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Husqvarna Rider 13 AWD Workshop Manual

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Workshop manual
Rider 13 AWD
Rider 175 AWD
Rider 15V2 AWD
English

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  Summary of Contents for Husqvarna Rider 13 AWD

  • Page 1 Workshop manual Rider 13 AWD Rider 175 AWD Rider 15V2 AWD English...
  • Page 3: Table Of Contents

    Workshop Manual for the Rider 13 AWD, Rider 175 AWD and Rider 15V2 AWD Safety Instructions ..........3 Removing/Fitting the Cable Pulley ....54 General Instructions ..........3 Adjusting the parking brake, Special Instructions ..........3 Rider AWD-machines ........55 Risk of sparking ..........4 Adjusting of the Hydrostatic Transmission Special Tools ............5...
  • Page 4 Electrical system ..........115 Wiring diagram Rider 13 AWD, Rider 15V2 AWD and Rider 175 AWD ....115 Ignition and Starter Lock .........117 Main fuses ............117 Safety System ..........118 Hydraulic System ..........120 Hydraulic Hygiene ...........120 Hydraulic Oils ..........120 Fixing Oil Leaks ..........120 Keep the hydraulic oil clean ......121...
  • 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 48-01 506 56 76-01 506 89 92-01 506 89 93-01 535 41 32-01 506 79 06-01 6021-034...
  • Page 8 SPECIAL TOOLS 506 66 48-01 506 56 76-01 506 79 06-01 8009-518 6021-035 535 41 32-01 506 89 93-01 8009-517 8009-515 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: Specifications

    SPECIFICATIONS Specifications Rider 13 AWD Rider 15 V2 AWD Rider 175 AWD Dimensions and weight Length, base machine 2010 mm / 6.58 ft 2020 mm / 6.61 ft 2020 mm / 6.61 ft Length with Combi 112 2400 mm / 7.87 ft 2450 mm / 8.04 ft...
  • Page 11 SPECIFICATIONS Rider 13 AWD Rider 15 V2 AWD Rider 175 AWD Electrical System Type 12 V, negative grounded 12 V, negative grounded 12 V, negative grounded Battery 12 V, 24 Ah 12 V, 24 Ah 12 V, 24 Ah Main fuse...
  • Page 12 SPECIFICATIONS Cutting unit Combi 94 Combi 103 Cutting width 940 mm / 37" 1030 mm / 40.5" Cutting heights 45–95 mm / 1.75–3.75" 45–95 mm / 1.75–3.75" Blade length 360 mm / 14" 410 mm / 16" Guaranteed noise level 100 dB(A) 100 dB(A) Width...
  • Page 13: Delivery And Dealer Service

    DELIVERY AND DEALER SERVICE Delivery and Dealer Service After the first 5 resp. 8 hours Briggs & Stratton after 5 hours and Kawasaki after Delivery Service 8 hours. Fill the battery with battery acid and charge for Change engine oil. four hours.
  • Page 14: 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 (25 hours). the customer as to what additional work is to Replace the air cleaner’s pre-filter (foamed be carried out.
  • Page 15: Service Schedule

    DELIVERY AND DEALER SERVICE Service Schedule = Described in this workshop manual. The following is a list of maintenance procedures that must be performed on the rider. Most of the = Not described in this workshop manual or the points that are not described in this workshop operator’s manual.
  • Page 16 Check/adjust the parking brake. Inspect the flame proofing/spark – arrestor (extra equipment). Replace the engine oil filter – (every 200 hours). Not Rider 13 AWD Clean/replace the spark plugs. – Change the inline fuel filter. – Clean the cooling fins. –...
  • Page 17 DELIVERY AND DEALER SERVICE Maintenance Page Daily Daily At least Maintenance interval in Weekly mainte- mainte- once a hours mainte- nance nance year nance before after Check the play in the engine valves Check whether the oil needs to be 4, 5) changed in the transmission (every 200 hours).
  • Page 18: 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 19 DELIVERY AND DEALER SERVICE Packaging and Unpacking Packed components: The machine is normally packed using special Number Component packaging when delivered from the factory. This 1 pc Steering wheel with steering rod packaging is comprised of a wood base with a strong cardboard top section, all held together with 1 pc Allen screw for steering rod...
  • Page 20: 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. Contact a doctor as soon as possible.
  • Page 21: Steering Wheel

    DELIVERY AND DEALER SERVICE Steering Wheel • Fit the steering wheel with the steering rod on the steering column. Choose a suitable height position. • Thread the Allen screw into the thread of the steering column. Work the wheel and tighten the Allen screw so that it reaches the bottom of the thread.
  • Page 22: Check The Oil Level In The Hydraulic Tank

    DELIVERY AND DEALER SERVICE Check the oil level in the hydraulic tank Remove the transmission cover. Loosen both screws (one on each side) and lift off the transmission cover. Leave the cover removed for now. 6021-030 Transmission cover Check that there is oil in the hydraulic tank. Fill if necessary with engine oil SAE 10W/40 (class SF-CC).
  • Page 23: Checking And Adjusting The Cutting Unit

    DELIVERY AND DEALER SERVICE Checking and Adjusting the Cutting Unit Performed after checking the tyre air pres- sures. See “Adjusting the Units Parallellism and Cutting Height”. Test Running Fill with petrol. The engine should be run on a minimum of 87-octane unleaded petrol (not mixed with oil).
  • Page 24: Engine Speed Regulator

    Engine Speed Regulator Cutting height setting Check that the engine’s max. speed is adjusted at: Max speed Idling Rider 13 AWD 2900–3100 rpm 1500 rpm Rider 15V2 AWD 2825–2975 rpm 1500 rpm Rider 175 AWD 2825–2975 rpm 1500 rpm Final inspection Bleed the hydraulic system of excess air after test running.
  • Page 25 DELIVERY AND DEALER SERVICE English-...
  • Page 26: Design And Function

    General 8042-002 This publication describes the Husqvarna Rider 13 AWD, Rider 15V2 AWD and Rider 175 AWD from the 2006 model. There are special workshop manuals for older machines. Husqvarna Riders are a series of large capacity riders. They are available in several sizes, ranging from the smallest, the Rider 11, to the largest, the ProFlex 21 AWD.
  • Page 27 DESIGN AND FUNCTION Rider 13 AWD is equipped as standard with cutting unit type Combi 94 Rider 15V2 AWD and Rider 175 AWD can be delivered with Combi 103 or Combi 112. 8009-288 6021-025 Combi 103 Combi 94 8009-288 Combi 112...
  • Page 28: Serial Number

    DESIGN AND FUNCTION Serial Number The machine’s serial number is found on the printed plate at the front under the seat. Stated on the plate, from the top, are: • The machine’s type designation. • The manufacturer’s type number. • The machine’s serial number (s/n).
  • Page 29: Engine

    DESIGN AND FUNCTION Engine Husqvarna Rider AWD are Rider lawn mowers with air-cooled engines from Briggs & Stratton or Kawasaki. Major engine repairs are not described in this workshop manual. This information can be found in the engine manufacturer’s manuals, which contain detailed information about adjusting and repairing the engines.
  • Page 30: Steering

    DESIGN AND FUNCTION Steering All mowers in the Rider series have articulated 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 31: Driving

    8009-626 Front axle Rear axle on Rider 13 AWD, Rider 15V2 AWD, Rider 175 AWD from above. There is a hydraulic bypass valve that is operated by a control behind the left-hand wheel to move the machine without the rear axle’s drive engaged.
  • Page 32 DESIGN AND FUNCTION The oil is drained using two plugs on the underside. One plug drains the hydraulic motor and the other drains the differential. 8009-832 Oil drainage 8009-856 Drive system AWD English-...
  • Page 33: Cutting Unit

    The entire Rider series is equipped with a front-mounted cutting unit in order to mow efficiently even in confined areas. Rider 13 AWD is supplied with cutting unit Combi 94. Rider 15V2 AWD and Rider 175 AWD are supplied with cutting unit Combi 103 or Combi 112.
  • Page 34 DESIGN AND FUNCTION The mowing deck is raised and lowered using the When lowering the unit, the two connecting rods, mechanical lifting lever, which actuates a shaft that via the three-point link, will alter the belt adjuster rotates. so that the drive belt is tensioned and the blades begin to rotate.
  • Page 35 DESIGN AND FUNCTION English -...
  • Page 36: Repair Instructions

    REPAIR INSTRUCTIONS Repair instructions Removing the Briggs & Stratton engine Remove the engine cover and transmission cover. IMPORTANT INFORMATION Hold the bolts so that the poles are not put under strain. Loosen the battery’s retaining strap. Remove the protective cover and loosen 8009-427 the cable connections.
  • Page 37 REPAIR INSTRUCTIONS Remove the hose clamp on the fuel hose by the fuel pump and pull the fuel hose downwards. Tie the hose higher than the fuel tank level. 8009-425 Loosen the exhaust pipe clamp. Then remove the exhaust pipe. Loosen the muffler’s mounting bolts if necessary.
  • Page 38 REPAIR INSTRUCTIONS 10. Insert tool, part number 506 79 06–01, in 506 89 92-01 the centre of the engine belt pulley. Loosen and remove the Allen screw that holds the belt pulley and engine shaft together. Use tool, part number 506 89 92–01, to 506 79 06-01 counterhold.
  • Page 39 REPAIR INSTRUCTIONS Fitting the Briggs & Stratton engine IMPORTANT INFORMATION Hold the bolts so that the poles are not put under strain. 6019-039 Lower the engine into place and tighten the engine fixtures (two on each side of the engine) with a torque of (20–25 Nm/ 14–18 lbft).
  • Page 40 REPAIR INSTRUCTIONS Press in the belt adjuster and align the pump belt in position. 8009-839 Fit the belt guide. Adjust the belt guide against the lower belt in the belt pulley as needed. Fit the skid guard if used. 8009-737 Attach the throttle cable to the carburet- tor and fit the cable clip without tighten- ing it.
  • Page 41 REPAIR INSTRUCTIONS Choke not actuated. 8009-404 Fit the exhaust pipe and tighten the mounting bolts on the exhaust flange and muffler and finally the pipe clamp. 8042-115 Firmly fit the fuel hose to the fuel pump and attach the hose clamp. 8009-425 10.
  • Page 42 REPAIR INSTRUCTIONS 11. Screw into place the cable from the start relay to the starter. 8009-426 12. Lift the battery into position and attach the cable connectors and cover, tighten the fastening strap. 8009-427 English-...
  • Page 43: Removing The Kawasaki Engine

    REPAIR INSTRUCTIONS Removing the Kawasaki engine Remove the engine cover and transmission 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. 8009-526 Loosen the battery cable connections. Battery installation Then lift out the battery.
  • Page 44 REPAIR INSTRUCTIONS Loosen the exhaust pipe clamp. Then remove the exhaust pipe. Loosen the muffler’s mounting bolts if necessary. 8042-115 Exhaust system Push in the belt adjuster and pry off the pump belt. 8009-839 10. Remove the belt guide for the engine belt pulley.
  • Page 45 REPAIR INSTRUCTIONS 11. Push tool no. 506 56 76–01 into the cen- tre 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.
  • Page 46: Fitting The Kawasaki Engine

    REPAIR INSTRUCTIONS Fitting the Kawasaki 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 47 REPAIR INSTRUCTIONS Fit the belt guide. Adjust the belt guide against the lower belt in the belt pulley as needed. Fit the skid guard. 8009-737 Belt guide Attach the throttle cable to the throttle and fit the cable clip without tightening it. Make sure that it goes into the proper hole.
  • Page 48 REPAIR INSTRUCTIONS IMPORTANT INFORMATION Hold the battery cable bolts in place so that the electrodes are not strained. Lift the battery into position and attach the cable connectors and cover, tighten the fastening strap. 8009-427 Battery installation Fit the engine cover and transmission cover.
  • Page 49: Checking The Engine's Oil Level, Briggs & Stratton

    REPAIR INSTRUCTIONS Checking the engine’s oil level, Briggs & Stratton 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.
  • Page 50: Changing The Engine Oil, Briggs & Stratton

    REPAIR INSTRUCTIONS Changing the engine oil, Briggs & Stratton The engine oil should be changed the first time after 5 hours running time. It should then be changed after every 50 hours of running time. With heavy loads or high temperatures replace the oil after every 25 hours of driving.
  • Page 51: Checking The Engine's Oil Level, Kawasaki

    REPAIR INSTRUCTIONS Checking the engine’s oil level, Kawasaki Check the oil level in the engine when the Rider stands horizontal with the engine switched off. Open the engine cover. Loosen the dipstick, pull it up and wipe it off. Now insert the dipstick again, without tightening it.
  • Page 52: Fuel Tank

    REPAIR INSTRUCTIONS Fuel tank Removal WARNING! Petrol is highly flammable and environmentally hazardous. Exercise caution to avoid fire and spillage. Place an appropriate container to catch the petrol. The tank holds approx. 7 litres / 7.4 USqt. Empty the petrol tank by removing the hose from the connector under the tank.
  • Page 53: Changing The Engine Oil Kawasaki

    REPAIR INSTRUCTIONS Changing the engine oil Kawasaki The engine oil should be changed the first time after 8 hours running time. It should then be changed after every 100 hours of running time. WARNING! Engine oil can be very hot if it is drained directly after stopping the engine.
  • Page 54: 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.
  • Page 55: Replacing The Steering Cables

    REPAIR INSTRUCTIONS 8009-372 Power steering and steering cables Replacing the Steering Cables Loosen the steering cables’ rear mount (1). Remove the frame plate. Loosen the steering cables’ front fixture (2) by the steering chain (3) and pull out the steering cables through the frame.
  • Page 56: Removing/Fitting The Cable Pulley

    REPAIR INSTRUCTIONS 8009-371 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 57: Adjusting The Parking Brake, Rider Awd-Machines

    REPAIR INSTRUCTIONS Adjusting the parking brake, Rider AWD-machines 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 machine does not stand still, the parking brake should be adjusted according to the following.
  • Page 58: Adjusting Of The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS Adjusting of the Hydrostatic Transmission Cable The hydrostatic transmission cable is adjusted as follows: Remove the transmission cover. Loosen both screws (one on each side) and lift off the transmission cover. Check that the front ball joint on the rod is fitted in the second hole from the top on the rear axle’s control arm.
  • Page 59: Adjusting The Throttle Cable, Briggs & Stratton

    REPAIR INSTRUCTIONS Adjusting the throttle cable, Briggs & Stratton The throttle cable may need to be adjusted, if the engine does not respond as it should when accelerating, if it produces black smoke or maximum revs are not reached. Loosen the clamping screw (by the arrow), and slide the throttle to the choke position.
  • Page 60: Checking And Adjusting The Choke Cable, Kawasaki

    REPAIR INSTRUCTIONS Checking and adjusting the choke cable, Kawasaki If the engine produces black smoke or is difficult to start, this can be because the choke cable is incorrectly adjusted (upper cable). If adjustments are necessary, they can be made as follows: Loosen the clamping screw for the cable’s outer casing and move the choke lever to the full choke position.
  • Page 61 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 ball joint. 8009-203 Clean, see “Working Methods”. Mark and Locking spring remove the hydraulic hoses from the couplings under the machine.
  • Page 62 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. 6012-027 Lower bearings 12. Remove the upper bearings from above; if they are stuck tap them from below.
  • Page 63: Removing The Pendulum Shaft

    REPAIR INSTRUCTIONS Removing the Pendulum Shaft Jack up the rider in front of the rear frame. Clean, see “Working Methods”. 6012-029 Jacking up Mark and remove the hydraulic hoses from the couplings under the machine. 8009-820 Hydraulic hoses Loosen the idler’s spring. 8009-821 Idler’s spring English-...
  • Page 64: Replacing Bushings

    REPAIR INSTRUCTIONS Remove the hydrostatic transmission cable from the arm and the casing from the bracket. 8009-822 Hydrostatic cable Remove the circlip and lift off the hydrostatic transmission’s fan. Remove the rear belt from the impeller and the adjuster pulley. Remove the circlip and washer from the 8009-823 pendulum shaft and pull loose the rear...
  • Page 65: Fitting The Pendulum Shaft

    REPAIR INSTRUCTIONS Fitting the Pendulum Shaft Lubricate half the shaft (the half that has not been lathed) and press it into the steering spindle from the rear (see illustration). Fit the washer and circlip on the pendulum shaft by the inner mount. Fit the dust cover (with thin lip towards the rear) approx.
  • Page 66 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. 8009-825 Circlip Release the front synchronisation link for speed from the front axle.
  • Page 67 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. 8009-826 Hydraulic pipe, top Remove the five bolts holding the front axle and lower the front axle.
  • Page 68 REPAIR INSTRUCTIONS 8009-829 Rear front axle mounting 10. Release the parking brake cable from the front axle. 8009-691 Parking Brake Cable 11. Loosen the stop screws (2) and remove the bearing on right-hand side. 8009-625 Right front axle bearings Assembly Assemble the front axle in the reverse order in relation to dismantling.
  • Page 69: Rear Axle

    REPAIR INSTRUCTIONS Pipe couplings are lightly oiled before assembly. Grease the axles for protection against corrosion before the wheels are fitted. The spacer sleeves on the inside of the wheels are of different lengths. Left 36.3 mm with washer Right 45.5 mm, no washer Do not mix up the rear axle’s spacer sleeves.
  • Page 70 REPAIR INSTRUCTIONS Drain out the oil if necessary, two plugs. 8009-832 Oil drainage Mark the hydraulic hoses and release 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.
  • Page 71 REPAIR INSTRUCTIONS Release the cable and link rod for the accelerator from the horizontal arm. Remove the clutch control. Pry off the rear V-belt from the fan pulley. Place the belt over the groove on the crankshaft belt pulley and move it between the fan blades.
  • Page 72 Ensure the steering wheel position does not change while work is in progress. The measurement should be made using Husqvarna's laser tachometer. Max. deviation is 5 %. Check that the synchronisation link is fitted in the top hole on the front axle’s arm.
  • Page 73 REPAIR INSTRUCTIONS Jack up and block the machine with the wheels on one side on the ground and the wheels on the other side in the air. Check that the steering wheel position has not changed. Mark the free running wheels with reflex tape or the like.
  • Page 74: Replacing The Hydrostatic Transmission Shaft Seals

    REPAIR INSTRUCTIONS Replacing the Hydrostatic Transmission Shaft Seals Seal Replacement, Ingoing Shaft Remove the cooling fan, it is held by a circlip. Remove the belt pulley from the ingoing shaft by pulling it upwards and then removing the circlip under the pulley. IMPORTANT INFORMATION The area around the seal must be abso- lutely clean! If the hydrostatic transmis-...
  • Page 75 REPAIR INSTRUCTIONS Place the seal on the shaft with the smooth side up and press it carefully down. Use the thick end of a 1/4" extender to carefully tap the seal down until the top of the seal is even with the upper edge of the shaft housing.
  • Page 76 REPAIR INSTRUCTIONS Wrap insulating tape around the out- going shaft from the beginning of the key groove and outwards until even the threads of the circlip are covered with tape. This is done to protect the new seal from damage. Lubricate the shaft and the inside of the new seal with lubricant so that the seal slips on smoothly.
  • Page 77: Replacing The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS 11. Bleed the hydraulic system of excess air, according to “Bleeding the drive system”. 12. Run the rider and make sure that there are no oil leaks from the new shaft seals. 13. Check the oil level after test running and top up as needed.
  • Page 78 REPAIR INSTRUCTIONS Remove the transmission cover. 6021-030 Transmission cover Remove the spring lock and the hydro- static transmission cable’s rear link joint from the arm. Remove the rear clamp. 8009-214 Rear link joint Lift off the front link joint and pull out the cable.
  • Page 79: Fitting The Hydrostatic Transmission Cable

    REPAIR INSTRUCTIONS Remove the entire hydrostatic transmis- sion cable. 6019-009 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. 6019-018 Front link joint Run the cable through the rider so that it follows the same path as the old cable did.
  • Page 80 REPAIR INSTRUCTIONS Press in the cable casing in the forward fastener in the centre bracket. 6019-023 Forward mount in centre bracket Tighten the hydrostatic transmission cable’s front clamp. Press the link joint onto its fastener and attach the locking spring. 6019-024 Front clamp Attach the link joint to the rear part of the...
  • Page 81 REPAIR INSTRUCTIONS 10. Connect the rear link joint and attach the locking spring. 8009-203 Locking spring 11. Tighten the rear link joint’s lock nut. 12. Screw on the frame plate. 13. Test drive the machine forwards and in reverse. 8042-119 Frame plate English-...
  • Page 82: Bleeding The Drive System

    REPAIR INSTRUCTIONS Bleeding the drive system IMPORTANT INFORMATION Ensure cleanliness. Used oil may not be reused. Handle waste oil as environmental hazardous waste. Avoid skin contact; wash with soap and water in case of spillage. See “Hydraulic Hygiene” on page 120. IMPORTANT INFORMATION The tank must never be run empty while work is underway.
  • Page 83 REPAIR INSTRUCTIONS Fill the tank completely with oil. Wait a few minutes and top up. 6012-048 Transmission oil tank Turn the wheels by hand and top up. Make sure that the clutch control valves are closed. Start the engine and idle, top up. Release the parking brake and actuate the forward and reverse pedals 4 x 5 seconds, top up.
  • Page 84: Adjustment Of The Transmission's Neutral Position

    REPAIR INSTRUCTIONS Adjustment of the transmission’s neutral position Bleed the drive system, see “Bleeding the drive system”. Lift the rear of the Rider, front and back, so that the all wheels spin freely and place jack stands under the machine. The neutral position is adjusted by turning the hexagonal shaft on the transmission (see figure).
  • Page 85: Transmission Maintenance

    REPAIR INSTRUCTIONS Method 2 1 = Shaft 2 = Lock nut If the drive shafts do not rotate backwards despite the fact that the hexagonal shaft has rotated a full revolution, the neutral position is to be adjusted in the following manner: •...
  • Page 86 REPAIR INSTRUCTIONS Hydrostatic transmission front axle / rear axle The transmission holds about 5 litres (5.2 US qt) (SAE 10W/40 engine oil, class SF–CC or higher). Drain the hydrostatic transmissions using the two plugs on each axle. Replace the hydrostatic transmission filter, see separate instructions.
  • Page 87: Adjusting The Lever Housing

    REPAIR INSTRUCTIONS Remove the cover and pull out the filter. 6020-003 Hydrostatic transmission filter Fit the new filter in position. Coax it in so that the rubber seal in the front end-plate enters its position. If the spring protrudes so that it must be pressed together before the cover “threads catch”...
  • Page 88: Replacing The Hydraulic Pump's Drive Belt

    REPAIR INSTRUCTIONS Replacing the hydraulic pump’s drive belt Removal Remove the transmission cover. 6021-030 Transmission cover Pry off the belt from the belt adjuster. 8009-839 Belt tensioning Remove the belt guide for the centre belt. 8009-736 Belt guide Pull off the centre belt from the engine’s pulley and pull out the rear section.
  • Page 89 REPAIR INSTRUCTIONS Pry off the pump belt upwards on the engine pulley. Pry off the pump belt from the pump pulley. Guide the belt between the fan blades. Pull the pump belt off of the engine’s pulley and move it under the engine belt pulleys.
  • Page 90: Replacing The Centre Belt

    REPAIR INSTRUCTIONS Replacing the Centre Belt Remove the rear belt guide for the centre belt. Remove the centre belt and mount a 8009-737 Rear belt guide new belt. Fit and adjust the belt guide with the lower belt on the engine belt pulley. 8009-736 Belt guide Check and adjust the belt adjuster.
  • Page 91: Replacing The Front Belt

    REPAIR INSTRUCTIONS Replacing the front belt Dismantling The entire belt is removed according to the following when a snow blade is to be attached to the machine. Put the cutting unit in the service position. Pull the centre belt off of the centre pulley.
  • Page 92 REPAIR INSTRUCTIONS Place the centre belt in position in the centre pulley’s lower groove. 8009-695 Centre pulley Reset the cutting unit in the mowing position. Make sure that the tongue (3) mates with the loop on the underside of the machine. 8009-595 Tongue in the loop The belt is fitted on the cutting unit’s...
  • Page 93: Equipment Frame

    REPAIR INSTRUCTIONS Equipment frame Removal Remove the cutting unit, see “Removing the Cutting Unit”. Unscrew the adjust nuts completely so that the springs release. 8009-845 Adjuster nuts Remove the split pin and release the link for the height adjustment from the triangular link.
  • Page 94: Fitting The Cutting Unit

    REPAIR INSTRUCTIONS Pull the equipment frame forwards. Assembling the equipment frame Insert the equipment frame in position Fit the chain for the lift of the equipment frame. Insert the hairpin spring from the rear. Fit the guide screw on the left-hand side. The screw is inserted at angle from the front through the hole in the equipment frame, whereupon the frame is moved...
  • Page 95 REPAIR INSTRUCTIONS 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. 8009-595 Tongue in the loop Fit the screw and secure with a locking pin. 6017-120 Bolt in the front bracket Place the belt over the runner pulley and...
  • Page 96: Removing The Cutting Unit (Combi 103, Combi 112)

    REPAIR INSTRUCTIONS Fit the anti-scalp rollers in position Fit the front cover. 8009-439 Support wheels Secure the springs on the adjuster pulley. 8009-598 Adjuster pulley’s spring Removing the cutting unit (Combi 103, Combi 112) WARNING! Wear protective glasses when dismantling the cutting unit. The springs that tension the belt can fly off and cause personal injury.
  • Page 97: Removing The Cutting Unit

    REPAIR INSTRUCTIONS Removing the cutting unit Combi 94 Position the machine on flat ground. Apply and lock the parking brake. Set the cutting height control in the lowest position and lift up the cutting unit. 8042-047 Remove the front hood by removing the pin.
  • Page 98 REPAIR INSTRUCTIONS Place the handle on the frame arch. 8042-049 Lift off the drive belt and hang on the load-relieving hook. 8042-050 Loosen on the cutting height stay and place in the holder. 8042-051 English-...
  • Page 99: The Cutting Unit's Service Position

    REPAIR INSTRUCTIONS Grip the front edge of the unit and pull forwards until it stops. 8042-052 Unscrew the screws holding the cutting deck. 8042-118 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.
  • Page 100 REPAIR INSTRUCTIONS Remove the front cover by loosening the split pin. (Complete instructions for the service position can be found on the inside of the front cover). 8042-096 Dismantling the front cover Loosen the two anti-scalp rollers, located under the front cover. 8042-084 Support wheels English-...
  • Page 101 REPAIR INSTRUCTIONS Fit the two anti-scalp rollers on each side of the cutting unit’s rear section. WARNING! Wear protective glasses when dismantling the cutting unit. The springs that tension the belt can fly off and cause personal injury. 8042-086 Placement of the anti-scalp rollers Loosen the spring on the drive belt’s belt idler.
  • Page 102: Releasing The Service Position

    REPAIR INSTRUCTIONS Lift off the drive belt (1). Now pull out the split pin (2). 8042-086 Drive belt and split pin Pull the frame forwards and refit the pin. 8042-087 Refit the split pin 10. Grasp the cutting unit’s front edge, pull out and lift up into the service position.
  • Page 103: Placing In The Service Position Combi 94

    REPAIR INSTRUCTIONS Placing in the service position Combi 94 Position the machine on flat ground. Apply and lock the parking brake. Set the cutting height control in the lowest position and lift up the cutting unit. 8042-047 Remove the front hood by removing the pin. 8042-035 Loosen the spring on the drive belt’s belt idler by loosening the handle.
  • Page 104 REPAIR INSTRUCTIONS Place the handle on the frame arch. 8042-049 Lift off the drive belt and hang on the load-relieving hook. 8042-050 Loosen on the cutting height stay and place in the holder. 8042-051 English-...
  • Page 105 REPAIR INSTRUCTIONS Grip the front edge of the unit and pull forwards until it stops 8042-052 Lift the unit until it stops and a clicking sound is heard. 8042-053 The unit locks automatically in the vertical position. 8042-054 English-...
  • Page 106: 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 8042-054 Replace the cutting height stay and the belt. Tension the belt with the belt adjuster. 8042-055 Fit the front cover.
  • Page 107: Adjusting The Unit's Parallelism And Cutting Height

    REPAIR INSTRUCTIONS Adjusting the Unit’s Parallelism and Cutting Height When a new cutting unit is attached, you need to adjust the parallelism and cutting height. Starting position: Check the air pressure in the tyres 60 kPa/0.6 bar/9 PSI. The cutting unit shall be lowered onto a flat surface.
  • Page 108: Cutting Height

    REPAIR INSTRUCTIONS Cutting height Loosen the nut on the height adjustment strut. Adjust so that the distance between ground and the cutting unit’s edge at the front of the cover is for: • Combi 94 40 mm • Combi 103 40 mm •...
  • Page 109: Checking And Adjusting The Ground Pressure

    REPAIR INSTRUCTIONS Checking and Adjusting the Ground Pressure In order to achieve the best mowing result the cutting unit should follow the ground without touching it too heavily. Pressure is adjusted using a screw and spring on each side of the rider.
  • Page 110: Removing Blades With Bearings

    REPAIR INSTRUCTIONS 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 as illustrated. The belt position diagram is also on a decal on the inside. 8009-376 Belt adjuster spring Removing Blades with Bearings...
  • Page 111 REPAIR INSTRUCTIONS Loosen the four screws that hold the blade bearing and remove the entire bearing assembly from the cutting unit. 6012-083 Screws, blade bearing Remove the hub using a puller. Do not lose the key that sits between the hub and the shaft.
  • Page 112 REPAIR INSTRUCTIONS 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 113 REPAIR INSTRUCTIONS Remove the nuts, which hold the bearing housing in position, from the top of the cover. Make sure that the unit is posi- tioned with the belt pulley against the unit’s cover. 8009-293 Bearing housing nuts Place a wooden block under the unit cover so that the blade is free from the supporting surface.
  • Page 114: Sharpening And Balancing Blades

    REPAIR INSTRUCTIONS IMPORTANT INFORMATION When tightening the blade shaft screws, the transmission side should always be tight- ened first and then the blade screws. The belt pulley can be turned the wrong way, the thicker side should be turned downwards towards the blade. An oil filter wrench, for example, can be used to hold the pulley in place when the screw is tightened.
  • Page 115: Removing The Bioclip Plug (Combi)

    REPAIR INSTRUCTIONS WARNING! If the blades are cracked, whether caused by poor repair or other damage, they could break while being used. The risk increases if the blades are poorly balanced. Removing the BioClip plug (Combi) To change a Combi unit from the BioClip function to a cutting unit with rear ejection, remove the BioClip plug, which is located under the unit, attached with three screws.
  • Page 116 REPAIR INSTRUCTIONS English-...
  • Page 117: Electrical System

    ELECTRICAL SYSTEM Electrical system Wiring diagram Rider 13 AWD, Rider 15V2 AWD and Rider 175 AWD 8009-849 Electrical system: component locations Microswitch, seat Key for colour abbreviations in wiring diagram Ignition and Starter Lock = Red Microswitch, lifting lever = Blue...
  • Page 118 ELECTRICAL SYSTEM 8009-679 Wiring diagram AWD English-...
  • Page 119: Ignition And Starter Lock

    ELECTRICAL SYSTEM Ignition and Starter Lock Loosen the right-hand wing cover. Remove the inner protecting plate on the gear lever carrier. Release the connector from the ignition lock by pulling it straight down. Remove the ignition key and the rubber seal.
  • Page 120: Safety System

    ELECTRICAL SYSTEM Safety System Check daily to ensure that the safety system works The rider is equipped with a safety system that by attempting to start the engine when one of the prevents starting or driving under the following conditions is not met. Change the conditions and conditions.
  • Page 121 ELECTRICAL SYSTEM Microswitch lifting lever Loosen the right-hand wing cover. Remove the inner protecting plate on the gear lever carrier. Disconnect the connector from the microswitch. Remove the microswitch. Assembling is done in the reverse order without setting. 8009-422 Microswitch: Mowing Deck Microswitch: Seat Fold up the seat and remove the spring disc with spring and spacer sleeve.
  • Page 122: Hydraulic System

    HYDRAULIC SYSTEM Hydraulic System • Dirt particles that enter the system include: - Contaminants entering when topping up with oil. Hydraulic Hygiene - Dust particles from the workshop. Keep the hydraulic system clean. Remember to: - Gasket and thread sealants from assembly. •...
  • Page 123: 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 124: Hydraulic System Awd

    HYDRAULIC SYSTEM Hydraulic system AWD Hydraulic tank Filter Hydraulic pump, variable Hydraulic motor, fixed Control arm displacement Hydraulic motor, variable 8009-857 English-...
  • Page 125: Hose Bundle

    HYDRAULIC SYSTEM Hose bundle The hoses under the 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.
  • Page 126 HYDRAULIC SYSTEM English-...
  • Page 127 The engine will not start...
  • Page 128 Engine starts but does not run satisfactorily...
  • Page 129 The motor runs normally, low /no power...
  • Page 130 Low power, abnormal noise...
  • Page 131 Transmission: Overheating, other indications...
  • Page 132 Uneven mowing result, vibrations...
  • Page 134 115 03 16-26 2008W12...