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Husqvarna Rider Pro 18 AWD Repair Manual

Husqvarna Rider Pro 18 AWD
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Workshop manual
Rider Pro 18 AWD
ProFlex 21 AWD
English

Table of Contents

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Husqvarna Rider Pro 18 AWD Specifications

General IconGeneral
BrandHusqvarna
ModelRider Pro 18 AWD
CategoryLawn Mower
LanguageEnglish

Summary

Safety Instructions

General Instructions

General guidelines for safe operation and maintenance of the rider.

Special Instructions

Specific warnings related to fuel, compressed air, and sharp components.

Risk of sparking

Precautions to avoid battery explosion, fire, or eye injuries from sparking.

Special Tools

Special Tools Listing

Lists and illustrates specialized tools required for specific repair tasks.

Specifications

Dimensions and Weight

Technical details on machine size, weight, and capacity with attachments.

Wheels Specifications

Information on tyre specifications and air pressure requirements.

Engine Specifications

Details about the engine manufacturer, model, power, and fuel requirements.

Drive Axles Specifications

Specifications for front and rear drive axle types and oil.

Electrical System Specifications

Electrical system components, battery type, fuses, and bulb specifications.

Hydraulic System Specifications

Details on hydraulic pump type and working pressures.

Tightening Torques

Specified torque values for various machine components.

Cutting Unit Specifications

Specifications for different cutting unit models, including width and noise.

Check List

Tolerances and measurements for checking cutting unit alignment and function.

Play Specifications

Specified acceptable play for control cables and levers.

Delivery and Dealer Service

Delivery Service Procedures

Step-by-step procedure for preparing the rider for customer delivery.

Initial Service Intervals

Maintenance tasks required after 8, 50, 25, 50, 100/200 hours of operation.

300-Hour Service

Major service requirements for the 300-hour interval.

Seasonal Maintenance

Seasonal maintenance tasks to ensure optimal performance.

Comprehensive Service Schedule

A comprehensive table outlining maintenance tasks by interval.

Customer Delivery Procedures

Guidelines for dealers on customer delivery and information provision.

Packaging and Unpacking

Instructions for safely unpacking the machine from its shipping packaging.

Battery Installation and Care

Procedures for filling, charging, and fitting the battery correctly.

Arm Supports Fitting

Dealer responsibility for fitting arm supports if supplied.

Steering Wheel Installation

Instructions for fitting the steering wheel to the steering column.

Towing Eye and Counterweight

Guidance on fitting the tow hook and counterweight.

Engine Oil Level Check

Steps to check the engine oil level using the dipstick.

Hydraulic Oil Level Check

Procedure for checking the hydraulic oil level via the sight glass.

Wheels Installation and Pressure

Instructions for fitting wheels and setting tyre pressure.

Skid Guard Fitting

Dealer responsibility for fitting skid guards if provided with the machine.

Cutting Unit Adjustment

Steps for checking and adjusting the cutting unit's alignment.

Test Running Procedure

Procedures for safely testing the machine after initial setup.

Starting the Engine Safely

Safety checks and steps for starting the engine correctly.

Engine Speed Regulation

Checking and verifying the engine's maximum speed settings.

Muffler Inspection

Procedure for checking muffler security and tightening torque.

Final Inspection and Handover

Final checks and procedures after test running and before handover.

Administration and Documentation

Documentation tasks including filling sales papers and service journals.

Design and Function

General Overview

Overview of the Husqvarna Rider series and its features.

Cutting Unit Types

Description of the different cutting unit types available for the riders.

Serial Number Identification

Location and identification of machine, engine, and transmission serial numbers.

Engine Details

Information about the Kawasaki twin-cylinder engines used in the riders.

Steering System Explanation

Explanation of the articulated and hydraulic servo steering system.

Driving System

Details on the hydrostatic transmission and AWD drive system.

Cutting Unit Components

Detailed breakdown of cutting unit components and their functions.

Repair Instructions

Engine Removal and Installation

Step-by-step guide for safely removing and installing the engine.

Fuel Tank Maintenance

Procedures for removing and fitting the fuel tank.

Pulse Air Valve Intake Filter Cleaning

Steps for cleaning the pulse air valve intake filter.

Engine Oil Change Procedure

Guide for draining old oil, replacing the filter, and refilling with new oil.

Steering Cable Adjustment

Process for checking and adjusting steering cable tension for proper steering.

Steering Cable Replacement

Detailed steps for removing and fitting new steering cables.

Power Steering Removal and Fitting

Procedure for removing and installing the power steering unit.

Cable Pulley Removal and Fitting

Steps for disassembling and reassembling the cable pulley.

Parking Brake Adjustment

How to adjust the parking brake for correct operation.

Hydrostatic Transmission Cable Adjustment

Procedure to adjust the hydrostatic transmission cable for proper function.

Throttle Cable Adjustment

Steps to check and adjust the throttle cable for correct engine speed.

Choke Cable Adjustment

How to adjust the choke cable for optimal starting and running.

Articulated Steering Bearings Replacement

Detailed process for replacing bearings in the articulated steering system.

Pendulum Shaft Removal

Steps for safely removing the pendulum shaft.

Bushings Replacement

Instructions for replacing bushings in the rear frame.

Pendulum Shaft Installation

Guide for installing the pendulum shaft and related components.

Pump Unit Removal and Fitting

Procedures for removing and fitting the hydraulic pump unit.

Drive Axle Maintenance

General notes on drive axle maintenance and specific instructions for front/rear axles.

Front Axle Removal

Steps for removing and dismantling the front axle.

Rear Axle Removal

Instructions for removing and dismantling the rear axle.

Wheel Drive Synchronization

Procedure for synchronizing wheel drives for correct cornering speed.

Outgoing Shaft Seal Replacement

Detailed steps for replacing seals on outgoing shafts.

Hydrostatic Transmission Cable Replacement

Instructions for removing and fitting the hydrostatic transmission cable.

Transmission Maintenance

General information and schedule for transmission oil changes.

Hydrostatic Transmission Oil Change

Procedure for changing oil in the front and rear hydrostatic transmissions.

Hydraulic Tank Suction Filter Replacement

Steps for replacing the hydraulic tank's suction filter.

Lever Housing Adjustment

How to adjust the lever housing for proper cutting unit control.

Hydraulic Pump Drive Belt Replacement

Detailed procedure for replacing the hydraulic pump drive belt.

Centre Belt Replacement

Instructions for replacing the centre belt on the cutting unit.

Front Belt Replacement (Pro 18 AWD)

Steps for removing and fitting the front belt for the Pro 18 AWD.

Front Belt Replacement (ProFlex 21 AWD)

Instructions for replacing the front belt on the ProFlex 21 AWD.

Equipment Frame Removal

Procedures for removing and fitting the equipment frame.

ProFlex Cutting Unit Components

Identification and description of ProFlex cutting unit components.

Fitting Cutting Unit Pro 18

Step-by-step guide for attaching the cutting unit to the Pro 18.

Pro 18 Cutting Unit Service Position

How to place the Pro 18 cutting unit into its service position.

Placing Pro 18 Cutting Unit in Service Position

Detailed steps for putting the Pro 18 cutting unit into service position.

Fitting Cutting Unit ProFlex

Instructions for attaching the cutting unit to the ProFlex model.

Releasing Pro 18 Cutting Unit from Service Position

Procedures for safely releasing the Pro 18 cutting unit from service position.

Unit Parallelism and Cutting Height Adjustment

Guide to adjusting the cutting unit's parallelism and cutting height.

Cutting Height Adjustment

Specific steps for setting the cutting height for different combi units.

Cutting Height Range Adjustment

How to adjust the overall range of cutting height settings.

Ground Pressure Adjustment

Procedure for checking and adjusting the cutting unit's ground pressure.

ProFlex Cutting Unit Service Position

How to position the ProFlex cutting unit for service and maintenance.

Placing ProFlex Cutting Unit in Service Position

Detailed steps for placing the ProFlex cutting unit into service position.

Releasing ProFlex Cutting Unit from Service Position

Procedures for safely releasing the ProFlex cutting unit from service position.

Removing Cutting Unit ProFlex

Instructions for removing the cutting unit from the ProFlex rider.

Equipment Frame Dismantling (ProFlex)

Steps for dismantling the equipment frame on ProFlex models.

Combi Cutting Unit Belt Change

Guide for replacing the V-belt on Combi cutting units.

Blade and Bearing Removal

Detailed process for removing blades and their associated bearings.

Blade Sharpening and Balancing

Instructions for sharpening and balancing cutting blades.

BioClip Plug Removal (Combi)

How to remove the BioClip plug for rear ejection conversion.

Electrical System

Wiring Diagram and Component Locations

Overview of the electrical system, wiring diagram, and component identification.

Ignition and Starter Lock

Procedure for removing and fitting the ignition and starter lock assembly.

Hour Meter Installation

Instructions for removing and installing the hour meter.

Fuse Information and Replacement

Information on fuse types, locations, and replacement.

Light Bulb Replacement

Steps for replacing the headlamp and other light bulbs.

Safety System Operation

Explanation of the rider's safety interlock systems.

Mowing Deck Microswitch

Information on the mowing deck microswitch and its adjustment.

Seat Microswitch

Details on the seat microswitch and its replacement.

Pedal Micro Switch Adjustment

Adjustment procedure for the microswitch related to pedal operation.

Hydraulic System

Hydraulic Hygiene Practices

Essential practices for maintaining the cleanliness of the hydraulic system.

Hydraulic Component Locations

Visual guide to identifying key hydraulic system components on the rider.

Bleeding the Hydraulic System

Procedures for removing air from the hydraulic system.

Power Steering Reference

Reference to power steering removal/fitting instructions.

Lift Cylinder Replacement (ProFlex)

Step-by-step guide for replacing the lift cylinder on ProFlex models.

Valve Assembly Procedures (ProFlex)

Instructions for removing and refitting the hydraulic valve assembly.

Hydraulic Oil Filter Change

Procedures for changing the hydraulic oil filter and oil.

Control Valve Replacement (ProFlex)

Steps for replacing the control valve on ProFlex models.

Control Valve Dismantling/Assembly (ProFlex)

Detailed procedures for dismantling and assembling the control valve.

Pressure Limiting Valve Troubleshooting

Information on troubleshooting low hydraulic pressure related to the valve.

Hydraulic Hose Bundle Management

Identification and routing of hydraulic hose bundles.

The engine will not start.

Starter Does Not Turn Engine

Troubleshooting steps for when the starter motor fails to engage.

Fuel Delivery Faults

Diagnosing issues related to fuel delivery to the engine.

Faulty Fuel Supply System

Steps to identify and resolve problems with the fuel supply system.

Spark Plug Not Sparking

Troubleshooting steps for ignition system failures affecting the spark plug.

Engine starts but does not run satisfactorily

Spark Plug Issues

Issues related to spark plug condition and thermal value.

Ignition Setting Incorrect

Problems arising from incorrect ignition timing or settings.

Faulty Ignition Module or Sensor

Diagnosing failures in the ignition module or related sensors.

Low Fuel Level or Delivery

Troubleshooting low fuel levels or delivery issues.

Soiled Fuel Filter

Issues caused by a dirty or clogged fuel filter.

Blocked or Kinked Fuel Lines

Problems related to fuel lines being obstructed or kinked.

Faulty Carburetor

Issues arising from improper carburettor settings or faults.

Blocked Tank Ventilator

Troubleshooting a blocked tank vent affecting fuel flow.

Clogged Air Filter

Problems caused by a dirty or blocked air filter restricting airflow.

Correct Spark Plug Thermal Value

Correct spark plug selection based on thermal rating.

Incorrect Pre-Ignition Timing

Issues related to incorrect pre-ignition timing.

General Incorrect Settings

General incorrect settings affecting engine performance.

Blocked Carburetor Needles/Jets

Carburetor jet blockages causing poor running.

Low Engine Oil Level

Engine damage or poor performance due to low oil levels.

Blocked Cooling Fins or Air Intake

Overheating issues caused by obstructed engine cooling.

Cooling Fan Damage

Problems arising from a faulty or damaged cooling fan.

Choke System Operation

Issues related to the choke system's operation.

Choke Cable and Valve Check

Procedure for checking and adjusting the choke cable and valve.

Machine Overloading

Engine performance issues due to overloading the machine.

Adjust Driving Style

Adjusting operator technique to avoid overloading.

General Ignition Faults

General ignition system faults affecting engine performance.

Carburetor Problems

General troubleshooting for carburetor related issues.

Insufficient Engine Cooling

Diagnosing and fixing engine overheating problems.

Exhaust Smoke Diagnosis

Interpreting exhaust smoke color as an indicator of engine issues.

Engine Damage Indicators

Identifying signs of severe engine damage.

Engine Compression Test

Method for testing engine compression to diagnose internal issues.

Engine Overheating Solutions

Causes and solutions for engine overheating.

Correct Fuel Type Usage

Using the correct fuel type for optimal engine performance.

Old Fuel Issues

Issues arising from using stale or degraded fuel.

Fuel Octane Degradation

Problems related to fuel octane degradation over time.

Replacing Stale Fuel

Recommendation to replace old or degraded fuel.

Uneven Engine Operation

Troubleshooting uneven engine operation or loss of power.

Exhaust System Faults

Issues related to the engine's exhaust system.

Abnormal Exhaust Noise

Diagnosing and fixing abnormal exhaust noises.

The motor runs normally, low /no power

Drive Belt Condition

Issues with the drive belt's condition affecting power transmission.

Drive Belt Idler Malfunction

Troubleshooting a malfunctioning drive belt idler.

Engine Shaft Pulley Slippage

Problems with the engine shaft pulley securing to the axle.

Wheel Hub or Axle Slippage

Issues with the wheel hub or axle slipping.

Hydraulic Pump Input Pulley Slippage

Drive belt slippage on the hydraulic pump's input shaft pulley.

Hydraulic Pump Inner Leakage

Diagnosing internal leaks within the hydraulic pump.

Hydraulic Motor or Differential Faults

Faults in the hydraulic motor or differential components.

Blocked Hydraulic Tank Suction Filter

Problems caused by a blocked suction filter in the hydraulic tank.

Low Hydraulic Oil Level

Insufficient hydraulic oil level affecting system operation.

Air in Hydraulic System

Issues caused by air entering the hydraulic system.

Bypass Valve Lever Position

Problems related to the bypass valve lever position.

Defective Accelerator Control

Faults in the accelerator control mechanism.

Transverse Axle Internal Damage

Diagnosing internal damage to the transverse axle.

Brake Adjustment or Jamming

Issues with the brake system being improperly adjusted or stuck.

Brake Linkage and Cable Maintenance

Maintenance for brake linkage and cables.

Rear Drive Belt Condition

Problems with the rear drive belt condition or slippage.

Missing or Damaged Keys

Issues arising from damaged or missing keys in drive components.

Partial Brake Release Symptom

Symptoms of the parking brake not fully releasing.

Parking Brake Engagement Check

Safety requirement regarding the parking brake for certain operations.

Lock Mechanism Function Check

Procedure for checking the proper functioning of the lock mechanism.

Hydraulic Transmission System Issues

General issues related to the hydraulic transmission system.

Parking Brake Applied Status

Indication that the parking brake is engaged.

Reduced Machine Speed or Drive Loss

Symptoms of reduced machine speed or complete loss of drive.

No Machine Movement

Complete failure of the machine to move forwards or backwards.

Low power, abnormal noise

Engine Speed Drop

Engine RPM dropping under load or operation.

Hydraulic Pump Drive Belt Issues

Issues related to the drive belt for the hydraulic pump.

Transmission Overheating

Problems with the transmission overheating.

Low Transmission or Hydraulic Oil

Insufficient oil levels in the transmission or hydraulic system.

Belt Tensioning Mechanism Check

Inspecting and adjusting the belt tensioning system.

Worn Drive Belt

Problems caused by a worn or damaged drive belt.

Damaged Fan Impeller

Faults with the cooling fan impeller causing noise or damage.

Loose or Damaged Pulleys

Issues with loose or damaged pulleys affecting belt drive.

Blocked Suction Filter

A blocked suction filter causing flow restrictions.

Front or Rear Axle Faults

Problems identified within the front or rear axle assemblies.

Engine Fault Diagnosis

General engine faults leading to low power or noise.

Transmission System Faults

General faults within the transmission system.

Drive Belt Issues

Issues specifically related to the main drive belt.

Hydraulic Pump Cooling Fan

Problems with the cooling fan associated with the hydraulic pump.

Pump Input Shaft Pulley Problems

Issues with the belt pulley on the pump's input shaft.

Hydraulic Pump Unit Issues

General problems related to the hydraulic pump unit.

Hydraulic System Air Ingress

Diagnosing and fixing air ingress into the hydraulic system.

Axle Synchronization Problems

Problems when the front and rear axles are not properly synchronized.

Machine Slows Under Heavy Load

Symptoms of reduced performance when operating under heavy load.

Abnormal Transmission Noises

Identifying and resolving unusual noises originating from the transmission.

Machine Overloading

Issues caused by operating the machine beyond its intended capacity.

Adjust Driving Style to Prevent Overload

Adjusting operator technique to avoid overloading.

Abnormal Cutting Unit Noises

Diagnosing and fixing unusual noises from the cutting unit.

Foreign Objects Interfering with Parts

Issues caused by foreign objects interfering with moving parts.

Partial Brake Release

Symptoms indicating the brake is not fully releasing.

Parking Brake Check and Adjustment

Procedure to check and adjust the parking brake.

Transmission or Internal Part Replacement

When to replace the entire transmission or internal components.

Incorrect Throttling Port Connection

Incorrect connection of the throttling mechanism.

Correct Throttling Control Position

Correct positioning of the throttling control.

Pump or Drive Shaft Internal Damage

Diagnosing internal damage to the pump or drive shaft.

Damaged Unit Replacement

Recommendation to replace damaged units.

Abnormal Driving Noises

Diagnosing unusual noises during machine operation.

Suspected Drive Shaft Issues

Suspected drive shaft issues causing noise.

Stationary Machine Noises

Unusual noises occurring when the machine is stationary.

Suspected Hydraulic Pump Faults

Suspected faults within the hydraulic pump causing noise.

Transmission: Overheating, other indications

Transmission Overheating Causes

Symptoms and causes of transmission overheating.

Poor Air Circulation Effects

Issues related to inadequate airflow around the transmission.

Cooling Fan Faults

Faults with the cooling fan affecting transmission temperature.

Cooling Fan Repair or Replacement

Action to take if the cooling fan is damaged or loose.

Correct Engine Oil Level for Cooling

Ensuring correct engine oil level for transmission cooling.

Low Transmission Oil Level Consequences

Consequences of low oil levels in the transmission system.

Cleaning Cooling Surfaces

Removing dirt and debris from cooling surfaces.

Cooling Fins Blockage

Specific cause of poor air circulation affecting cooling.

Partial Brake Release Symptoms

Symptoms of the brake system not fully releasing.

Parking Brake Check and Adjustment

Procedure to check and adjust the parking brake.

Transmission or Internal Part Replacement

When to replace the entire transmission or internal components.

Incorrect Throttling Port Connection

Incorrect connection of the throttling mechanism.

Correct Throttling Control Position

Correct positioning of the throttling control.

Pump or Drive Shaft Internal Damage

Diagnosing internal damage to the pump or drive shaft.

Damaged Unit Replacement

Recommendation to replace damaged units.

Jerky Engine Start

Problems with the engine starting smoothly.

Defective Accelerator Control

Faults in the accelerator control mechanism.

Control Jamming, Damage, or Spring Failure

Issues related to jamming, damage, or spring failure in controls.

Correct Engine Oil for Cooling

Ensuring correct engine oil level for transmission cooling.

Low Transmission Oil Level

Consequences of low oil levels in the transmission system.

Rear Drive Belt Slippage

Problems with the rear drive belt condition or slippage.

Belt Tensioning Mechanism Check

Inspecting and adjusting the belt tensioning system.

Worn Drive Belt

Problems caused by a worn or damaged drive belt.

Belt Adjuster Bearing Maintenance

Maintenance for belt adjuster bearings.

Drive Belt Replacement

Recommendation to replace worn drive belts.

Pump Return Spring and Cams

Issues related to the return spring and cams on the hydraulic pump.

Uneven mowing result, vibrations

User Error Causes

Common mowing problems attributed to operator actions.

Machine Mechanical Faults

Mowing issues caused by mechanical faults in the machine.

Cutting Unit Related Issues

Problems related to the cutting unit's condition or adjustment.

Engine Related Mowing Issues

Engine-related issues causing uneven mowing or vibrations.

Vibration Troubleshooting

Causes and troubleshooting for excessive machine vibrations.

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