Introduction and safety regulations 1 Introduction and safety regulations 1.1 General 1.4 Revisions This Workshop Manual provides a comprehensive Any modifications to the ride-on mower will be description of how to troubleshoot, repair and test gradually introduced into ongoing production. As the ride-on mower.
Introduction and safety regulations 1.6 General directions 1.8 Risk of sparks The workshop where the ride-on mower is to be Sparks can occur when working on the battery and repaired must be equipped with safety devices in the thick cables. accordance with local regulations.
Introduction and safety regulations 1.9 Symbols on the machine Warning for rotating parts. Mind your hands and feet. This product complies with applicable EC directives. Rotating blades Keep hands and feet away from under the hood Fast when the engine is running Slow Never drive across a slope.
Delivery and service 2 Delivery and service 2.1 Service schedule The following is a list of maintenance procedures that must be performed on the ride-on mower. Most points not described in this workshop manual can be found in the operator’s manual. Not described in this workshop manual or operator's manual.
Delivery and service Care Chap- Daily Daily After Weekly Maintenance mainte- mainte- the first mainte- least interval in hours nance nance nance once a 100 200 400 before after hours year Check the V-belts 5.7.3 Check joint bearing in articulated 5.1.6 unit Check/adjust the cutting height...
Delivery and service 2.2 Assembly and control Check the transmission oil level Work on the system entails particular demands on Battery cleanliness and the system must be vented before The machine is equipped with a sealed the machine is used. For more information, refer to maintenance-free battery.
• Check the operation of the parking brake. Speed control Check the max engine speed with a Husqvarna original tachometer. Make sure the max speed is • Check driving forwards (1) and in reverse (2). regulated to 3000 ± 75 rpm.
Service tools 3 Service tools The following special tools are used when working on the rider: Special tools for engine and transmission can be found in the respective workshop manual. Optical tachometer 502 28 80-01 Puller - belt pulley 506 66 48-01 Tool for measuring wheel 578 92 62-01 Battery charger (EU)
Service tools 3.1 Laser tachometer Measure rpm Safety during use: 1. Put the switch to RPM position for measuring rpm or TOT for measuring the number of • Class 1 laser product. revolutions. • Take care whenever the laser beam is on. Do not look straight into the beam.
Service tools 3.2 Screw fasteners Hydraulic Couplings Metric threads are used on the machine. When assembling hydraulic hoses and pipes, first tighten their cap nuts by hand to stop. Then tighten a Some bolt fasteners are locked with screws treated further 1½...
Design and Function 4 Design and function 4.1 Serial number Transmission serial number (3) Machine's serial number (1) The transmission serial number is on a barcode decal located on the transmission. The machine's serial number can be found on the •...
Design and Function 4.3 Steering 4.2 Engine All ride-on mowers in the P500 series have The machine has a twin-cylinder, overhead valve articulated steering. The machines are equipped engine with pressure lubrication and separate oil with hydraulic power steering. Steering forces from filter.
The front bypass valve is open if it can not be driven in reverse. P524 has 2 valves, one bypass valve for the front axle and one for the rear axle. The bypass valve is opened and closed in the same way on the front and rear axles.
Design and Function 4.6 Cutting deck The machine can be fitted with the Combi 112 and Hydraulic deck lift. Combi 122 cutting decks. The Combi-unit, equipped with a BioClip-plug, finely The cutting deck is raised and lowered with a chops the cuttings to fertilizer. Without the BioClip- hydraulic cylinder.
Chassis 5 Repair instructions 5.1 Chassis 5.1.1 Throttle and choke cables Checking the choke cable Tools Dimension Make sure the engine responds to the throttle and Combination wrench 10 mm that the correct engine speed is attained at full throttle. For further information, see “6.1.4 Technical Torx data - Dimensions”...
Chassis Dismantling the throttle and choke 5. Pull the throttle or choke control down through cables the opening. 1. Remove the side cover. Cut the front tie bands. 2. Loosen the circuit board by removing the nut. 7. Loosen the wire from the control. Move the circuit board out of the way.
Chassis 5.1.2 Driver’s seat Tools Dimension 13 mm Combination wrench Dismantling Fold the driver's seat up. Loosen the seat switch by turning the connector counterclockwise. Use a combination wrench to remove the 4 bolts from the adjustable seat mounting. Lift off the driver's seat. Assembling Assemble in reverse order.
Chassis 5.1.3 Brake cable Checking the brake cable 4. Remove the E-clip. Tools Dimension 5. Pull back the rubber protection so that the cable Combination wrench 13 mm can pass through the bracket opening. Torx T 30 Snipe nose pliers Torque wrench Check that the parking brake is adjusted correctly by placing the machine on a slope.
Chassis Adjusting the brake cable Put the machine in a level position. Check that the parking brake is not on. Loosen the locking nuts (1). Adjust the play between the casing and the adjustment screw to 1 mm (0.040") when pulling the casing.
Chassis 5.1.4 Wheel hub Dismantling Remove the SGA clip. Older versions of the wheel hub can occur. Tools Dimension Socket wrench 19 mm Allen Key 6 mm Torque wrench Circlip pliers 1. Place a jack assembly under the machine as illustrated.
Chassis 5.1.5 Link stay Tools Dimension Dismantle the cover protecting the belt and the link stay under the engine. Torx Combination wrench 13 mm Combination wrench 15 mm Combination wrench 17 mm Dismantling Apply park brake. Remove the cover over the rear transmission. 10.
Chassis Assembling 14. Release pump belt tension by: Assemble in the reverse order. The front link stay grease nipple must point to the right. Torque tighten as below. a. The rear screw for the link stay is screwed into the goods. In addition, there is a locknut for securing the screw.
Chassis 5.1.6 Changing joint bearing in articulated unit Control stay Joint bearing in articulated unit Steering cylinder Link stay Tools Dimension WARNING! Never insert hands or fingers as Combination wrench 13 mm heavy components are unstably Combination wrench 15 mm supported.
Drill a 3 mm hole over the lubricating point. Check the joint bearing thoroughly for cuttings. For further information, refer to the Service Bulletin on the Husqvarna support site "B1500032". Ø3 mm ± 0.5 Ø3 mm ± 0,5 Control stay...
Chassis 18. The rear carriage is now free, but can not be lowered without reversing first. Support the rear carriage and lower it slightly as illustrated. Do not lower too far, avoid the positions with crosses in the illustration. Shaft with locking lug Steering cylinder Screw 12.
Chassis Assembling It is essential the screw is tightened to the correct torque for fastening the ball in the joint bearing. • If the ball is loose or badly lubricated, it may start to move on the pin. This will cause much wear on the pin.
Chassis Lubrication of articulated bearing The articulated bearing must be lubricated according to the service schedule. 1. Lubricate the articulated bearing with the machine standing with all wheels on the ground. Press grease into the lubricating duct through the grease nipple. Link stay Washer Sleeve...
Propulsion 5.2 Propulsion 5.2.1 Dismantling the engine cover Tools Dimension Combination wrench 17 mm x2 Remove the screws on both sides of the engine cover. Save the plastic washers used as spacers between the screw and the cover. Lift off the engine cover. Assembling Assemble in reverse order.
Propulsion 5.2.2 Engine 1. Air Filter 8. Groove on engine shaft 2. Oil filler 9. Belt pulley 3. Lifting points for overhead crane. 10. Key on engine shaft a. Hole for M8 screw. 11. Magnetic clutch b. Lifting eye 12. Key on belt pulley 4.
Propulsion Dismantling the motor Remove the engine cover. For more Remove the hose clamp on the fuel hose by the information, refer to “5.2.1 Dismantling the fuel pump and pull the fuel hose downwards. engine cover” on page 29. Suspend the hose to stop fuel leaking. Remove the battery, see section “5.3.3 Battery”...
Propulsion 10. Loosen the oil cooler and set aside. 15. Remove the cover protecting the pump drive belt in order to access the front engine mounting. 11. Unplug the electrical connector for the magnetic 16. Remove the engine mountings, two each side, clutch.
Propulsion 5.2.3 Solenoid clutch Assembling Dismantling 1. Assemble in reverse order. Tools Dimension 2. Place the belt pulley key in the groove on the Wrench x2 engine shaft. Ratchet wrench 16 mm Dismantle the engine, see section “5.2.2 Engine” on page 30. Counterhold underneath the magnetic clutch with a wrench.
Propulsion 5.2.4 Transmission oil change 4. Clean thoroughly around the filler. Tools Dimension 5. Open the filler cap. Torx Allen Key 10 mm Flat-blade screwdriver Observe cleanliness. Follow the directions in section “5.6.1 Hydraulic hygiene” on page 52. Transmission capacity is 0.9 liters (0.9 US qt) fully synthetic engine oil SAE 10W/50 in the respective gearbox Make it easier to change oil by warming up the engine before draining the oil.
Propulsion 5.2.6 Replacing the engine oil filter 5.2.7 Changing engine oil Tools Dimension WARNING! 19 mm Combination wrench Risk of spray and burn injuries. The engine’s oil filter may be very hot WARNING! immediately after stopping. Allow the Engine oil can be very hot if it is engine to cool down first.
Propulsion 5.2.8 Replacing the engine air filter Dismantling Assembling Raise the engine cover. Assemble in reverse order. Loosen the two fasteners holding the filter cover and remove it. 2. Fit the new filter cartridge. Make sure the filter cartridge is correctly fitted over the air intake in the filter housing.
Propulsion 5.2.9 Hydrostatic cable If adjustment of the hydrostatic cable is insufficient, a Tools Dimension further adjustment can be made with the cable Combination wrench 10 mm adjuster next to the hydraulic pump. Flat-blade screwdriver Loosen the locknuts (1) and adjust the play with the adjustment screw (2).
Propulsion Dismantling the hydrostatic cable Loosen the clamp on both ends of the hydrostatic cable at the frame and the center console. Remove the frame plate by loosening the screws. Loosen the front hydrostatic cable locking nut 1/4 turn and remove the locking spring. Lift off the link joint and pull out the cable.
Propulsion 5.2.10 Wheel speed The relationship between the rear and front wheel speed should always be the same or constantly faster on the rear wheels than the front wheels. Wheel speed must however be max 3% faster on the rear wheels than the front wheels.
Propulsion Checking and adjusting wheel speed - straight ahead 1. Make sure the wheels are pointing straight ahead and are parallel by measuring the wheelbase on both sides of the machine. The measurement should be the same on both sides of the machine.
Propulsion Checking and adjusting wheel speed - full lock Adjusting the wheel speed - full lock is performed only when changing the transmission. Basic speed locknut Slewing speed locknut N=17 N=14 Basic speed adjuster nut Slewing speed adjust- N=17 ment screw N=14 Joint bearing 2 Recoil spring Override spring...
Electrical system 5.3 Electrical system 5.3.1 Electrical system There is more detailed information concerning the electrical system on the Husqvarna website. Numbers correspond to: 1. Main fuse 20 A 7. Microswitch, pedal carrier 2. Starter relay 8. Fuse holder 3. Seat switch 9.
Electrical system 5.3.2 Circuit boards Dismantle the screw holding the circuit board bracket. It is important to check the circuit outside of the circuit board first, to ensure this is correct, before replacing the circuit board. This is so that the new circuit board is not damaged by an external fault.
Electrical system 5.3.3 Battery 5.3.4 Fuses The main fuse is placed in a detachable holder Tools Dimension under the battery. Combination wrench x2 10 mm Type: Flat pin, 20 A. Dismantling Do not use any other fuse when changing. Open the engine hood. Loosen the battery fastening strap.
Electrical system 5.3.5 Safety system 5.3.6 Replacing the light bulbs For information about the bulb type, see “6 The ride-on mower is equipped with a safety system Specifications” on page 85. that prevents starting or driving under the following • Remove the front cover, steering column.
Electrical system 5.3.7 Ignition switch 5.3.8 Hour meter Tools Dimension Tools Dimension Combination wrench 18 mm / 19 mm?? Torx Torx Wrench Dismantling Dismantling Remove the side cover. 1. Remove the front cover, steering column. Loosen the ignition switch connection from the circuit board.
Electrical system 5.3.9 PTO button 5.3.10 12V switch Tools Dimension Tools Dimension Combination wrench 10 mm Torx Torx Dismantling Dismantling 1. Remove the side cover. 1. Remove the side cover. 2. Loosen the switch connection from the circuit board. 2. Loosen the PTO button connection from the 3.
Fuel system 5.4 Fuel system 5.4.1 Fuel tank Remove the front screw holding the fuel tank in place on the tank support. Tools Dimension Combination wrench 13 mm Torx Dismantling Compress the hose with pliers and remove the hose clip and hose from the bottom fuel filter connection.
Fuel system 5.4.2 Replacing the fuel filter Tools Dimension Round nose pliers Hose pliers Dismantling 1. Pinch together the inlet and outlet of the fuel hose to prevent fuel leaking out. 2. Use round nose pliers to remove the clips from the filter.
Cooling system 5.5 Cooling system 5.5.1 Changing the oil cooler 6. Remove the screws, two on each side of the cooler. Dismantling Tools Dimension Combination wrench 10 mm Combination wrench 19 mm 1. Open the engine cover. 2. Loosen the electrical connector. 7.
Cooling system 5.5.2 Changing thermostat unit 5. Remove the thermostat from the hydraulic Tools Dimension hose. Torx Drill bit 4 mm Snipe nose pliers The electrical thermostat is on the oil cooler. The oil cooler fan starts at oil temperatures of around 70°C. Dismantle the side cover.
Hydraulic system 5.6 Hydraulic system Keep hydraulic system fluid clean 5.6.1 Hydraulic hygiene You must be completely sure that when opening a Keep the hydraulic system clean. Remember to: can of oil for the hydraulic system, the area around • Clean thoroughly before opening the filler cap the filler cover is absolutely free from dust, dirt, or disconnecting anything.
Hydraulic system Hydraulic couplings, pipes and hoses Hydraulic pipes must always be loosened at both Always check and note how hose, lines, pipes, etc. ends when dismantling. are tightened throughout the machine before loosening or dismantling. They must always be It is essential to use two tools, of which one is used refitted with the same tightening force as originally.
Hydraulic system 5.6.2 Component locations Power steering Hydraulic tank Valve block working hydraulics Hydraulic filter with valve block Hydraulic pump Steering cylinder Lift cylinder Rear transmission Front transmission 10. Hydraulic system cooler The hose’s nipple for the cylinder’s piston side is Pressure to the hydraulic system is provided by the equipped with a throttle.
Hydraulic system 5.6.3 Filter holder 5.6.4 Changing hydraulic filter Tools Dimension WARNING! Used oil filters shall be treated as Allen Key 8 mm environmentally hazardous and Combination wrench 17 mm turned in to the workshop or other Combination wrench 22 mm designated area for disposal.
Hydraulic system 5.6.5 Hydraulic tank 3. Remove the protecting cover protecting the right Tools Dimension side of the machine. Torx Combination wrench 10 mm Combination wrench 13 mm Combination wrench 14 mm Combination wrench 27 mm Combination wrench 32 mm Dismantling 1.
Hydraulic system 10. Remove the driver seat. For more information, 17. Dismantle the lever for the valve block from refer to “5.1.2 Driver’s seat” on page 18. below by loosening the nut. 11. Remove the frame section under the driver seat 18.
Hydraulic system 5.6.6 Changing the valve block 5. Remove the knobs from the throttle control, Tools Dimension choke control and the height adjustment control. Torx Combination wrench 10 mm Combination wrench 13 mm Combination wrench 19 mm Combination wrench 22 mm 1.
Hydraulic system 5.6.7 Rear transmission Tools Dimension Torx Combination wrench 14 mm Combination wrench 16 mm Combination wrench 17 mm Combination wrench 22 mm Combination wrench 32 mm Combination wrench 15 mm Combination wrench 17 mm Combination wrench 18 mm Combination wrench 22 mm Combination wrench...
Hydraulic system Dismantling Raise the machine and support it under the Loosen the rear end of the control stay (1) by frame. Refer to the illustration for the permitted dismantling the screw (3) with nut (5). Make sure not to misplace the bushing (4). area.
Hydraulic system 13. Slide in the bearing unit. 17. If the transmission is being changed, the devices for adjusting the wheel speed (1) and 14. Remove the screw (4). adjustment screw for the slewing speed (2) must be transferred to the new transmission as below: 15.
Hydraulic system Assembling Assemble the hydraulic hoses and torque Assemble in reverse order. Start by refitting any tighten as instructed. remove hydraulic adapters. Torque tighten the adapter on top (1) to 32 Nm. The two other Insert the screw (1) for the recoil spring through adapters (2) and (3) are tightened to 50 Nm.
Hydraulic system 5.6.8 Front transmission Tools Dimension Groove joint pliers Combination wrench 18 mm Combination wrench 22 mm Combination wrench 27 mm Combination wrench 32 mm Allen Key 10 mm Torque wrench Combination wrench 22 mm Combination wrench 27 mm English –...
Hydraulic system Dismantling 1. Remove the tool frame, see “5.7.1 Tool frame” on page 76. 2. Remove the left wing cover. 4. Undo the hydraulic pipes from underneath the front axle. Fit protective plugs. A small amount of oil may leak out even if the front axle has been drained.
Hydraulic system 6. Undo the hydraulic pipe and hoses from the front 9. Remove the screws holding the front axle and axle. lower the front axle. 7. Remove the parking brake cable. For more information, refer to “5.1.3 Brake cable” on page 19.
Hydraulic system 5.6.9 Hydraulic pump Hydraulic pump Belt pulley Pump belt Dismantling Tools Dimension Torx 1. Remove the driver seat. For more information, refer to “5.1.2 Driver’s seat” on page 18. Allen Key 6 mm 2. Remove the fuel tank. For more information, Combination wrench 8 mm refer to “5.4.1 Fuel tank”...
Hydraulic system 6. Remove the frame section under the driver 9. Remove the SGA clip from the pump. seat by removing the 6 screws. In order to lift 10. Loosen the pump belt pulley with two screws away the frame section, the cable retainers from the pump shaft and lift up.
Hydraulic system 13. Loosen the bolts from the front and rear brack- 19. Use a jack assembly to lift the rear of the machine to make room for the pump. Place a ets of the steering cylinder. Push the steer- jack assembly under the machine as illustrated.
Hydraulic system 5.6.10 Replacing pump belt The condition of the belt pulleys should be checked when changing belts in the machine. Replace belt pulleys if necessary. Tools Dimension Combination wrench 13 mm Combination wrench 15 mm Combination wrench 17 mm Torx 6.
Hydraulic system 12. Lift off the PTO belt from the belt pulley to make room to prise off the pump belt. 13. Prise off the pump belt from the hydraulic pump pulley. 14. Lift off the pump belt from the engine pulley and around the magnetic clutch.
Hydraulic system 5.6.11 Changing the PTO belt 7. Remove the protecting cover on the tool frame. The condition of the belt pulleys should be checked when changing belts in the machine. Replace belt pulleys if necessary. Tools Dimension Combination wrench 13 mm Dismantling 1.
Hydraulic system 11. Steer full lock right for easier access to the 16. Unhook the belt from the hook on the center drive belt. belt pulley. 12. Remove the belt protector over the rear trans- mission. 13. Lift off the belt from the engine pulley from 17.
Hydraulic system 5.6.12 Lift cylinder Tools Dimension Combination wrench 19 mm Circlip pliers Torx Dismantling 1. Lower the cutting deck. 2. Remove the cover over the frame tunnel. 7. Remove the lifting cylinder through the frame tunnel. Assembling 1. Assemble in the reverse order. 2.
Hydraulic system 5.6.13 Steering cylinder Changing joint bearing in steering cylinder Dismantling Start the engine and turn the steering wheel full lock to the right. Tools Dimension Combination wrench 13 m Combination wrench 19 mm Circlip pliers Press tool Shaft with locking lug Hydraulic connection Cable tie Steering cylinder...
Hydraulic system 5.6.14 Power steering 4. Dismantle the steering wheel (4), secured using Tools Dimension one screw (6) under the steering wheel hub (5). Torx Retain the key (5) and the washer (7). Dismantle the cover (2) over the steering servo housing. Combination wrench 13 mm Combination wrench...
Cutting system 5.7 Cutting system 5.7.1 Tool frame 5. Remove the left wing cover. Tools Dimension Combination wrench 13 mm Combination wrench 18 mm Combination wrench 19 mm Torx Dismantling 1. Remove the cutting deck. For further instruc- tions, refer to section “5.7.2 Cutting deck” on page 78.
Cutting system Assembling 9. Release the belt from the tool frame. 10. Lower the tool frame by removing its rear lead 1. Slide in the tool frame. Make sure that the screws. In order to release the tool frame on height adjustment stay is inserted into the the left side completely it must first be pulled equipment frame.
Cutting system 5.7.2 Cutting deck Service position for cutting deck 7. Grip the front edge of the cutting deck and pull forwards until it stops. In order to provide good accessibility for cleaning, repair and servicing, the cutting deck can be set in the service position.
Cutting system Attaching the cutting deck 1. Place the machine on a flat surface and apply Removing the cutting deck the parking brake. Check that the lever for setting the cutting height is in its lowest, service, 1. Put the cutting deck in the service position up to position.
Cutting system 5.7.3 Changing the belt on the cutting deck Loosen the screws on the cutting cover. Lift the WARNING! cutting deck frame and take out the cutting deck Protect your hands with gloves when cover. working on the blades. Pinch hazard when working on the belt.
Cutting system 5.7.5 Adjusting the parallelism of the 5.7.4 Setting parallelism and cutting cutting deck height Parallelism and cutting height must be adjusted 1. Remove the front cover. when a new cutting deck is fitted. 2. Loosen the nuts on the parallel strut. Starting point: •...
Cutting system 5.7.6 Adjusting the cutting height range 5.7.7 Checking and adjusting ground pressure 1. Remove the right side cover. In order to obtain the best cutting results, the cutting deck must follow the surface without resting on it too hard.
Cutting system 5.7.8 Changing height adjustment cable 7. Take the cable out of the rubber strap. Tools Dimension Combination wrench x2 13 mm Combination wrench x2 17 mm Torx Dismantling 1. Remove the cutting deck. For further instructions, refer to section “5.7.2 Cutting deck”...
Cutting system 5.7.9 BioClip plug To change the Combi Deck from BioClip function to cutting deck with rear ejection, remove the BioClip plug fastened under the cutting deck with three screws. Put the cutting unit in service position, see “5.7.2 Cutting deck” on page 78. Remove the three screws holding the BioClip plug.
Specifications 6 Specifications 6.1 Technical data 6.1.1 Technical data - Sound and vibration levels P 5240 Cutting deck C 112 C 122 Noise emissions (see note 3) Noise power level, measured dB(A) Noise power level, guaranteed dB(A) Noise levels (see note 4) Noise pressure level at user's ear, dB(A) Vibration levels (see note 5) Vibration level in steering wheel, m/s...
Appendices and schedules 7.3 Troubleshooting schedule Checking cables and connectors: Measure voltage: Use a multimeter in voltage mode. Hold the red When checking cables, look for the following: measuring probe against the measurement point • Cable breaks and the black measuring probe against a grounding point (e.g.
Appendices and schedules Fault Possible Steps Troubleshooting Action cause Machine PTO Enabled Check the PTO switch. Deactivate PTO does not P-brake not Check P-brake Activate P-brake start the activated. start motor when the Battery Make sure the 20A wired fuse is intact. Replace fuse key is voltage...
Appendices and schedules Fault Possible Steps Troubleshooting Action cause Machine Wiring fault Check the pink wire and connectors between J1 Repair the cable or will not start (pin 4) and the fuel valve. replace the cabling. despite the Check the black cable and connectors between J1 start motor (pin 6) and the engine.
Appendices and schedules Fault Possible Steps Troubleshooting Action cause Battery Check the 5A “Fuse P.T.O.” Replace fuse activation voltage Measure the voltage on J6 (pin 3) with the key in Go to steps 3-6. does not “ON” position. The voltage should be equal to the work battery voltage.