HUSQVARNA RIDER 16 RIDE on MOWER Workshop Manual

Workshop manual English Rider 11, Rider 13, Rider 11 Bio, Rider 13 Bio, Rider 16 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 1 Workshop manual Rider 11, Rider 13 Rider 11 Bio, Rider 13 Bio Rider 16 Contents Safety regulations ............................................... 2 General instructions ......................................... 2 Special instructions .......................................... 2 Special tools ........................................................ 3 Technical data ..................................................... 4 Tightening moments ......................................... 4 Play .................................................................. 4 Mowing deck .................................................... 5 Control points ................................................... 5 Delivery and dealer service ................................ 7 Maintenance schedule ..................................... 9 Delivery measures ............................................ 10 To our dealer .................................................. 10 Packaging and unpacking .............................. 10 Parts enclosed in packaging .......................... 10 Battery ............................................................ 11 Steering wheel ............................................... 12 Tow plate ........................................................ 12 Oil levels ........................................................ 12 Wheels ........................................................... 13 Checking and adjusting of the mowing deck’s ground pressure and parallelism ........ 13 Test running ................................................... 14 Speed regulator ............................................. 15 Administration ................................................ 15 Design and function .......................................... 16 General .......................................................... 16 Serial number ................................................. 17 Engine ............................................................ 18 Steering .......................................................... 19 Driving ............................................................ 20 Mowing deck .................................................. 20 Reparation instructions .................................... 23 Removing engine ........................................... 23 Replacing engine ........................................... 25 Fuel tank ........................................................ 27 Changing engine oil ....................................... 28 Checking and adjusting steering wires .......... 28 Replacing steering wires ................................ 29 Removal/installation of steering axle ............. 29 Removal/installation of wire wheel ................. 30 Checking and adjusting brake wire ................ 31 Checking and adjusting gear control .............. 32 Checking and adjusting freewheel clutch ....... 32 Checking and adjusting throttle control .......... 33 Replacing articulated steering bearing ........... 33 Removal of swing axle ................................... 35 Replacing bushings ........................................ 35 Installation of swing axle ................................ 36 Removal/installation of gear box .................... 37 Removal/installation of hydrostatic transmission ................................................... 37 Replacing hydrostat. trans. axle seals ........... 38 Input axle .................................................. 38 Outgoing axles .......................................... 39 Replacing hydrostatic transmission wire ........ 40 Bleeding hydrostatic transmission oil system 44 Adjustment of transmission neutral position .. 44 Transmission maintenance ............................ 45 Oil change ................................................. 45 Removal of belt .............................................. 46 Checking and adjusting cutting unit ground pressure ......................................................... 47 Checking and adjusting parallelism of the mowing deck .................................................. 47 Adjusting cutting height area .......................... 49 Adjusting cutting height .................................. 49 Removing the cutting unit .............................. 50 To leave the service position .......................... 51 Dismantling the cutting unit ............................ 52 Replacing cutting unit belts ............................ 53 Replacing belt on BioClip 103 and Combi 103 ................................................. 53 Replacing belt on BioClip 90 ..................... 54 Belt replacement on mowing deck with side- or rear discharge BioClip 112 and Combi 112 ................................................. 54 Replacing breakpin ........................................ 55 Removal of blades with bearings ................... 55 Grinding and balancing of blades .................. 57 Electrical system ............................................... 58 Circuit diagram Rider 11 ................................ 58 Circuit diagram Rider 13 and Rider 13 Bio .... 59 Circuit diagram Rider 16 ................................ 60 Inspection of safety system ............................ 61 Troubleshooting chart For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

2 – English Safety regulations General instructions The workshop handbook is written for personnel who are assumed to have general ride-on mower reparation and service know-how. The workshop where the ride-on mower is repaired should be equipped with safety devices in accordance with local regulations. No-one should attempt to repair the ride-on mower without having first read and understood the contents of this handbook. The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer. The below-mentioned boxes are included in this workshop handbook, as is appropriate. Special instructions The fuel used in the ride-on mower has the following hazardous characteristics: • Toxic fluid and fumes • Can cause eye and skin complaints • Can cause breathing difficulties • Highly flammable When using compressed air, do not direct the compressed air stream towards your, or anybody else's, body. Air can be forced into the blood stream, thereby constituting a danger to life . Use eye protection when working with tensioned springs. Use hearing protectors when test driving. After test driving, do not touch the silencer before it has cooled down. Risk of burn injuries. This especially applies if the ride-on mower is equipped with a catalytic converter. If consumed, the lining on and in the catalytic converter element is dangerous to health. Use protective gloves when working with the catalytic converter/silencer. The blades are sharp and can cause cutting injuries. Always use protective gloves when you are handling the blades. Use protective glasses when working with the mowing deck. If the belt's tension spring comes off and flies upwards, this can cause injury to persons. Use eye protection when working with the battery with the plugs removed. Be extra careful when handling battery acid. Spilling acid on the skin can cause severe burn injuries. If acid is spilt on the skin, rinse immediately with water. If acid gets into the eyes, this can cause blindness, contact a doctor. Be careful with the maintenance of the battery. Explosive gas is formed in the battery. Never handle the battery when smoking or in the vicinity of naked flames or sparks. Otherwise, the battery can explode and cause severe injuries. IMPORTANT INFORMATION This box indicates a risk of damage to the material if the instructions are not followed. WARNING! The warning box indicates a risk of injury to persons if the instructions are not followed. IMPORTANT INFORMATION Waste oil and old filters shall be handled as hazardous waste. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 3 Special tools The following special tools are used when working on the ride-on mower. Special tools for the engine and transmission are specified in resp. Workshop Manuals. 506 66 48-01 Puller for engine pulley. 506 79 06-01 Ball-ended Allen key 3/8" to unscrew the engine pulley socket head cap screw (Briggs & Stratton). 506 89 92-01 Counter-hold for engine belt pulley. 506 89 93-01 Tool for the articulation spring. 535 41 32-01 Set of drifts for bushings on the swing axle. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

4 – English Technical data Tightening moments Carrier steering 5–10 Nm 3,5-7 lbft Pulley steering wire 20–30 Nm 14-21 lbft Belt wheel 35–40 Nm 25-28 lbft Blades 45–50 Nm 32-36 lbft Blade bearings 20–25 Nm 14-18 lbft Belt tensioner wheel 15–25 Nm 10-18 lbft Holder screws, engine 20–25 Nm 14-18 lbft Holder screws, gear box 20–25 Nm 14-18 lbft Engine pulley 70–80 Nm 50-56 lbft Dimensions: Rider 11 Rider 13 Length 2 090 mm/6,85 ft 2 000 mm/6,56 ft Width 880 mm/2,89 ft 900 mm/2,95 ft Height (over steering wheel) 1 070 mm/3,52 ft 1 060 m/3,48 ft Weight 197 kg/433 lb 190 kg/419 lb Track front 720 mm/2,36 ft 625 mm/2,05 ft Track rear 620 mm/2,04 ft 625 mm/2,05 ft Wheel base 860 mm/2,81 ft 860 mm/2,81 ft Tyre size 16 x 6.50 x 8 16 x 6.50 x 8 Air pressure 60 kPa/8,5 PSI 60 kPa/8,5 PSI Max. gradient 15° 15° Engine: Rider 11 Rider 13 Manufacture Briggs & Stratton Briggs & Stratton Model 28N707 286707 Power 7,7/10,5 kW/hp 9,2/12,5 kW/hp Displacement 362 cm 3 465 cm 3 Fuel min. 85 octane unleaded min. 85 octane unleaded Tank capacity 7 litres/7,4 USqt 7 litres/7,4 USqt Oil SAE 30 or SAE 10W/30 SAE 30 or SAE 10W/30 class SF-CC class SF-CC Oil capacity 1,4 litres/1,5 USqt 1,4 litres/1,5 USqt Gearbox: Rider 11 Rider 13 Manufacture Peerless MST 205 Tuff Torq K46 Oil SAE 10W/30 class SF-CC Oil capacity 2,2 litres/2,35 USqt Gears, forwards 5 Gears, reverse 1 Electrical system Rider 11 Rider 13 Type 12 V, negative earth 12 V, negative earth Battery 12 V, 24 Ah 12 V, 24 Ah Main fuse Flat pin yoke 15 A Flat pin yoke 15 A Spark plug Champion CJ8 or J8 Champion CJ8 or J8 Spark plug gap 0,75 mm/0,030" 0,75 mm/0,030" Play Clutch wire R 11: 8–10 mm (5/16" - 3/8") Brake control lever against stop bolt R 11: 0–1 mm (0 - 0.040") Brake control lever R 11: 7–9 mm (1/4" - 3/8") Brake wires R13, R16: 1 mm (0.040") Wires, hydrostatic transmission pedals R13, R16: 0 mm For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 5 Technical data Dimensions: Rider 16 Length 2 000 mm/6,56 ft Width 900 mm/2,95 ft Height (over steering wheel) 1 060 mm/3,48 ft Weight 208 kg/459 lb Track front 625 mm/2,05 ft Track rear 625 mm/2,05 ft Wheel base 860 mm/2,81 ft Tyre size 16 x 6.50 x 8 Air pressure 60 kPa/8,5 PSI Max. gradient 15° Engine: Rider 16 Manufacture Briggs & Stratton Model - 2002 28N707 Model 2003 - 282H070110E1 Power 11,4/15,5 kW/hp Displacement 465 cm 3 /28,42 cu inch Fuel min 85 octane unleaded Tank capacity 7 litres/7,4 USqt Oil mineral-2002 SAE 30 or 10W/30 class CD-CF Oil synthetic 2003 - SAE 5W/30 or 10W/30 class SJ-CF Oil mineral 2003 - or SAE 30 class SF-CC Oil capacity 1,4 litres/1,5 USqt Gearbox: Rider 16 Manufacture Tuff Torq K 46 Oil SAE 10W/30 class SF-CC Oil capacity 2,2 litres/2,35 USqt Electrical system Rider 16 Type 12 V, negative earth Battery 12 V, 24 Ah Main fuse Flat pin yoke 15 A Spark plug - 2002 Champion CJ8 or J8 Spark plug 2003 - Champion QC12YC Spark plug gap 0,75 mm/0,030" Mowing deck: Rear ejector 85 Rear ejector 97 Side ejector 97 Bio 90 Bio 103 Cutting width 850 mm 970 mm 970 mm 900 mm 1 030 mm Cutting height 40-90 mm 40-90 mm 40-80 mm 45-95 mm 45-95 mm Blade length 304 mm 350 mm 350 mm 480 mm 410 mm Noise level 100 dB(A) 100 dB(A) 100 dB(A) 100 dB(A) 100 dB(A) Weight 29,0 kg 48,0 kg 45,0 kg 39,0 kg 47,0 kg Overall width 950 mm 1 075 mm 1 300 mm 1 000 mm 1 115 mm Mowing deck: BioClip 112 Combi 103 Combi 112 Cutting width 1 200 mm 1 030 mm 1 220 mm Cutting height 40-90 mm 45-95 mm 40-90 mm Blade length 420 mm 410 mm 420 mm Noise level 100 dB(A) 100 dB(A) 100 dB(A) Weight 50,0 kg 47,0 kg 52,0 kg Overall width 1 230 mm 1 115 mm 1 230 mm For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

6 – English Control points Mowing deck parallelism with cutting height in pos. 1: ± 2 mm ± 0,079" Cutting height control in pos. 1: Rider 11 = 37 ± 2 mm 1,46" ± 0,079" Bio = 45 ± 2 mm 1,77" ± 0,079" Other = 40 ± 2 mm 1,57" ± 0,079" Synchronous transmission belt tension Bio 103 version 1, Combi 103: Automatic adjustment Synchronous transmission belt tension Bio 103 version 2 at 10 N force, impression: 7 mm 1/4" Synchronous transmission belt tension Bio 90 at 7 N force, impression: 8 mm 5/16" Dist. between support plate and drive belt: 3–6 mm 1/8" - 1/4" Distance belt tensioner control lever and belt guide, disengaged unit: 17 ± 5 mm 7/16" ± 3/16" Technical data For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 7 Delivery and dealer service Pre-delivery service 1. Top up battery with acid and recharge for four hours. 2. Fit the steering wheel, tow plate, and where appropriate other parts. 3. Adjust cutting unit: Adjust lift springs (effective weight of cutting unit should be 12–15 kg (26,5-33 lb), or set to maximum lift if brush is to be fitted). (Only applies to BioClip and Combi.) Adjust cutting unit so that rear edge is about 2–4 mm (1/8") higher than front edge. Adjust cutting unit height setting so that cutting height limit is 5 mm (3/16") above the frame of the unit at the lowest cutting height. 4. Check that engine has correct amount of oil. 5. Check that the right amount of oil is in the transmission. (Not Rider 11) 6. Check and adjust tyre pressure (60 kPa/0,6 bar/8,5 PSI). 7. Connect battery. 8. Fill with fuel and start engine. 9. Check that machine does not move in neutral. (Not Rider 11) 10. Check: Forward drive. Reverse drive. Operation of blades. Seat safety switch. Lift lever safety switch. 11. Check engine revs 2 900 - 3 100 rpm. Rider 16, 2003- model, 2 800-3 000 rpm. 12. Tell customer about: Need and benefits of following the service schedule. Need and benefits of having machine serviced every 300 hours. The effects of maintenance on the machine’s second-hand value. Applications for BioClip and Combi. 13. Complete proof of sale, etc. After first 5 hours 1. Change engine oil. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

8 – English Delivery and dealer service Dealer service 25 hours service 1. Change the engine oil on the side-valve engine (With high load and temperature on the overhead-valve engine). 2. Clean/replace the airfilter’s pre-filter or oil-foam element, if fitted. (More frequent intervals in dusty operating conditions.) 3. Clean/replace the air filter’s filter cartridge (25 hours, 100 hours if pre-filter is fitted). (More frequent intervals in dusty operating conditions.) 4. Check the tyre pressures. 5. Check the mower deck (visual inspection) 6. Lubricate the belt tensioner. 7. Lubricate joints and axles. 8. Adjust the brake (Rider 11). 9. Check the V-belts. 10. Clean the engine’s cooling air intake. 11. Check/clean the hydrostatic transmission gear’s cooling fins. 50 hours service 1. Carry out 25 hours service as above. 2. Change engine oil. 3. Check the oil level in the transmission. (Rider 13, 16). 4. Check/adjust the parking brake. (Rider 13, 16). 5. Check/adjust the throttle wire. 6. Clean the cooling fins on the engine and transmission. 7. Check/adjust the settings on the mowing deck. 8. Inspect the flame guard/spark arrester. (extra equipment) 100 hours service 1. Carry out 25 hours service as above. 2. Carry out 50 hours service as above. 3. Replace the pre-filter and filter cartridge in the air filter. 4. Replace the fuel filter in the pipe. 5. Clean/replace the spark plug. 300 hours service 1. Inspect the machine. Reach agreement with the customer about which additional work should be carried out. 2. Carry out 25 hours service as above. 3. Carry out 50 hours service as above. 4. Carry out 100 hours service as above. 5. Check the valve clearance on the engine. At least once a season 1. Change the engine oil (25/50 hours). 2. Replace the pre-filter in the air filter. 3. Replace the filter cartridge in the air filter. 4. Check/adjust the settings on the mowing deck. 5. Adjust the parking brake. 6. Inspect the flame guard/spark arrester (extra equipment). 7. Clean/replace the spark plug. 8. Replace the fuel filter in the pipe. 9. Clean the cooling fins on the engine and transmission. 10. Check the valve clearance on the engine. 11. 300 hours service should be carried out by an authorised service workshop. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

HUSQVARNA RIDER 16 RIDE on MOWER Workshop Manual

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