Husqvarna Rider 16C AWD Workshop Manual
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Husqvarna Rider 16C AWD Workshop Manual

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Summary of Contents for Husqvarna Rider 16C AWD

  • Page 1 Workshop manual Rider 16C AWD Rider 18 AWD Rider 15T/s AWD English...

  • Page 2: Table Of Contents

    Workshop Manual for the Rider 16 AWD, Rider 18 AWD and Rider 15T AWD, Rider 15Ts AWD Safety Instructions ..........4 Adjusting the throttle cable, Briggs & Stratton ...59 Checking and adjusting the choke cable, Kawasaki ..60 General Instructions ............ 4 Replacing the Articulated Steering Bearings .....60 Special Instructions .............
  • Page 3 English-...

  • Page 4: 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 5: 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 6 SAFETY INSTRUCTIONS English-...

  • 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 32-01 502 28 80 506 79 06-01...
  • 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 16 AWD Rider 18 AWD Dimensions and weight Length, base machine 2020 mm / 6.61 ft Length with cutting deck, see note 1 2230 mm / 7.32 ft 2240 / 2260 / 2280 mm / 7.35 / 7.41 / 7.48 ft Width, base machine 890 mm / 2.92 ft...
  • Page 11 SPECIFICATIONS Rider 16 AWD Rider 18 AWD Electrical System Type 12 V, negative grounded 12 V, negative grounded Battery 12 V, 24 Ah 12 V, 24 Ah Main fuse Flat pin, 15 A Flat pin, 15 A Spark plug Champion RC12YC EMS Platinum Electrode gap 0.75 mm / 0.030"...
  • Page 12 SPECIFICATIONS Rider 15T AWD Rider 15Ts AWD Dimensions and weight Length, base machine 2020 mm / 6.61 ft 2020 mm / 6.61 ft Length with cutting deck, 2240 / 2260 / 2280 mm / 7.35 / 7.41 / 2240 / 2260 / 2280 mm / 7.35 / 7.41 / see note 1 7.48 ft 7.48 ft...
  • Page 13 SPECIFICATIONS Rider 15T AWD Rider 15Ts AWD Electrical System Type 12 V, negative grounded 12 V, negative grounded Battery 12 V, 24 Ah 12 V, 24 Ah Main fuse Flat pin, 15 A Flat pin, 15 A Spark plug Champion RCJ8Y Champion RCJ8Y Electrode gap 0.75 mm / 0.030"...
  • Page 14 SPECIFICATIONS Cutting unit CombiClip 94 CombiClip 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 15: Delivery And Dealer Service

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

  • Page 16: 300-Hour Service

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

  • Page 17: 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 18 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 Clean around all belts, belt – pulleys, etc. Lubricate the belt adjuster – (nipple) Lubricate all cables –...
  • Page 19 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 the fuel hose. Replace if necessary Check whether the oil needs to be 4, 5) changed in the transmission...

  • Page 20: 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 21 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 22: 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 23: 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 24: 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 oil Synthetic 10W/50 IMPORTANT INFORMATION Check and top up with oil after test...

  • Page 25: 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 26: Engine Speed Regulator

    DELIVERY AND DEALER SERVICE Check that the cutting unit works and that no unusual sounds are heard. Using the lever, the cutting height can be adjusted in 7 different positions. 8042-015 Engine Speed Regulator Cutting height setting Check that the engine’s max. speed is adjusted at: Max speed Idling...
  • Page 27 DELIVERY AND DEALER SERVICE English-...

  • Page 28: Design And Function

    General 8042-501 This publication describes the Husqvarna Rider 16 AWD, Rider 15 AWD and Rider 18 AWD from the 2010 model. There are special workshop manuals for older machines. All Riders have articulated steering to ease mowing around trees and other obstacles. They also have front-mounted cutting units for controlled mowing and the best possible cutting result.

  • Page 29: 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 30: 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 31: 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 32: Driving

    DESIGN AND FUNCTION Driving All Rider AWD models are equipped with a hydrostatic transmission that gives the driver complete control over driving. The speed is controlled using the forward or reverse pedals. The AWD machines are equipped with constantly engaged all wheel drive, which means a differential lock is not required.
  • Page 33 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 34: Cutting Unit

    DESIGN AND FUNCTION Cutting unit The entire Rider series is equipped with a front-mounted cutting unit in order to mow efficiently even in confined areas. Rider 16 AWD is supplied with cutting unit CombiClip 94. Rider 15T/s AWD and Rider 18 AWD are supplied with cutting unit CombiClip 103 or CombiClip 112. The Combi unit functions as a BioClip unit when a BioClip plug is fitted, but can be changed to rear ejection by removing the BioClip plug.
  • 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 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 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. 8042-529 Tongue in the loop The belt is fitted on the cutting unit’s drive pulley once the unit has been pushed back into its rear position.

  • Page 93: Equipment Frame

    REPAIR INSTRUCTIONS Equipment Frame Removal Remove the cutting unit, see “Removing the cutting unit (CombiClip 103, CombiClip 112)” on page 97. Push down the equipment frame and drop the catch. Equipment frame in uppermost position Check the measurement of the adjuster screws' position.

  • Page 94: Fitting The Cutting Unit (Combiclip 103, Combiclip 110)

    REPAIR INSTRUCTIONS Remove the equipment frame's rear guide screws. In order to completely lower the equipment frame on the left- hand side, it must first be pulled back. Rear guide screw Pull out the equipment frame. . Assembly Push in the equipment frame. Make sure that the height adjustment stay is inserted into the equipment frame.
  • Page 95 REPAIR INSTRUCTIONS and that the lifting lever for the cutting unit is in mowing position. Push the equipment frame down and place the catch against the frame. 8042-083 Engage the belt in the belt holder. 8042-510 Push the deck in and put the front guide plugs in the grooves on the equipment frame, one on each side.
  • Page 96 REPAIR INSTRUCTIONS Push the unit in so that the interior plugs touch the bottom of the equipment frame’s grooves. 8042-512 Fit the drive belt around the drive wheels of the cutting unit. Make sure the belt is placed on the correct side of the belt tensioner wheel.

  • Page 97: Removing The Cutting Unit (Combiclip 103, Combiclip 112)

    REPAIR INSTRUCTIONS Removing the cutting unit (CombiClip 103, CombiClip 112) WARNING! Wear protective glasses when dismantling the cutting unit. The springs that tension the belt can fly off and cause personal injury. Carry out points 1-6 to put the cutting unit in the service position, see Service position for the cutting unit.

  • Page 98: Removing The Cutting Unit (Combiclip 94)

    REPAIR INSTRUCTIONS Removing the cutting unit (CombiClip 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 99 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 100: 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 101 REPAIR INSTRUCTIONS Remove the front cover. WARNING! Wear protective glasses when dismantling the cutting unit. The spring which tensions up the belt may break and cause personal injury. 8042-508 Disengage the spring for the drive belt tensioning wheel. 8042-514 Loosen on the cutting height stay and place in the holder.

  • Page 102: Restoring From Service Position

    REPAIR INSTRUCTIONS Grip the front edge of the unit and pull forwards until it stops. 8042-251 Lift the unit until it stops and a clicking sound is heard. The unit locks automatically in the vertical position. 8042-252 Restoring from service position Grip the front edge of the unit and loosen the lock, fold down and slide in the unit.

  • Page 103: Placing In The Service Position Combiclip 94

    REPAIR INSTRUCTIONS Placing in the service position CombiClip 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. 8042-463 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: Checking And Adjusting The Ground Pressure

    REPAIR INSTRUCTIONS Tighten the nut. Recheck that the parallelism has not changed. If so, the parallelism must be readjusted. Check and adjust if necessary the cutting unit’s ground pressure as described in the next section. IMPORTANT INFORMATION When changing the cutting unit, you must readjust the parallelism and cutting height.
  • Page 109 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 Replacing the cutting unit belts...

  • Page 110: Removing Blades With Bearings

    REPAIR INSTRUCTIONS Remove the two bolts on the unit frame. 8042-246 Remove the screws on the cutting cover. Lift the unit frame and remove the cutting unit cover. 8042-267 Loosen the spring that tensions the V- belt and pry off the belt. Assemble the parts in the reverse order.
  • Page 111 REPAIR INSTRUCTIONS Remove the screws holding the pulley. Lock the blade with a wooden block or hold the belt pulley in place, with an oil filter wrench, for example. Do not lose the key that sits between the pulley and the shaft. Remove the pulley. A puller may be required for this.
  • Page 112 REPAIR INSTRUCTIONS Mark one end of the shaft. Push out the shaft with a puller. Tap out the bearing and remove the spacer. 6012-086 Removing the shaft You can purchase the entire assembly, complete with shaft housing, shaft, spacer, and bearings. Fit in the reverse order to removal.
  • Page 113 REPAIR INSTRUCTIONS Loosen the screw that holds the belt pulley (2) a few turns. Lock the blade with a wooden block or hold the belt pulley in place, with an oil filter wrench, for example. 8009-292 Locking the blades Remove the nuts, which hold the bearing housing in position, from the top of the cover.

  • Page 114: Sharpening And Balancing Blades

    REPAIR INSTRUCTIONS Replace the blade bolt in the shaft. Screw it in a few turns and tap or press down the hub. Do not lose the key that sits between the hub and the shaft. Mark one end of the shaft. Press or tap out the shaft.

  • Page 115: Removing The Bioclip Plug (Combi)

    REPAIR INSTRUCTIONS Fix the blade in a vice and sharpen it with a sharpening file. Balance the blade by: • Attaching a punch, e.g. horizontally in the vice as shown. • Thread the hole in the centre of the blade over the punch and make sure that the blade is equally weighted.
  • Page 116 REPAIR INSTRUCTIONS English-...

  • Page 117: Electrical System

    ELECTRICAL SYSTEM Electrical system Wiring diagram Rider 16 AWD, Rider 15T AWD and Rider 18 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 Microswitch, pedal arrangement = White Main fuse 15 A...
  • 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 136 115 39 31-26 2010W33...

This manual is also suitable for:

Rider 18 awdRider 16 awdRider 15ts awdRider 15t awd

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