changing

    Hydraulic System Rear Transmission, Changing Tools Dimension Quantity Torx Combination 14 mm wrench Combination 16 mm wrench Combination 17 mm wrench Combination 22 mm wrench Combination 32 mm wrench Socket wrench 17 mm Socket wrench 18 mm Socket wrench 22 mm Socket wrench 27 mm Allen Key...
  • Page 51 Hydraulic System Loosen the rear end of the connecting rod (1) Dismantling by dismantling the screw (3) with nut (5). Raise the machine and support it under the frame. Make sure not to misplace the bushing (4). Refer to the illustration for the permitted area. Dismantle the rear wheels and wheel hubs from the transmission.
  • Page 52 Hydraulic System 10. If the transmission is being changed, the devices for adjusting the wheel speed (1) and damper for the rear wheels speed (2) must be transferred to the new transmission as below: IMPORTANT! Do not get the components mixed up. It is a good idea to dismantle and reassemble one adjustment device at a time before work on the next adjustment device commences.
  • Page 53 Hydraulic System Assemble the hydraulic hoses and torque Assembling tighten as instructed. Assemble in reverse order. Start by refitting any Insert the screw (1) for the rear wheel speed remove hydraulic adapters. Torque tighten the damper through the link head (3). Assemble adapter on top (1) to 32 Nm.

  • Page 54: Front Transmission, Changing

    Hydraulic System Front Transmission, Changing Tools Dimension Quantity Groove joint pliers Combination 18 mm wrench Combination 22 mm wrench Combination 27 mm wrench Combination 32 mm wrench Allen Key 10 mm Torque wrench Socket wrench 22 mm Socket wrench 27 mm Dismantling Raise the machine and support it under the frame.
  • Page 55 Hydraulic System Loosen the lock nut (2) and dismantle the Dismantle the hydraulic pipes (4), (6) at both ends. parking brake cable (3), tension spring (6), split Loosen the hydraulic hose (5) from the pin (4) and clevis pin (5) on the end of the transmission.

  • Page 56: Filter Holder, Changing

    Hydraulic System Filter Holder, Changing Assembling Install in reverse order. Tools Dimension Quantity If the adapters are to be refitted, they must be Allen Key 8 mm torque tightened to 50 Nm except pos. 5 in the Combination 17 mm illustration, which is tightened to 60 Nm.

  • Page 57: Valve Block Working Hydraulics, Changing

    Hydraulic System Valve Block Working Hydraulics, Changing Steering Servo, Changing Tools Dimension Quantity Tools Dimension Quantity Socket wrench Combination wrench Socket wrench Combination Allen Key wrench Allen Key Combination Combination wrench wrench Combination Socket wrench wrench Torque wrench Combination wrench Torx Combination Dismantling...
  • Page 58 Hydraulic System Unscrew the two screws holding the headlamp IMPORTANT! insert (2). Do not misplace the two loose clip nuts on the lamp insert console. Make sure the O-rings remain mounted in the adapter on the steering servo. Lift out the headlamp insert. IMPORTANT! Connections can be interchanged.

  • Page 59: Steering Cylinder, Replacement

    Hydraulic System Dismantle the steering servo and plate (2). Steering Cylinder, Replacement Dismantle the plate from the steering servo. Tools Dimension Quantity Socket wrench 13 mm Combination 14 mm wrench Combination 19 mm wrench Side cutters Torque wrench U-grip for torque 19 mm wrench Dismantling...

  • Page 60: Steering Cylinder, Changing Joint Bearing

    Hydraulic System Dismantle the shaft with the locking lug (1) from Fit a new cable tie on the cable at the front shaft the steering cylinder's front fastening and cut off locking lug. the cable tie. Remove the steering cylinder. Tightening torque for screws and hydraulic Note how the adapter for the rear hydraulic connections as instructed.

  • Page 61: Lifting Cylinder, Replacement

    Hydraulic System Lifting Cylinder, Replacement Assembling Assemble in the reverse order. Tools Dimension Quantity Bleed the lift cylinder by lowering and lifting the Combination 19 mm lift arms repeated times with the engine started. wrench Circlip pliers Check for any leakage from the lift cylinder Screw driver 10 mm hydraulic connections.

  • Page 62: Cutting Deck

    Cutting deck Remove the grease nipple (4). CUTTING DECK Lock the blade with a wooden block. Bearing Housing Blade Bearing, Changing Loosen the flanged nut (1) on the belt pulley Tools Dimension Quantity about 1.5 turns. Torx Put a 24 mm socket with extender on the loosened nut.

  • Page 63: Bearing Housing, Changing Bearing

    Cutting deck Tightening torque for the blade screw and belt 12. Remove the four nuts (1) with screws holding pulley nut is 110 Nm. the bearing housing. Lubricate the bearing through the grease nipple 13. Remove the bearing housing (2). before taking the cutting deck into service.
  • Page 64 Cutting deck Clean the contact surfaces on the blade, blade washer, bearing housing and belt pulley. Clean the inside of the bearing housing. Lubricate the bearing seats, blade mounting and pack boxes with a thin layer or lubricant. Assemble bearing (6), spacers (5), (8) and packing boxes (4).

  • Page 65: Technical Data

    Technical Data Technical Data P 520D P 525D Dimensions Length without cutting deck, cm/in 208 / 81.9 211 / 83.07 Width without cutting deck, cm/in 111 / 44.1 114 / 44.88 Height, cm/ft 129 / 50.8 133 / 52.4 Operating weight without cutting deck,...

  • Page 66: Technical Data - Sound And Vibration Levels

    Technical Data Technical Data - Sound and Vibration Levels P 520D P 525D Combi 132 Combi 155 Combi 132 Combi 155 Noise emissions (see note 3) Noise power level, measured dB(A) Noise power level, guaranteed dB(A) Noise levels (see note 4)
  • Page 69 115 73 58-26 2014W42...

This manual is also suitable for:

P 525d

Table of Contents