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Husqvarna P524 EFI Workshop Manual

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Workshop manual
P524 EFI
English
662 - 001 - 23.10.2018

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  Summary of Contents for Husqvarna P524 EFI

  • Page 1 Workshop manual P524 EFI English 662 - 001 - 23.10.2018...
  • Page 2: Table Of Contents

    10 Troubleshooting 4.4 To fill fuel..............9 10.1 To measure voltage........... 75 4.5 To start the engine, P524 EFI........ 9 10.2 To measure resistance........75 4.6 To do a check of the engine speed...... 10 10.3 To do a check of cables and connectors....75 4.7 To do a last inspection.........
  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 662 - 001 - 23.10.2018 Introduction - 3...
  • Page 4: Safety

    2 Safety 2.1 General safety instructions • Explosive gases can come from the battery. Do not smoke near the battery. Keep the battery away from WARNING: Read the warning instructions that open flames and sparks. follow before you use the product. 2.4 Risk of sparks The service center that repairs the product must have Sparks can occur when you do work on the battery and...
  • Page 5 Move rearward. Warning: rotating parts. Keep body parts away. This product is in accordance with applicable EC directives. Hot surface. Noise emission to the environment according to the European Community's Directive. The product's emission is specified in the Technical data chapter and Do not touch.
  • Page 6 Do not use the safety belt if the ROPS is disengaged. Cutting height. Always use the safety belt when the ROPS is engaged. Servicing position. The blades are engaged. Note: Other symbols/decals on the product refer to certification requirements for some commercial areas. The blades are disengaged.
  • Page 7: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Pre delivery inspection Complete the sales certificate and the customer records. Write the serial number in the operator's manual and confirm the delivery service in the service book. 662 - 001 - 23.10.2018 Prepare and do servicing on the product - 7...
  • Page 8: Assembly

    4 Assembly 4.1 Product overview P524 EFI 6 7 8 9 10 11 12 13 4.2 Battery 1. Forward drive pedal 2. Rearward drive pedal It is not necessary to do maintenance on the battery. It is 3. Light switch the responsibility of the dealer to install the battery.
  • Page 9: Tire Pressure

    Keep a minimum space of 2.5 cm. 7. Push the throttle control to full throttle position. 4.5 To start the engine, P524 EFI 1. Make sure that the bypass valves are closed. Refer Bypass valves on page 21 .
  • Page 10: To Do A Check Of The Engine Speed

    4.6 To do a check of the engine speed 1. Do a check of the engine speed with a Husqvarna tachometer. 2. Make sure that the maximum speed is correct. Refer Technical data on page 84 . 4.7 To do a last inspection •...
  • Page 11: Function Test

    5 Function test 5.1 To do a check of the operation conditions The operation conditions are as follows: • The engine can only be started when the drive of the blades is disengaged. • The engine can only be started when the parking brake is applied.
  • Page 12: Servicing

    6 Servicing 6.1 Servicing schedule not described in this workshop manual can be found in the operator’s manual. The following is a list of maintenance procedures that must be performed on the ride-on mower. Most points Maintenance Daily Week- First Maintenance interval in hours 10 h...
  • Page 13 Maintenance Daily Week- First Maintenance interval in hours 10 h 40 h 25 h 100 h 200 h 400 h Lubricate according to the lubrication chart. Hydrostatic cable with links. Parking brake wire. Throttle control. Choke control. Pivoting wheel. Belt adjuster. 2.
  • Page 14 Maintenance Daily Week- First Maintenance interval in hours 10 h 40 h 25 h 100 h 200 h 400 h Hydraulic oil. Replace the pump belt. Replace the cutting deck drive belt. Oil in the gearbox (SAE 10W/40) / (SAE 10W/50 Synthetic only for AWD).
  • Page 15: Lubrication Overview

    6.2 Lubrication overview 1. Rear axle bearing alcohol. If the friction between the drive belt and the pulley is not sufficient after you clean with alcohol, 2. Link rod replace the drive belt. 3. Articulation bearing 4. Front axle bearing CAUTION: Do not use gasoline or other 5.
  • Page 16: To Lubricate The Cutting Deck

    6.7 To lubricate the parking brake cable b) Lubricate the cable with thin engine oil until the oil starts to release from the bottom. Replace the 1. Remove the 4 screws and remove the frame plate. cable if the oil does not release from the bottom. 2.
  • Page 17: To Lubricate The Seat Slides

    6.9 To lubricate the seat slides 6.12 To lubricate the joint bearing 1. Tilt the seat forward. 1. Lubricate the joint bearing of the articulation with a grease gun until grease comes out. 2. Lubricate the seat slides with engine oil. 6.10 To lubricate the hydrostatic transmission cable 6.13 To lubricate the link rod...
  • Page 18: Servicing Tools

    7 Servicing tools 7.1 Servicing tools • Do not point the laser beam at explosive gases. Note: Special tools for engine and transmission can be 7.2.2 To measure rpm with tachometer found in the related workshop manual. Attach more than one piece of tape on the surface to get the accurate result when measuring at low speed.
  • Page 19: Screw Fasteners

    • Do not cause mechanical chock to the tachometer. tension of the screw in the frame decreases. The screw will then come loose during operation. • Remove the batteries if the tachometer is not used for long periods. 7.3 Screw fasteners ®...
  • Page 20: Function Overview

    8 Function overview 8.1 Serial numbers on the product The product serial number is on the printed type plate (A) above the right footrest plate. The type plate gives the designation, the type number from the manufacturer and the serial number (s/n) of the product. The engine serial number (B) is on the right side of the engine.
  • Page 21: Hydrostatic Transmission

    8.4 Hydrostatic transmission Bypass valve of the front transmission. The product has hydrostatic transmission. The hydraulic pump and the transmissions are 3 different units. 1. Loosen the locknut (A) ¼ - ½ turn. 2. Turn the bypass valve (B) 2 turns counterclockwise. 3.
  • Page 22 Pull up the PTO button to operate a PTO clutch that enables the blades to rotate. The blades stop turning when you push down the PTO button. The cutting height lever is attached to the shaft with a joint and a spring. The cutting height lever can be put in 6 operation positions and 1 service position.
  • Page 23: Repair Instructions

    9 Repair instructions 9.1 Chassis 9.1.1.3 To remove the front cover 1. Release the clip on the front cover with the tool 9.1.1 To remove the covers attached to the ignition key. 9.1.1.1 To remove the engine cover To disassemble 1.
  • Page 24 9.1.1.6 To remove the right footrest plate 3. Remove the 4 bolts from the adjustable seat bracket. 1. Turn and remove the knob on the rearward drive pedal (A). 2. Remove the 2 screws (B and C) and remove the footrest plate.
  • Page 25 9.1.3.2 To replace the parking brake cable 8. Pull back the rubber protection until the parking brake cable can go through the bracket opening. To remove 1. Remove the frame tunnel cover. Refer to the covers on page 23 . 2.
  • Page 26 5. Tighten the nuts moderately to prevent damage to 5. Remove the snap ring and washer in the center of the threads. the wheel hub. 6. Make sure that the parking brake operates correctly. 9.1.4 Wheel hub 9.1.4.1 To disassemble and assemble the wheel hub 1.
  • Page 27 7. Remove the snap ring. 8. Remove the wheel hub. 9. Examine the key in the shaft. Replace the key if it is damaged. 10. Assemble in opposite sequence. 662 - 001 - 23.10.2018 Repair instructions - 27...
  • Page 28 9.1.5 Rear axle 9.1.5.1 Articulated steering overview 1. Control stay 3. Remove the pulley guard. 2. Joint bearing in articulated steering 3. Steering cylinder 4. Link stay 9.1.5.2 To disassemble the link stay 1. Apply the parking brake. To remove 2.
  • Page 29 4. Put a jack assembly below the product to make it 10. Disassemble the rear end of the link stay. stable when the link stay is removed. The illustration shows where to put the supports. To disassemble and 11. Disassemble the seat. Refer to 5.
  • Page 30 16. Remove the 2 screws that hold the bracket for the 9.1.5.4 To disassemble the joint bearing in the pump belt pulley. articulated steering 1. Put a jack assembly below the product. The illustration shows where to put the supports. 2.
  • Page 31 8. Remove the protective cover (A) above the steering 16. Remove the locknut (D), screw (C), washer (E) and joint. sleeve (B) that attach the rear link stay. 17. Lift the rear edge of the rear axle with a jack assembly to decrease the load on the link stay.
  • Page 32 9.1.5.5 To assemble the joint bearing in the 9. Lubricate the link stay through the grease nipples. articulated steering 10. Assemble the steering cylinder (C) to the rear 1. Lubricate the bearing seat and pin with grease that bracket. prevents corrosion. 2.
  • Page 33: Propulsion System

    9.2 Propulsion system 6. Remove the fuel hose from the fuel filter. 9.2.1 To remove and install the engine To remove the 1. Remove the engine cover. Refer to covers on page 23 Risk of 2. Disconnect and remove the battery. Refer to sparks on page 4 .
  • Page 34 9. Remove the 2 clamps on the exhaust pipes below 11. Remove the 3 screws from the brackets of the the muffler. hydraulic oil cooler and put the hydraulic oil cooler to the side. 10. Remove the exhaust pipes from the engine. 12.
  • Page 35 13. Disconnect the PTO clutch. 18. Remove the 4 engine fixtures. 14. Remove the torque stop for the PTO clutch. 19. Use the lift plates to lift the engine. Make sure not to do damage to the PTO clutch when you lift the engine.
  • Page 36 4. Remove the belt pulley (B) and the PTO clutch (A). 9.2.4 To replace the engine oil and the oil filter If the engine is cold, start the engine for 1–2 minutes 9.2.3 To do a check of the engine oil level before you drain the engine oil.
  • Page 37 Technical data on page 10. Fill with new oil as given in 7. Remove the inner air filter behind the air filter 84 . cartridge. 11. Start the engine and let it idle for 3 minutes. 12. Stop the engine and make sure that the oil filter does not leak.
  • Page 38: Electrical System

    9.3 Electrical system touches the spark plug seat. 8. Tighten the spark plug with the spark plug wrench until the washer is compressed. 9.3.1 Electrical system overview, P524 EFI 1. Main fuse, 20 A 9.3.2 To replace the circuit board 2. Battery CAUTION: To prevent damage to the new 3.
  • Page 39 3. Disconnect all connections from the circuit board. 3. Remove the plastic nut. Use pliers to push in the plastic catches that hold the 4. Push the warning lamp through the control panel. connections. 9.3.4 To replace the battery 4. Remove the screw that holds the circuit board bracket.
  • Page 40 b) To replace the fuse for the power outlet, remove 3. Disconnect the cables from the broken lamp. the side cover of the control panel. The fuses for the power outlet is below the control panel. 2. Pull the fuse from the holder. 4.
  • Page 41 9.3.7 To replace the ignition switch 3. Compress the clips on the hour meter and push out the hour meter. 1. Remove the side cover of the control panel. Refer to To remove the covers on page 23 . 2. Disconnect the ignition switch connection from the circuit board.
  • Page 42 4. Compress the clips on the PTO button and push the 4. Loosen the screw that holds the circuit board and PTO button up through the panel. move the circuit board to the side. 5. Remove the 2 screws on the throttle control bracket and pull out the throttle control.
  • Page 43: Fuel System

    3. Remove the 12V socket nut below the control panel. 4. Push the 12V socket up through the control panel. 5. Assemble in opposite sequence. 9.4 Fuel system 9.4.1 Fuel system overview 662 - 001 - 23.10.2018 Repair instructions - 43...
  • Page 44: Hydraulic System

    9.4.2 To replace the fuel filter 4. Remove the rear screw from the fuel tank support. 1. Remove the engine cover to get access to the fuel filter. 5. Lift the fuel tank. 2. Compress the fuel tank hose to prevent leakage. 3.
  • Page 45 removed from the product. If not, the fault can not be connecting. Make sure the protection is clean before found and there will be contaminations in the test using it. equipment. It is also possible that the sent component is 9.5.4 Hydraulic couplings, pipes and hoses not the fault and is thus sent back without repair.
  • Page 46 9.5.5 Hydraulic overview 1a: Hydraulic tank – pump 5b: Valve block – lift cylinder 1b: Hydraulic tank – pump 5c: Valve block – power steering 1c: Hydraulic tank – hydraulic oil cooler 6a: Power steering – steering cylinder 2a: Filter – valve block 6b: Power steering –...
  • Page 47 3. Remove the oil cap and examine the hydraulic oil 4. Put a container below the oil drain plug. level. Correct level is 40–60 mm from the top of the strainer. 4. If the oil level is too low, fill with the type of oil given 5.
  • Page 48 5. Disconnect the hydraulic hoses and put protective 4. Heat up the thermostat sensor with a hot air gun. caps in all hydraulic openings. 6. Remove the 4 screws that hold the hydraulic oil cooler. 5. Replace the thermostat if the hydraulic oil cooler does not start when the thermostat sensor is at the temperature of 70ºC.
  • Page 49 Technical data on 6. Remove the thermostat. 7. Fill the hydraulic tank. Refer to page 84 . 8. Operate the equipment lift and the power steering. 9. Do a check that there are no leaks around the hydraulic oil filter. 10.
  • Page 50 9.5.13 To replace the hydraulic oil tank 10. Remove the 2 screws from the cable retainers and the 4 screws in the frame section below the operator 1. Remove the side cover of the control panel and the seat. To remove the covers right footrest plate.
  • Page 51 16. Remove the 6 nuts of the side panel and lift the side 6. Disassemble the hydraulic couplings at the 2 ends of panel. the lift cylinder. 17. Remove the hydraulic oil tank. 18. Assemble in opposite sequence. 9.5.14 To disassemble the lift cylinder 7.
  • Page 52 3. Remove the clamp on the front end of the 6. Remove the clamp on the rear end of the hydrostatic hydrostatic transmission cable. transmission cable. 4. Remove the front ball joint from the hydrostatic 7. Remove the hydrostatic transmission cable. transmission cable.
  • Page 53 3. Turn the vertical arm clockwise to the maximum 9.5.16 Hydraulic pump position. 9.5.16.1 To disassemble the hydraulic pump To disassemble 1. Remove the operator seat. Refer to and assemble the seat on page 24 . To replace the fuel 2.
  • Page 54 8. Loosen the locknut (B) on the adjustment screw. 14. Remove the protection cover from the right side of the product. 9. Loosen the adjustment screw (C) for the pump belt fully. 10. Disassemble the belt pulley for the pump belt on the left side of the product.
  • Page 55 21. Put a jack assembly below the product. The 3. Disconnect the electrical connector of the PTO illustration shows where to put the supports. clutch. 22. Tilt the hydraulic pump and remove it from below. Note: If you replace the hydraulic pump, move the hydraulic adapters to the new hydraulic pump.
  • Page 56: Transmission Maintenance

    9.6 Transmission maintenance 7. Remove the protection cover below the engine pulley. 9.6.1 To replace the oil in the hydrostatic transmissions WARNING: Transmission oil is dangerous. If you spill transmission oil on your skin, clean with soap and water. WARNING: Used oil and filters are dangerous to the environment.
  • Page 57 b) Front transmission. 9.6.3 To disassemble and assemble the rear transmission 1. Put a jack assembly below the product. The illustration shows where to put the supports. 6. Attach the drain plug when the oil is drained. 7. Fill the transmission with new oil. 2.
  • Page 58 8. Loosen the rear end of the control stay (A) from the 11. Remove the stop screws. linkage (B). Remove the nut (E), screw (C) and bushing (D). 12. Remove the bearing unit. 13. Remove the joint screw. 9. Loosen the front end of the control stay (A). Remove the nut (G), screw (F) and washer (H).
  • Page 59 15. Remove the transmission out of the frame. 9.6.4 To disassemble and assemble the speed adjustments of the rear transmission 1. Remove the screw (A), nut (D), spring (E) and washer (F) from the device for the slewing speed adjustment. 2.
  • Page 60 5. Remove the hydraulic hoses from the front 8. Loosen the screws that hold the bearing units and transmission. Put on protective plugs. Although the remove the bearing units. front axle is drained, a small quantity of oil can leak out.
  • Page 61 6. Connect the hydraulic pipe and the hydraulic hoses 8. Make sure that the joint bearing does not touch the to the transmission. thrust washers. 7. Attach the parking brake cable. 8. Put grease with corrosion protection on the axles. To disassemble and 9.
  • Page 62 9.6.7.2 To do a check of the wheel speed after a 6. Divide the VRMU rpm with the FMU rpm. The result transmission replacement must be 1.35-1.38. If you do not get this result, To adjust the wheel adjust the wheel speed. Refer to 1.
  • Page 63: Cutting System

    5. Attach the front end of the control stay (A) to the 5. Release the clip on the front cover with the tool chassis. Make sure that the washer (B) is between attached to the ignition key, and remove the cover. the control stay and the chassis.
  • Page 64 10. Hold the front edge of the cutting deck with 2 hands 3. Lower the cutting deck and push it in until it stops. and pull it out. 4. Put the drive belt around the drive wheel for the cutting deck. 5.
  • Page 65 7. Turn the screws right or left until the ground 9.7.6 To adjust the parallelism of the cutting pressure is between 12 and 15 kg (26.5-33 lb). deck Make sure that the springs have equal tension on 1. Remove the front cover. the right and left sides.
  • Page 66 3. Adjust the cable until the distance between the 4. Remove the pulley and the cable retainer. ground and the front of the cutting deck cover is 25 Note: If the cutting height in one of the cutting height 5. Loosen the locknuts on the cable sheath. positions is adjusted, the other cutting heights are 6.
  • Page 67 10. Pull back the rubber protection until the cable can go 4. Put the cutting deck in mow position. through the bracket opening. 5. Attach the BioClip plug in the opposite sequence. 9.7.10 To replace the blades 1. Put the cutting deck in servicing position. 2.
  • Page 68 5. Loosen the 4 screws that hold the blade bearing and 8. Make a mark on one end of the shaft. Push out the remove the bearing assembly from the cutting deck. shaft with a puller. Tap out the bearing and remove the spacer.
  • Page 69: Equipment Frame

    7. Attach the blades. 6. Remove the automatic belt tensioner stay. 9.8 Equipment frame 9.8.1 To disassemble the equipment frame To remove the 1. Remove the cutting deck. Refer to cutting deck on page 63 . 2. Push down the equipment frame. Lift the equipment frame lock to vertical position.
  • Page 70: Steering

    9.9 Steering 14. Pull the equipment frame forward. 9.9.1 To disassemble the steering cylinder 1. Start the engine and turn the steering wheel fully to the right. 2. Stop the engine. 3. Disconnect the 2 hydraulic hoses from the steering cylinder.
  • Page 71 9.9.3 To replace the joint bearing of the steering 9.9.5 To replace the power steering servo cylinder 1. Remove the 2 screws and remove the steering column cover. 1. Remove the snap ring (C). 2. Disconnect the headlight connection (A). 2.
  • Page 72: Belts

    7. Remove the cover (B) above the steering servo 6. Remove the 4 screws and remove the belt guard. housing. 8. Remove the 4 screws that hold the power steering servo (A). 9. Put a container below the steering servo to collect the spill oil.
  • Page 73 10. Remove the belt guard in front of the rear 16. Attach a new drive belt in the opposite sequence. transmission. Make sure that the drive belt for the cutting deck is attached as the illustration shows. Make sure that it is put correctly in the adjuster pulley, identified by an arrow in the illustration.
  • Page 74 5. Remove the 2 bolts on the cutting deck frame. 6. Remove the screws on the cutting deck cover. Lift the cutting deck frame and remove the cutting deck cover. 7. Disconnect the tension spring for the V-belt and remove the V-belt. 8.
  • Page 75: Troubleshooting

    10 Troubleshooting 10.1 To measure voltage On connection, the value must be low (<1 Ohm). On broken connection, the value must be high (>500 Ohm). Use a multimeter in voltage mode. 1. Hold the red measuring probe against the point 10.3 To do a check of cables and where you measure the voltage.
  • Page 76 Fault Possible Steps Troubleshooting Action cause Measure the resistance of the relay. It must be 3.7-4.2 Ω. Replace the starter re- lay. Make sure the relay clicks when the key is turned to "Start". Replace the starter re- lay. Parking Do a check of the parking brake microswitch.
  • Page 77 Fault Possible Steps Troubleshooting Action cause Defective Do a check of the parking brake microswitch. Replace the parking micro- brake mi- switch. croswitch. The product Defective Do a check of the parking brake microswitch. Replace the does not stop parking micro- when the oper- brake mi-...
  • Page 78 Fault Possible Steps Troubleshooting Action cause 12V socket Battery Make sure the switch for the 12V socket is on. Enable the does not work voltage 12V socket Do a check of that the key switch is in the “ON” position. Turn the key switch to “ON”.
  • Page 79: Diagrams

    11 Diagrams 11.1 Wiring diagram Green Green 662 - 001 - 23.10.2018 Diagrams - 79...
  • Page 80: Hydraulic Overview

    11.2 Hydraulic overview 80 - Diagrams 662 - 001 - 23.10.2018...
  • Page 81 662 - 001 - 23.10.2018 Diagrams - 81...
  • Page 82: Belt Position Diagram

    12 Belt position diagram 12.1 Cutting deck belt 12.2 PTO belt 82 - Belt position diagram 662 - 001 - 23.10.2018...
  • Page 83: Pump Belt

    12.3 Pump belt 662 - 001 - 23.10.2018 Belt position diagram - 83...
  • Page 84: Technical Data

    13 Technical data 13.1 Technical data P524 EFI Product dimensions on page 86 Dimensions, refer also to Length without cutting deck, mm 2058 Weight without cutting deck, with empty tanks, kg Tire dimensions 18×8.50×8 Tire pressure, rear – front, kPa / bar / PSI 100 / 1.0 / 14.5...
  • Page 85 P524 EFI Fuse for power outlet, flat pin type, A Electrode gap, mm/in 0.75/0.030 Lamps LED, 2×12V 4.6–6.5W, GU5.3, MR16 Cutting deck Type Combi 103 Combi 112 Combi 122 Cutting deck Combi 103 Combi 112 Combi 122 Cutting width, mm...
  • Page 86: Tightening Torques

    13.2 Tightening torques Tightening torques P524 EFI Belt pulley - cutting deck 35-40 Nm / 25-28 lb ft Blades M10 bolt 45-50 Nm / 32-36 lb ft Blades M12 bolt 75-80 Nm / 53-56 lb ft Blade bearings 20-25 Nm / 14-18 lb ft...
  • Page 87 Dimensions that include the cutting deck are measured with the cutting deck Combi 122 attached. 1145 mm 1000 mm 30° 977 mm 2514 mm 137 mm 1174 mm 1275 mm 2675 mm 370 mm 765 mm 1924 mm 662 - 001 - 23.10.2018 Technical data - 87...
  • Page 88 1141126-26 2018-11-06...