Workshop Manual

P 520D
P 525D
English
 Workshop Manual

P 520D, P 525D

Contents

Introduction........................................................... 2 Fuel System ....................................................... 35

Safety Instructions .............................................. 3 Fuel Tank, Assembly and Dismantling............ 35
General Safety Instructions............................... 3 Bleeding the Fuel System............................... 36
Special Safety Directions.................................. 3 Electrical System . ............................................. 37
Special Tools ....................................................... 4 Battery, Changing............................................ 38
Hydraulic Equipment......................................... 4 Circuit Board, Changing.................................. 39
Tool for Measuring Wheel Speed...................... 4 Parking Brake Sensor, Changing.................... 40
Laser Tachometer............................................. 4 Ignition Switch, Changing................................ 41
Remember When Measuring............................ 4 Hour Meter, Changing..................................... 42
Measure rpm..................................................... 5 Hydraulic System .............................................. 43
Read the Last, Highest and Lowest Values...... 5 Hydraulic Hygiene........................................... 43
Change Batteries............................................... 5 Rectify Oil Leaks............................................. 43
Care................................................................... 5 Keep Hydraulic System Fluid Clean................ 43
Serial Number ...................................................... 6 Working Methods............................................ 43
Screw Fasteners................................................... 7 Hydraulic Couplings, Pipes and Hoses........... 44
Hydraulic Couplings.......................................... 7 Hydraulic System............................................ 44
Chassis . ............................................................... 8 Suction Filter, Changing.................................. 45
Removing Driver's Seat..................................... 8 Hydraulic Pump, Changing.............................. 46
Changing Throttle Cable................................... 8 Rear Transmission, Changing......................... 49
Changing Parking Brake Cable......................... 9 Front Transmission, Changing........................ 53
Dismantling Wheel Hub................................... 10 Filter Holder, Changing................................... 55
Changing Wheel Hub Bearing......................... 10 Valve Block Working Hydraulics, Changing.... 56
Changing Pedal Bracket Bushings.................. 11 Steering Servo, Changing............................... 56
Changing Lifting Arms and Bushings.............. 13 Steering Cylinder, Replacement...................... 58
Changing Link Stay......................................... 14 Steering Cylinder, Changing Joint Bearing..... 59
Changing Joint Bearing in Articulated Unit...... 16 Lifting Cylinder, Replacement......................... 60
Propulsion . ........................................................ 22 Cutting Deck ...................................................... 61
Air Filter, Dismantling and Assembly............... 22 Bearing Housing Blade Bearing, Changing..... 61
Drive Shaft for Hydraulic Pump, Dismantling Bearing Housing, Changing Bearing............... 62
and Assembling............................................... 23 Technical Data ................................................... 64
Changing Solenoid Clutch............................... 24 Technical Data - Sound and Vibration Levels...... 65
Engine, Dismantling, Assembling.................... 29 Technical Data - Fluids.................................... 65
Cooling System ................................................. 32 Technical Data - Cutting Deck......................... 65
Replacing the Cooler....................................... 33 Electric Diagram................................................. 66
Pressure Testing the Radiator......................... 34

English – 1
 Introduction
Husqvarna P520D/P525D is a professional machine The manual comprises the following chapters:
for professional use on large areas of land. It can be
equipped with accessories for mowing, clearing
Introduction
snow, sweeping, etc.
Presentation of the contents of the manual together
This Workshop Manual is intended as an aid for with explanations and advice.
personnel with general knowledge of the repair and
service of P520D/P525D. Service for this machine
Safety Instructions
requires knowledge corresponding to vocational
training for automotive mechanics with machinery This chapter must be read and understood by
or automobile specialty. everyone involved in the repair and service of the
machine. Additional safety regulations can be found
Modifications to the machine can be gradually in the operator's manual.
introduced into ongoing production. As these
modifications affect service and/or spare parts,
specific service information will be sent out on each Special Tools
occasion. This means this Workshop Manual can in Tips on necessary tools. Certain tools are sold by
time become out of date. In order to prevent this, the Husqvarna.
Manual should be read together with all service
information concerning the ride-on mower in
question. Repair Instructions
Working instructions and directions for adjustment
This Workshop Manual covers model years from
when there is a risk of personal injury, material
2011 and later. It concerns the machine including
damage or incorrect assembly are given priority.
removal and assembly of sub-contractor
components. For dismantling/assembling, adjusting
and testing sub-contractor components, please refer Specifications
to the manuals published by the respective An encyclopedia of data tailored to the needs of the
manufacture. mechanic.
Refer to the service book for delivery and dealer
service, and action list for planned maintenance of Appendices, Schematics, etc.
the machine.
Can be used to more than one section of the manual.

System Components, Manuals

Design and function or work on system components
is not described in this manual. This information can
be found in the manufacturer's own manuals, which
contain detailed information about dismantling,
assembling, special tools and spare parts.
Operator's manuals from the following sub-
contractors are included with the machine.
Kubota Diesel Engine
Operator’s manual D905 (P 520D)/D1105 (P 525D).
Bondioli & Pavesi
Propeller shaft service manual.

2 – English
 Safety Instructions
Safety During Repair Work the type of diesel but is normally higher than +50°C
(120°F).
This Workshop Manual contains the following
warning boxes in relevant places. You must be attentive to ensure spillage does not
occur when you open a system that contains oil or fuel.
WARNING! Avoid spillage, use a funnel and fill carefully.
The warning box warns of the risk
of personal injury if the instructions Choose an area, preferably with a concrete floor,
are not followed. when you handle or store oils and fuel so that any
spillage can be taken care of without it penetrating
into the ground.
IMPORTANT! When draining, ensure that a suitably sized
This box warns of material damage if the container is placed correctly. Remember that the oil
instructions are not followed. does not always run straight down.
Always wipe up spillage. When using cloths, sawdust
General Safety Instructions or oil absorbents, they must be treated as
environmental hazardous waste. Follow local
This Workshop Manual is written for personnel with a regulations.
general knowledge of repairing and servicing ride-on
mowers. Transfer the waste oil into a sealed container and
hand in for destruction. Remember to follow local
The workshop where the ride-on mower is to be regulations.
repaired must be equipped with safety devices in
accordance with local bylaws. Replaced oil and fuel filters are environmental
hazardous waste, handle them as waste oil.
No one may repair the ride-on mower without first
reading and understanding the content of this Do not spill fuel when filling up. Fuel spills harm the
workshop manual. environment and are a fire hazard.
The machine is tested and approved to be Wash your hands thoroughly when the job is done.
maintained only with the equipment the Coolant is poisonous and sweet. Ensure that
manufacturer has delivered or recommended. animals do not come into contact with open
Take care of the environment, there are numerous containers or pools of fluid.
environmental risks especially when performing
maintenance on the machine. This particularly
Battery
applies when dealing with engine oil, hydraulic oil, The battery is maintenance free and must not be
fuel, oil filters, hydraulic filters and fuel filters. opened. A discarded battery must be disposed of in
accordance with local environmental regulations.
Special Safety Directions
Do not smoke in the vicinity of the battery.
Fuel, Oils, etc.
Sparks can occur when working on the battery and
IMPORTANT! the thick cables. This can cause battery explosions,
fire or eye injuries. Sparks can not arise in the circuit
Waste oil and old filters shall be handled as once the battery ground frame cable (normally black
hazardous waste. negative cable) is disconnected. Avoid sparks and
their consequences by
Seek medical advice immediately if skin comes into
contact with fuel that is under high pressure. • using protective goggles.

The fuel used in the ride-on mower has the following • making sure the tank cap is fitted and there are
hazardous properties: no flammable liquids stored in open vessels.

• The liquid and its vapor are toxic and • not working with the starter motor circuit in the
carcinogenic. vicinity of spill fuel.
• Can cause eye and skin irritation. • disconnecting the negative battery terminal first
• Can cause breathing problems. and connecting it last
• Is environmentally hazardous. • taking care not to cause short circuits with tools
Diesel is less flammable than gasoline at normal • not short circuiting starter relay terminals in
temperatures, but becomes very flammable when order to operate the starter motor.
heated to its flash point. This varies depending on

English – 3
 Special Tools
The machine is designed so that the number of Laser Tachometer
special tools is kept to a minimum. The following
special tools are used when working on the ride-on
mower. Special tools for engine and transmission IMPORTANT!
can be found in the respective workshop manual. To avoid incorrect readings, the laser meter
• Counterhold for torquing solenoid clutch. must be held at right angles to the rim at a
distance of maximum 10 cm.
• Spring hook for changing belt on cutting deck.
• Tool for checking wheel speed.
Hydraulic Equipment
Testing nipple kit
RPM

1 pc. manometer 0-2.5 MPa (0-25 bar). TOT

1 pc. manometer 0-25 MPa (0-250 bar).

MEM

(Alternatively 1 pc. combination manometer with

above measuring range.)
The manometers should have test couplings to fit
quick coupling with M16x2 thread and 1 meter DIGITAL TACHOMETER

manometer hose.

Tool for Measuring Wheel Speed

Safety During Use:
• Class 1 laser product.
• Take care whenever the laser beam is on. Do
not look straight into the beam. Do not aim the
beam towards anyone else's eyes, neither
people nor animals.
• Do not aim the laser beam towards polished
surfaces where the beam can be reflected into
someone's eyes.
• Do not aim the laser beam at explosive gases.
Remember When Measuring:
• The reflecting surface must be smaller than the
8095-362

non-reflecting surface.
• If the object to be measured is shiny, cover the
measured surface with black tape or paint it
This tool is used together with the laser meter in black before the reflective tape is affixed.
order to rotate the wheel pair on one side while the
wheel pair on the other side is resting on the ground. • Clean the surface before affixing the tape.
• When measuring at low speed, a more precise
reading can be obtained by fastening more
pieces of tape evenly distributed around the
object being measured. Then divide the read
value with the number of tape pieces to obtain
the real rpm.

4 – English
Measure rpm Read the Last, Highest and Lowest Values
1. Put the switch to RPM position for measuring The instrument will automatically save the last,
rpm or TOT for measuring the number of highest and lowest readings for a measurement (i.e.
revolutions. as long as the measuring button is depressed). Press
in and hold the memory button (MEM) in order to see
2. Put a small piece of reflective tape (approx the saved readings. The reading is shown on the
1x1 cm) on the rotating object to be measured. display after 1-2 seconds. Reading indicated with:
3. Hold the laser tachometer at right angles about • First press Last ”LA”.
10 cm from the wheel rim.
• Second press Highest ”UP”.
4. Press in and hold the measuring button on the • Third press Lowest ”dn”.
side of the instrument. Aim the measuring beam
at the object and the reflective tape. The display Change Batteries
will light up after 1-2 seconds.
The batteries are beginning to be depleted when the
5. Hold in the measuring button during the whole low battery symbol is displayed.
measuring procedure. The instrument is turned 1. Open the battery cover by loosening the
off when the measuring button is released. recessed head screw holding it.

2. Remove the old batteries and replace them with

new ones. Use 4x 1.5 volt R6 (AA) batteries.

3. Make sure to insert the batteries the right way

round or the instrument can be damaged.

4. Close the battery cover and lock it with the screw.

Care
Clean the tachometer with a soft, damp rag. Never
use any form of solvent for cleaning.
1
Never dip into water or other liquid.
Do not expose the tachometer to direct sunlight, high
2
temperature, excessive amounts of dust or
mechanical impact.
Remove the batteries if the instrument is not being
3 used for long periods.
The tachometer may only be opened by an
10 authorized repair technician.
cm
8095-355

1. Wheel speed tool 3. Laser meter

2. Reflective tape

IMPORTANT!
To avoid incorrect readings, the laser meter
must be held at right angles to the rim at a
distance of maximum 10 cm.

English – 5
 Serial Number
Serial Number
The serial number can be found on the printed plate
attached to the right-hand frame member.
The plate includes the following information:
• Manufacturer
• Machine type designation.
• Manufacturer type number
• Weight
• Machine serial number (s/n).
Please provide the type designation and serial
number when ordering spare parts.
The engine type and serial number are on the
engine's valve cover. Please provide these when
ordering parts.
The hydraulic pump and hydraulic motors are
equipped with rating plates that indicate type
designation and serial or manufacture numbers.
Please provide these when ordering parts.

6 – English
 Screw Fasteners
Metric threads are used on the machine.
Some bolt fasteners are locked with screws treated
with Eslok® Nylon 180°. The screw threads have a
red coating. These screws can be refitted three
times before having to be replaced.
Always torque tighten screw unions to the specified
torque table unless specified otherwise in the text.

Spanner Size Allen Key Thread Tightening Torques

8 mm 4 mm M5 52 ft/lb (6 Nm)
10 mm 5 mm M6 52 ft/lb (10 Nm)
-- 3 mm M6 52 ft/lb (10 Nm)
13 mm 6 mm M8 52 ft/lb (24 Nm)
-- 4 mm M8 18 - 20 Nm
17 mm 8 mm M10 52 ft/lb (47 Nm)
17 mm -- M10 12.9 52 ft/lb (70 Nm)
18-19 mm 10 mm M12 52 ft/lb (81 Nm)
24 mm -- M16 80 ft/lb (110 Nm)
30 mm -- M20 52 ft/lb (200 Nm)
32 mm -- -- Hydraulic couplings, see
separate chapter.

Certain unions are screwed into the goods with a Hydraulic Couplings
through screw and a lock nut. The thread in the
When assembling hydraulic hoses and pipes, first
goods is intended to take the effective torque and
tighten their cap nuts by hand to stop. Then tighten a
the lock nut is to secure the union during use.
further 1½ flats of the wrench grip. This corresponds
Therefore, the main part of the torque - screw in the to an approximate 90° turn.
goods - should always be tightened first and then
secured with the lock nut, which is tightened with
less torque. If the lock nut is tightened with too high a 2
torque, the screw in the goods thread will be
unstressed and the bolt fastening will come loose
during use.

1
8095-299

1
2 1. Starting point
2. Torqued position = 1.5 flats = 90° angle
8095-309

1. Screw 3. Lock nut

2. Goods thread

English – 7
Chassis

Repair Instructions
CHASSIS Changing Throttle Cable
Removing Driver's Seat Tools Dimension Quantity
Socket wrench 10 mm 1
WARNING!
Combination 13 mm 1
The seat is heavy and can fall if let wrench
go. Secure it from falling. Risk of
Torx T30 1
personal injury.
Snipe nose pliers 1

Tools Dimension Quantity 1. Pull back on the throttle control (1) to its end
Combination 13 mm 1 position.
wrench
Socket wrench 13 mm 1 2. Remove the side cover.
Wire cutters 1 3. Open the engine cover.
1. Tilt the seat back. 4. Loosen one or both lock nuts (6) on the throttle
cable fastening on the engine control arm.
2. Cut the cable ties and loosen the connection (1). Remove the air cleaner if necessary to make
3. Secure the seat from falling back when the stay room.
(2) and hinge (4) are loosened. 5. Pull the throttle cable (4) through to the right
4. Unhook the stay (2) from the frame recess first, side. Note the route of the cable through the
then from the seat. machine.
5. Loosen the two hinges (4) and lift away 6. Press the throttle cable (4) out of the cable
the seat. holder (5).
6. Reassemble the seat in the reverse order. 7. If it is difficult to access, loosen the throttle
control. First remove the plastic knob on the
7. Check the safety breaker after assembly. control bracket. Then unscrew the bracket.
See the Operator's Manual.

1
1

2 5
2 4
3

6
7
8095-233

5
8095-255

1. Throttle control 5. Cable holder

4
2. Control bracket 6. Lock nuts
3. Screw 7. Control arm
1. Connection with cable ties 4. Hinge
4. Throttle control cable
2. Stay 5. Lock mechanism
3. Notch
8. Assemble in the reverse order.
9. Check the operation of the throttle control. See
Checking the Engine Speed.

8 – English
 Chassis

Changing Parking Brake Cable 4. Dismantle two screws (1) for the parking brake
bracket (2). Carefully bend the bracket out from
Tools Dimension Quantity the overlying frame section to expose the cable
Combination 13 mm 1 fastening.
wrench
5. Remove the cable eye (4) from the spring (5).
Torx T 30 1
Snipe nose pliers 1 6. Refit the new cable in reverse order.
Torque wrench 1 7. Check the handbrake adjustment in accordance
U-grip for torque 13 mm 1 with the operator's manual.
wrench 8. Torque tighten the nut/lock nut to 20 Nm.
Remove the seat if fitted for better access. See
Removing Driver's Seat.
1. Release the parking brake.

1 2 3 4

5 4 3
8095-328

8095-261
1. Parking brake cable 3. Bracket
2. Spring 4. Transmission bracket 1. Screw 4. Eyelet
2. Bracket 5. Spring
2. Loosen the lock nut (2) on the transmission end 3. Cable
of the cable.
3. Remove the split pin (4) and clevis pin (5), and
pull the torsion spring (6) away from the arm (1).

2
1

3
4
6 5
8095-232

1. Arm 4. Split pin

2. Lock nut 5. Clevis pin
3. Parking brake cable 6. Tension spring

English – 9
Chassis

Dismantling Wheel Hub Changing Wheel Hub Bearing

Tools Dimension Quantity Tools Dimension Quantity
Circlip pliers SGH 45° 1 Circlip pliers SGA 1
Socket wrench 15 mm 1 Circlip pliers SGH 1
Socket wrench 15 mm 1 1. Remove the wheel hub. See Removing Hub.
1. Loosen the wheel nuts on the wheel in question 2. Put the hub on a work bench.
but do not remove them yet.
3. Dismantle the bearing retaining rings (1), (2).
2. Raise the machine.
4. Dismantle the bearing housing (3).
3. Remove the wheel.
5. Drive out the ball bearings (4), (5). Use a press
4. Remove the circlip (1). or driving tool of a suitable diameter.
5. Remove the wheel hub. The front wheel hub 6. Assemble in the reverse order.
has four screws (3) from the transmission shaft
(7). The rear wheel hub has through screws with
square pin. IMPORTANT!
6. Remove and check the O-ring (2). Replace if Avoid stressing the inner race when the new
necessary. bearing.
7. Assemble in the reverse order.

IMPORTANT!

7 Do not forget to retighten the wheel nuts

1 when the machine has been lowered from the
6
jack assembly.

5 2
5 4
1

2
8095-305

4 3
1. Circlip 5. Axle
2. O-ring 6. Bearing housing
3
3. Screw 7. Transmission shaft

8095-308
4. Wheel bolt

1. Circlip 4. Ball-bearings
2. Circlip 5. Ball-bearings
3. Bearing housing

10 – English
 Chassis

Changing Pedal Bracket Bushings 3. Lower the lifting arms.

Tools Dimension Quantity 4. Turn off the machine and make sure it can not
be restarted.
Groove joint 1
pliers 5. Dismantle the pedal cable (2) split pin (4) and
Combination 13 mm 1 clevis pin (3).
wrench
Combination 15 mm 1
wrench
Socket wrench 13 mm 1
Screw driver 5 mm 1

1. Start the machine and raise the lift arms.

2. The lift arms can fly up if the lever for the 1
hydraulic lift is unintentionally operated. Prevent
this by pulling out the retainer spring (6) and 2
removing the clevis pin (7) for the auxiliary lift

8095-325
spring (8).
3 4 5

1. Reverse pedal 4. Split pin

2. Pedal cable 5. Torsion spring
3. Clevis pin

1 2 6. Dismantle the pedal cable (12) by removing

3 the split pin (6) and the clevis pin (7).

4 7. Loosen the link arm (1) by removing the nut (4).

Hold the profile washer (3) with a 13 mm
combination wrench so the bolt does not turn.
Take care not to damage the rubber seal on the
link arm.
8. Dismantle the retaining ring (10) and one
5 8 washer (11).
8095-321

6 7

12
1. Reverse pedal 5. Cable
2. Forward pedal 6. Retainer spring
3. Half speed catch. 7. Clevis pin 11
4. Link arm 8. Auxiliary lift spring 10

9
5 8
8095-324

1 2 3 4 6 7
1. Link arm 7. Clevis pin
2. Rubber seal 8. Forward pedal
3. Profile washer 9. Pedal shaft
4. Nut 10. Retaining ring
5. Recoil spring 11. Washer
6. Split pin 12. Pedal cable

English – 11
Chassis

9. Remove five screws (1) so that the base plate 11. Press out the pedal shaft (9) and dismantle one
(2) can be loosened from the front edge. pedal arm at a time. Lift up the base plate to
allow the reverse pedal to pass.

12

1 11

8095-276
2 10

1. Screw
2. Base plate
9
10. Remove five screws (1) so that the front edge of 5 8
the base plate (2) can be loosened.

8095-324
1 2 3 4 6 7
1. Link arm 7. Clevis pin
2. Rubber seal 8. Forward pedal
3. Profile washer 9. Pedal shaft
4. Nut 10. Retaining ring
5. Return spring 11. Washer
6. Split pin 12. Pedal cable
1

2 12. Pull the bushings (1) out of the pedal arms.

13. Fit new bushings.
8095-325

3 4 5

1. Reverse pedal 4. Split pin 2 3

2. Pedal cable 5. Torsion spring
3. Clevis pin
1
1 1
1

8095-331

1. Bushing
2. Forward pedal
3. Reverse pedal

IMPORTANT!
It is a good idea to fit the cable before the link
arm is refitted.

14. Refit the pedal bracket in the reverse order.

15. Lubricate the bushings through the grease
nipples.

12 – English
 Chassis

Changing Lifting Arms and Bushings 8. Press bushings (1), (3) out of the lift arms (2).

Tools Dimension Quantity

Combination 13 mm 1 3
wrench
Combination 16 mm 1
wrench 2
Combination 18 mm 1
wrench
Socket wrench 13 mm 1
1
Circlip pliers SGA 1

WARNING!
Heavy objects are released when
dismantling the lift arms.

8095-260
The cutting deck must be removed and the lift arms
placed in raised position.
1. Bushing 3. Bushing
Dismantling 2. Lifting arm

1. Remove the service cover.

2. Raise the machine and support the front edge.
3. Remove the wheels.
4. Dismantle the circlip (11) and two washers (9), (10).
5. Remove the screw (2) fastening the lug on the
shaft (1).
6. Tap out the shaft (1).
7. Dismantle the lift arm (6) by unscrewing and
removing the threaded bolt (3) and washers (4),
(7), and nylon spacer (5).

6
5

7 8
9
10 11
1 2 3 4 1
8095-251

1. Shaft with lug and grease nipple. 7. Washer

2. Screw 8. Nut
3. Threaded bolt 9. Washer
4. Washer 10. Washer
5. Nylon spacer 11. Circlip
6. Lifting arm

English – 13
Chassis

Assembling Changing Link Stay

1. Clean and lubricate with grease before Tools Dimension Quantity
assembling new bushings.
Torx T30 1
2. Hold the lift arm (6) in place and fit the threaded Combination 15 mm 1
bolt (3) and washers (4), (7), and nylon spacer (5). wrench
3. Fit the shaft (1) with washers (9), (10). Combination 17 mm 1
wrench
4. Tighten first according to the table.
Socket wrench 15 mm 1
5. Then loosen the threaded bolt (3) until the nut Socket wrench 17 mm 1
(8) starts to rotate.
Breaking bars 1
6. Assemble remaining parts in the reverse order. Torque wrench 1
7. Lubricate the rear bushing through the grease Ring end for 17 mm 1
nipple and oil the front bushing. torque wrench

1. Apply park brake.

2. Remove the cover over the rear transmission.
3. Place a jack assembly as illustrated and
stabilize the mower, so that it does not fall when
the link stay is dismantled.

6
5

7 8
9
10 11
1 2 3 4 1
1
8095-251

1. Shaft with lug and grease nipple. 7. Washer

2. Screw 8. Nut
3. Threaded bolt 9. Washer
4. Washer 10. Washer
5. Nylon spacer 11. Circlip
8095-343

6. Lifting arm

1. Area for jack assembly

14 – English
 Chassis

4. Note how the link stay grease nipples are turned 13. Assemble in the reverse order. The front link
for refitting. stay grease nipple must point to the right.
5. Turn the steering wheel to full right lock to prepare 14. Torque tighten as below.
the space for dismantling the link stay (1).
6. Loosen the front end of the connecting rod (2).
1
1

2
3

2
4

8095-270

8095-335
1. Link stay 2. Connecting rod
1. Upper bearing journal 3. Lower bearing journal

7. Dismantle the rear link stay fastening. Remove 2. Link stay 4. Screw
the lock nut (4), washer (5), screw (3) and
sleeve (2). The rear screw for the link stay is screwed into the
goods. In addition, there is a lock nut for securing the
screw. If the lock nut is tightened too much, the
3 torque on the screw will be released and the union
2 will come loose. See also information on bolt
fasteners in the introduction.
Tighten the screw (2) until it bottoms first.
1
Then tighten the screw to the torque specified in the
table.
Finally, screw on the lock nut (3) and tighten to the
5 torque specified in the table.
8095-290

1. Link stay 4. Lock nut 2

2. Sleeve 5. Washer
3. Screw

1
IMPORTANT!
The rear carriage and transmission weighs
more than 90 kg.
8095-358

3
8. Raise the back edge of the rear carriage with a
jack assembly to relieve the load on the link stay. 1. Screw 3. Lock nut
2. Screw
9. Use a screwdriver or a breaker bar to lift the link
stay off the steering block. NB! Heavy unstable
parts! Location Screw Nut
Front 52 ft/lb (65 Nm) -
10. Dismantle the front link stay fastening. Remove
link stay (1).
the screw (4).
Rear 52 ft/lb (47 Nm) 52 ft/lb (24 Nm)
11. Lift the upper bearing journal (1) so the link stay link stay (2).
can be swung out.
15. Lubricate the link stay through the grease nipples.
12. If the link stay is to be changed, the lower
bearing journal (3) must be removed and
reused.

English – 15
Chassis

Changing Joint Bearing in Articulated Unit

4
5

2
1. Connecting rod
2. Joint bearing
1
3. Control cylinder

8095-268
4. Link stay
5. Rear transmission

Tools Dimension Quantity

WARNING!
Combination 13 mm 1
Heavy objects are released when
wrench
dismantling the lift arms.
Combination 15 mm 1
wrench
Combination 16 mm 1
wrench WARNING!
Combination 22 mm 1 Never insert hands or fingers as
wrench heavy components are unstably
Combination 27 mm 2 supported. Use tools that reach.
wrench Risk of crush injuries.
Combination 32 mm 2
wrench
Socket wrench 15 mm 1
Socket wrench 17 mm 1
Socket wrench 19 mm 1
Circlip pliers SGH 1
Chisel 1
Torque wrench 1
Ring end for 17 mm 1
torque wrench

16 – English
 Chassis

Dismantling 6. Loosen the front end of the connecting rod (1).

Remove the flanged nut (2), screw (3) and
1. Jack up and block the machine under the frame
washer (4).
as illustrated.

IMPORTANT!
Make sure not to place the trestle so that the
connecting rod is damaged or parts of the
articulated unit are blocked.

2. Place a vessel under the transmission to collect 2 3

oil spill.
3. Clean according to the general instructions. 4
4. The hydraulic hoses can be mixed up. Mark the
lines so that they are reconnected on the correct
connections.
5. Loosen the hydraulic lines. Fit sealing plugs to
prevent leakage and contamination.

8095-268
1. Connecting rod 3. Screw
2. Flange nut 4. Washer

2
8095-322

1. Area allowed for supporting.

2. Area forbidden for supporting.

IMPORTANT!
Suspend the connecting rod with a cable
tie around the drive shaft so that it is not
damaged when the rear carriage is loosened.

English – 17
Chassis

7. Dismantle the protective cover (1) over the 12. Loosen the steering cylinder (3) from the rear
steering joint. fastening by dismantling the shaft with the
locking lug (1).
IMPORTANT! 13. Turn the steering wheel so that the cylinder
Check that the protective cover is intact. goes to front end position (fully contracted).
A damaged cover must not be refitted but
discarded and replaced with a new one.

8. Dismantle the lock nut (7) on the bottom of the 1 2

articulated steering.

IMPORTANT!
The screw is threaded into the frame goods.
3
It must always be unscrewed, even if the lock

8095-288
nut has been removed.

9. Turn the steering wheel full lock to the left for 1. Shaft with locking lug 3. Control cylinder
better access. 2. Screw

10. Unscrew the articulated steering (2).

14. Turn the rear carriage at an angle so that the
11. Put the steering in neutral position again. link stay (1) screw (3) can go free from the
engine oil tray.
1
IMPORTANT!
2
The rear carriage and transmission weighs more
than 90 kg.
3
4 15. Dismantle the rear link stay fastening. Remove
the lock nut (4), washer (5), screw (3) and
5 sleeve (2).
6
16. Raise the back edge of the rear carriage with a
jack assembly to relieve the load on the link stay.
17. Use a chisel or a breaker bar to lift the link stay
8095-310

7
off the steering block. NB! Heavy unstable parts!
1. Protective cover 5. Bearings
2. Screw 6. Pin 3
3. Compression washer 7. Lock nut 2
4. Lock washer

5
8095-290

1. Link stay 4. Lock nut

2. Sleeve 5. Washer
3. Screw

18 – English
 Chassis

18. The rear carriage is now free, but can not be Assembling
lowered without reversing first. Support the rear
It is essential the screw is tightened to the correct
carriage and lower it slightly as illustrated. Do
torque for fastening the ball in the joint bearing.
not lower too much, avoid the positions with
crosses in the illustration. • If the ball is loose or badly lubricated, it may
start to move on the pin. This will cause much
19. Raise the rear carriage over the frame pin.
wear on the pin.
20. Carefully move back the rear carriage. Extract
• There is a risk of overloading the screw when
the hydraulic hoses at the same time.
operating if it is tightened too hard.
1. Lubricate the bearing seatings and studs with
IMPORTANT! corrosion inhibiting grease.
Note how the hydraulic hoses are routed to
facilitate refitting.
IMPORTANT!
Only press the outer race when driving in the bearing.

2. Fit the new bearing (1) by carefully driving in the

outer race with a suitable driving or press tool.
3. Fit the circlip (2).

2
8095-289

8095-297
21. Dismantle the circlip (2).
22. Drive the bearing (1) out of the rear carriage. 1. Bearings 2. Circlip

IMPORTANT!
Carefully follow the instructions below for torque
tightening the link stay and articulated steering.
A torque wrench must be used.

1
8095-297

1. Bearings 2. Circlip

23. Clean the lubrication channel by pressing

grease through the grease nipple. Then clean
the bearing space with grease.

English – 19
Chassis

4. Put the rear carriage in place over the pin (6). Location Screw Nut
Articulated unit 52 ft/lb (85 Nm) 52 ft/lb (47 Nm)
IMPORTANT! Rear link stay. 52 ft/lb (47 Nm) 52 ft/lb (24 Nm)
Make sure the hydraulic hoses are routed correctly. 9. Assemble the link stay (1) with sleeve (2), screw
(3), washer (5) and lock nut (4).
5. Fit lockwasher (4), compression washer (3)
and screw (2).
3
2
IMPORTANT!
Make sure the lockwasher is positioned correctly
on the pin before fitting the screw. 1

6. Fit the lock nut (7).

7. Torque tighten as below. 5

8095-290
8. Special tightening torques: 4

The screw in the articulated steering and the rear

1. Link stay 4. Lock nut
screw for the link arm are threaded into goods. In
addition, there is a lock nut used for securing the 2. Sleeve 5. Washer
screw. If the lock nut is tightened too much, the 3. Screw
torque on the screw will be released and the union
will come loose.
10. Torque tighten as below.
• Tighten the screw until it bottoms first.
The rear screw for the link stay is screwed into the
• Then tighten the screw to the specified torque. goods. In addition, there is a lock nut for securing the
• Finally, screw on the lock nut and tighten to the screw. If the lock nut is tightened too much, the
specified torque. torque on the screw will be released and the union
• Then retighten the screw to the specified torque again. will come loose. See also information on bolt
fasteners in the introduction.

1 Tighten the screw (2) until it bottoms first.

Then tighten the screw to the torque specified in the
2
table.
Finally, screw on the lock nut (3) and tighten to the
3 torque specified in the table.

4
2
5
6

1
8095-310

1. Lid 7
2. Screw
3. Compression washer
4. Lock washer
8095-358

5. Bearings 3
1
6. Pin
7. Lock nut 2 1. Screw 3. Lock nut

3 2. Screw

4
Location Screw Nut
5 Front link stay (1). 52 ft/lb (65 Nm) -
6
8095-329

7 Rear link stay (2). 52 ft/lb (47 Nm) 52 ft/lb (24 Nm)

20 – English
 Chassis

11. Lubricate the link stay through the grease nipples.

12. Torque tighten as specified in the table.
13. Assemble the steering cylinder (3) to the
rear bracket.
14. Assemble the shaft with locking lug (1) with
the screw (2).

1 2

3
8095-288

1. Shaft with locking lug 3. Control cylinder

2. Screw

English – 21
Propulsion

PROPULSION

13 2
3

12 4
5

6 7

8
11 9

10

1. Intake 6. Drive shaft belt pulley 11. Engine cradle 8095-244

2. Engine 7. Solenoid clutch 12. Wheels

3. Hydraulic pump drive shaft 8. Drive shaft (PTO shaft) 13. Exhaust system
4. PTO belts 9. Spline joint to propeller shaft
5. Hydraulic belt coupling 10. Belt pulley cradle

Air Filter, Dismantling and Assembly

2
Tools Dimension Quantity
Socket wrench 7 mm 1 1
Combination 13 mm
wrench

1. Loosen the hose clip for the air filter (1).

2. Extract the intake (2) from the back plate.
3. Loosen the fastening bolts (3) a few turns and
8095-293

3
dismantle the air filter.
4. Install in reverse order. 1. Hose clip 3. Mounting bolts
2. Intake

22 – English
 Propulsion

Drive Shaft for Hydraulic Pump, Dismantling 6. Loosen the drive shaft from the engine flywheel.
and Assembling The drive shaft for the hydraulic pump should be
secured with some form of tool, e.g. a large
Tools Dimension Quantity combination wrench or chisel to prevent rotation
Allen Key 8 mm 1 when loosening.
Torx T30 1 7. Unscrew the spacer (1) and remove it from the
coupling holding together the drive shaft for
1. Prevent the machine from being started by
the hydraulic pump with the hydraulic pump.
removing the ignition key.
8. Dismantle the drive shaft for the hydraulic
2. Fold forward the driver's seat.
pump (2) by loosening it from the engine end.
3. Dismantle the protective cover over the
9. Install in reverse order.
hydraulic pump drive shaft.

1
2

8095-281
3

1 2 1. Spacer 3. Screws (x6)

3 2. Hydraulic pump drive shaft

10. To tension the PTO belts, tighten the adjustment

screw (2) until the sleeve (3) can not be turned
by hand.
11. Tighten the locking nut (1). Counter the
8095-249

4 adjustment screw.
1. Cable bridge 3. Fuel line clamp 12. Make sure the sleeve can not be turned by hand.
2. Cabling 4. Mounting bolts 13. Check the belt tension.

4. The cable bridge (1) can be dismantled for better

access. Start by loosening the cabling (2) from
the bridge clamps and the clamp for the fuel line
(3). Then dismantle the cable bridge. Note the
location of any cable ties before cutting them.
5. Relieve tension on the belts by first loosening
the belt tensioner lock nut (1) and then the
adjustment screw (2).
1
8095-333

2 3

1. Lock nut 3. Sleeve

2. Adjustment screw
1
8095-245

3
2

1. Lock nut 2. Adjustment screw

English – 23
Propulsion

Changing Solenoid Clutch

5 2

8095-280
1. Hydraulic pump drive shaft 3. Belt pulley cradle 5. Solenoid clutch
2. PTO belts 4. PTO shaft

WARNING!
Never insert hands or fingers as
heavy components are unstably
supported. Use tools that reach.
Risk of crush injuries.

Tools Dimension Quantity

Snipe nose pliers 1
Combination 15 mm 1
wrench
Combination 17 mm 1
wrench
Socket wrench 15 mm 1
Socket wrench 17 mm 1
Socket wrench 18 mm 1
Allen Key 15 mm 1
Torx T30 1
Torque wrench 1

24 – English
 Propulsion

1. Ensure that the engine cannot start. 9. Secure the shaft package on a workbench.
2. Unplug the connector (10) for the solenoid 10. Loosen the PTO shaft (1) from the clutch by
clutch cable (11). unscrewing four screws (2).
3. Release the spring tension on the belt adjuster (7).
4. Dismantle the front bearing mount (1) on the
PTO shaft.
5. Loosen both bearing housings for the belt
pulleys and dismantle the spacers. See Service
Actions, Change PTO Belts.
6. Loosen the spring (12).
7. Unscrew and dismantle the belt adjuster (7)
and the corresponding joint bearing with belt
pulley cradle (6) from the machine.
1
8. Lift away the shaft package downwards.
It may be necessary to raise the machine
slightly for clearance.
2

8095-326
1. PTO shaft 2. Hex screw

3 8
1
2 9

4
5 6 7

10
11
8095-253

12

1. Front bearing mount 7. Belt tensioner

2. PTO shaft 8. Dual belt pulley
3. Flange 9. Hole for counterhold
4. Screw 10. Connector
5. Solenoid clutch 11. Cable
6. Belt pulley cradle 12. Spring

English – 25
Propulsion

11. Counter the belt pulley (2) with a tool (3) when
IMPORTANT! unscrewing or torque tightening the center
screw (1).
High torque (assembly torque 114 Nm)! The
PTO shaft must be prevented from turning 12. Dismantle the front center screw (4) together
when undoing. Husqvarna provides a special with two washers (5) and sleeve (3).
tools for this. See illustration. Alternatively, the
13. Remove the shaft (2), sleeve (3) and retain
propeller shaft can be used as a counterhold.
the key (1).
14. Exchange the solenoid clutch (6).
1

1
2
2 3

4
5
3

8095-271
8095-282

4
1. Key 4. Center bolt
1. Front center screw 3. Counterhold
2. Axle 5. Washers (x2)
2. Belt pulley 4. Rear center screw
3. Sleeve 6. Solenoid clutch

26 – English
 Propulsion

Assembling

6
5
4

1 2 3
7

8095-334
10 11

1. Front bearing 4. Key 7. Screw, 114 Nm 10. Belt pulley

2. PTO shaft 5. Solenoid clutch 8. Washers 11. Axle
3. Sleeve 6. Rear storage bearing 9. Screw, 114 Nm

The illustration above shows assembling the

solenoid clutch in section.
1. Slide the solenoid clutch (1) half way onto the
shaft (2).
2. Then put in place the key (3). Use hand power.
Make sure the key is positioned correctly and
that the solenoid clutch subsequently falls easily
in place.

2
3 4

1
8095-316

1. Solenoid clutch 3. Key - half way

2. Axle 4. Key in place

English – 27
Propulsion

3. Fit the sleeve (3). Use hand power. If the sleeve 5. Tighten the center screw (1) to 114 Nm. Use the
sticks, tap it carefully with a plastic hammer. counterhold (3) on the belt pulley (2).
Do not strike hard.
6. Assemble remaining parts in the reverse order.
The sleeve can also be given the correct
location by assembling the washers (5), center 1
screw (4) and carefully screwing down the
sleeve.
4. Fit the center screw (4) with two washers (5).

2
1
2

3 3

4
5

8095-282
6 4
1. Center bolt 3. Counterhold
8095-271

2. Belt pulley 4. Center bolt

1. Key 4. Center bolt

2. Axle 5. Washers (x2) IMPORTANT!
3. Sleeve 6. Solenoid clutch It is essential the shaft is fitted straight all the
way so that the belt adjuster screw (1) is not
put under stress.
IMPORTANT!
Clean thoroughly between the flange and the
solenoid clutch before assembling.

IMPORTANT!
High torque (assembly torque 114 Nm)! The 1
PTO shaft must be prevented from turning
when undoing. Husqvarna provides a special
tools for this. See illustration. Alternatively, the
8095-360

propeller shaft can be used as a counterhold.

28 – English
 Propulsion

Engine, Dismantling, Assembling

2 1

8095-267
1. Radiator 3. Intake with air filter 5. Drive axle
2. Exhaust system 4. Battery 6. Engine

Dismantling
Tools Dimension Quantity
Socket wrench 7 mm 1
Socket wrench 15 mm 1
Socket wrench 17 mm 1
Socket wrench 18 mm 1
Combination wrench 10 mm 1
Combination wrench 13 mm 1
Torx T20 1
Torx T30 1
Allen Key 7 mm 1
Torque wrench 1

WARNING!
Hot components, allow the engine to cool.

WARNING!
Coolant is poisonous and hazardous
to the environment. Handle according
to local regulations.

English – 29
Propulsion

Dismantling 4. Remove the exhaust system by loosening

the fastening screws (1), (2).
1. Dismantle the engine hood.
5. Remove the battery. See Replacing the Battery.
2. To make room to remove the engine, either the
radiator or the drive shaft for the hydraulic pump 6. Loosen the hose clip (3) on the battery box.
must be removed.
7. Dismantle the holder for the supply fuse (1).
3. Remove the air filter. See Air Filter, Removing
8. Loosen the fastener for the electric cable (2)
and Fitting.
on the back of the battery box.
9. Dismantle the battery box fastenings (4) and
2 remove the battery box.
10. Dismantle the prefilter (5) and plug the hoses (6).
11. Loosen the return hose from the fuel injector and
1 plug or clamp it shut so fuel does not leak out.
12. Dismantle the fuel hose (6) between the prefilter
and the fuel pump.
13. Dismantle the fuel hose (6) between the prefilter
and the fuel pump.
1.  xhaust system
E 2. Engine retaining screw
retaining screw
2 3 4

5 6
1

8095-296
1. Supply fuse 4. Battery box fastening
2. Electric cable 5. Prefilter
3. Hose holder 6. Fuel pump hose

30 – English
 Propulsion

14. Dismantle the cable bridge (1). Start by 20. Dismantle the engine cushion M12 screws (1)
loosening the cables (2) from the bridge clamps through (4).
and the clamp for the fuel line (3). Then
dismantle the cable bridge. Note the location of 2
any cable ties before cutting them.

1 4

8095-315
1 2 3
3
1. Front left engine mount 3. Rear left engine mount
2.  ront right engine
F 4.  ear right engine
R
mount mount

21. Fasten approved lifting devices to the two

8095-249

4 engine lifting lugs and remove the engine.

22. Clean the engine bed.
1. Cable bridge 3. Fuel line clamp
2. Cabling 4. Mounting bolts 23. Check the removed and remaining parts around
the engine compartment.

15. Dismantle the side cover over the fuse box. Assembling

16. Dismantle the fuse box lid. 1. When replacing the engine, move requisite
components to the new engine.
17. Loosen the electrical connections from the engine
circuit board and remove the cables (1), (2). 2. Lift the engine into position.
Let the cables follow with the engine. 3. Make sure the engine is positioned correctly on
the engine cushions before torque tightening so
that there is no risk of it toppling over.
4. Check that the engine is in line with the center
axle and the hydraulic pump.

1 5. Assemble and torque tighten the screws/nuts

in the engine cushions to 85 Nm.
6. Remove the lifting device.
7. Assemble all parts in the reverse order.
2
8095-336

8. Bleed the fuel system before starting.

See Bleeding the Fuel System
1. Cable 2. Cable 9. Test run the machine and check for any
leakage.

18. Dismantle the cable from the fuel injector arm.

See Changing Throttle Cable.
19. Loosen or dismantle the drive shaft for the
hydraulic pump if not done earlier. See Drive
Shaft for Hydraulic Pump, Dismantling and
Assembling.

English – 31
Cooling system

COOLING SYSTEM

2 3 4 5

6
1

8095-256
1. Input cooler hose 4. Water Radiator 7. Incoming hydraulic hose
2. Lid 5. Hydraulic fluid cooler 8. Outgoing coolant hose
3. Air duct 6. Engine cover seal 9. Outgoing hydraulic hose

WARNING!
Do not open the radiator cap quickly
when the engine is hot, first release
the overpressure with the cap
partially slackened off. Risk of burns.
Use protective gloves and protective
goggles.
The antifreeze fluid and coolant
are hazardous to health. Store
them in marked containers that are
inaccessible to children and animals.

WARNING!
Coolant is poisonous and hazardous
to the environment. Handle
according to local regulations.

32 – English
 Cooling system

Replacing the Cooler 8. Loosen the incoming hydraulic connection (6)

from the radiator. Use a counterhold.
Tools Dimension Quantity
9. Fit protective plugs in all hydraulic connections.
Socket wrench 7 mm 1
Socket wrench 13 mm 1 10. Extract the air hose (5).
Combination 13 mm 1 11. Dismantle and discard the spring clip (3) holding
wrench the air duct (1) to the radiator. Exercise care so
Combination 27 mm 2 that the cover is not damaged.
wrench
12. Loosen the air duct by removing the screws
Combination 32 mm 2 holding the plates (7).
wrench
Chisel 1
13. Turn the the air duct 90° clockwise.
Torque wrench 1 14. Move the air duct towards the engine.

1. Dismantle the engine cover. 15. Lift up the radiator (4) and remove it.

2. Place a container under the radiator to collect 16. When changing radiator, transfer adapters
the coolant. and sealing strips over to the new radiator.

3. Loosen the lower coolant hose (3). 17. Assemble the adapters for the hydraulic
connections on the new radiator.
4. Loosen the upper coolant hose. Torque tighten 32 Nm.
5. Place a container under the radiator to drain 18. Check that the sealing strip between the cooler
the oil from the hydraulic system. and the engine compartment wall is undamaged
6. Clean around the connections as set out in and is seated correctly.
the general instructions. 19. Assemble in the reverse order. Tightening
7. Drain the hydraulic system by loosening the torque for hydraulic lines as specified.
lower hydraulic connection (2).
Use a counterhold.
IMPORTANT!
Insert the screws for the plate carefully.
Easy for threads to seize.

2 2
8095-277

3
3
1. Radiator 3. Lower coolant hose 4
1
2. Hydraulic connection

6
8095-265

1. Air duct 5. Air hose

2. Coolant hose 6. Incoming hydraulic
hose
3. Spring clip
7. Plate
4. Radiator

English – 33
Cooling system

20. Fill with coolant.

21. Fill the hydraulic system with oil.
22. Warm up the engine and top up with coolant and
oil as necessary.
23. Check for leakage after running warm.

Pressure Testing the Radiator

The radiator must be disconnected from the
remainder of the cooling system when testing at the
pressure below.
The max. permitted pressure in the coolant section
or the hydraulic section is 3 bar.
Oil or air can be used as the pressure medium.
Use a coolant system tester with an adapter to
pressure test the complete cooling system.

34 – English
 Fuel system

FUEL SYSTEM

2 3 8

1 4
5
6

8095-237
1. Fuel tank 3. Fuel cap 5. Prefilter 7. Hand pump
2. Fuel gage 4. Suction Hose 6. Main filter 8. Return hose

Fuel Tank, Assembly and Dismantling

IMPORTANT!
Fuel can leak out. If the level of fuel in the
tank is higher than the suction line, the
suction line must first be carefully pinched 2
with self-locking pliers or similar. 5 1

1. Loosen the suction line (1) from the end of the

4
prefilter and plug it with a 10 mm plug or bolt.
Alternatively, the hose can be carefully folded
and secured with a cable tie.
2. Loosen the return line (2) at the injectors.
8095-227

IMPORTANT! 1. Suction line 4. Rear mounting

2. Return line 5. Fuel tank
Do not forget to refit the Nordlock washers
on the mounting screws. 3. Front mounting

English – 35
Fuel system

3. Loosen the front mounting (3) from the tank. Bleeding the Fuel System
Keep the washers safe for refitting.
Tools Dimension Quantity
4. Loosen the rear mounting (4), move the
Combination 10 mm 1
mounting away and lift away the tank.
wrench
5. Tightening torque, mountings 12 Nm.
The fuel system may need bleeding if
6. Top up with fuel if necessary, start the machine
and check for leakage. • the fuel filter and fuel lines have been removed,

7. Bleed the fuel system if necessary. • the fuel tank has been emptied,
• the machine has not been used for a long period.
Facilitate bleeding by pumping using a hand pump.
Remove the fuel tank filler cap and check the return
fuel to the tank. When bubble free fuel flows to the
tank, the engine can be started.
Carry out full bleeding as follows:
1. Make sure the stop valve (2) is open.
See illustration.
2. Loosen the air screw (3) on the fuel filter (1)
at least 1/2 turn.
3. Pump using the fuel pump's hand pump (4)
until clean fuel, without air bubbles, exits the
air screw.
4. Tighten the air screw moderately.
5. Rotate the engine with the starter motor for
a maximum of 15 seconds. Wait 30 seconds
before the next start attempt.

1
4
8095-266

1. Fuel filter 3. Venting screw

2. Stop valve (open) 4. Hand pump

36 – English
 Electrical System

ELECTRICAL SYSTEM

1
2

20

21
11
19 6

5 12
18
3
4
7 8 13

10
14

15
9
17

16

1. Battery 12. Temperature gage 8095-243

2. Main Fuse 13. Warning lamp panel

3. Electric outlet switch 14. Headlights
4. Power outlet 15. Hour meter
5. Temperature sensor 16. Parking brake sensor
6. Supply fuse 17. Fuse box
7. Control for cutting deck drive 18. Starter motor connection
8. Seat switch connection 19. Generator connection
9. Solenoid clutch connection 20. Power supply to battery
10. Ignition switch 21. Fuel pump connection
11. Light switch

English – 37
Electrical System

Battery, Changing
IMPORTANT!
Tools Dimension Quantity Hold the bolts so that the battery terminals are not
Combination 10 mm 1 put under strain.
wrench
Combination 13 mm 1 5. Loosen and lift off the positive terminal cable lug
wrench
(1), which is located under the fuse holder.
Socket wrench 10 mm 1
6. Dismantle the battery bridge (2) with two screws.
1. Loosen the hose clip for the air filter (1). 7. Lift up the battery (3).
2. Extract the intake (2) from the back plate. 8. Connect a new battery in reverse order.
3. Loosen the fastening bolts (3) a few turns and
dismantle the air filter.
4. Loosen the negative terminal cable lug.

2
1
2

1 3
8095-293

1. Hose clip 3. Mounting bolts

2. Intake

8095-279
1.  ositive terminal cable
P 3. Battery
holder
2. Battery bridge

38 – English
 Electrical System

Circuit Board, Changing 5. Loosen all connections from the circuit board.
Use bent round nosed pliers to press in the
plastic catches holding the connections.
IMPORTANT!

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
partly due to cost, but also so that no external
fault can damage the new circuit board.

Tools Dimension Quantity

Round nose 1
pliers, bent
Screwdriver, PZ 1
Torx T20 1
Torx T30 1

1. Loosen the negative cable from the battery.

2. Dismantle the side cover.
3. Remove the cover over the distribution box.
4. Check the marking on the cable connections
and note the position of the cable harnesses.
Some connections have markings on the
cables. Supplement if necessary when the
connections have been disconnected.
Contacts are color coded and the corresponding
color is given on the circuit board.

11 10 9 8 7

3
2

5
8095-314

3 4

1. Cable with connection 7. Screws for circuit board

2. Cable with connections 8. Circuit boards
3. Cable with connections 9. Cable with connection
4. Cable with connections 10. Cable with connection
5. Cable with connections 11. Cable with connection
6. Starter module

English – 39
Electrical System

6. Dismantle the starter module (6) from the circuit Parking Brake Sensor, Changing
board (8).
Tools Dimension Quantity
7. Release all cables by loosening their rubber
Combination 17 mm 1
seals from the ends of the distribution box.
wrench
8. Dismantle the screws (7) holding the circuit board. Torx T30 1
9. Carefully remove the circuit board. Screwdriver, PZ 2 mm 1

10. Carefully put the new circuit board in place. Side cutters 1
Make sure it is lying in the correct position Feeler gage 1
before tightening any of the nuts. Deep socket 17 mm 1
11. Insert the screws and tighten moderately, Torque wrench
so as not to damage the circuit board.
Measuring how far the sensor projects from its
12. Fit the starter module. bracket towards the parking brake arm will make it
13. Make the connections according to the easier to fit the new one. Try to maintain this distance
markings, making sure that the plastic catches when assembling.
lock correctly. 1. Loosen the front nut (4) and pull out the sensor (5)
14. Put in place the cable harnesses. from the bracket.

15. Connect the battery. 2. Carefully remove the shrink hose (2).

16. Test all the electrical functions and check the 3. Loosen the sensor from the cable.
LEDs on the circuit board. 4. Fit a new shrink hose over the cable.
17. Assemble the distribution box cover. 5. Remove the rear nut (3) from the old sensor
18. Assemble the side cover. and fit it in the same position on the new sensor.

19. Check the function. 6. Fit the shrink hose so that it covers the sensor
LEDs and goes some way over the cable.
7. Position the sensor.
8. Fit the front lock nut.
Set the distance 2 - 3 mm between the sensor and
its target surface with the parking brake active.
11 10 9 8 Before tightening, check that the parking brake arm
7 does not collide with the sensor when it is moved
between end positions.
1

3 1 2 3 4 5 6
2
8095-361

m
2-3m
6

1. Cable 4. Nut
5
8095-314

2. Shrink hose 5. Sensor

3 4 3. Nut 6. Brake arm

1. Cable with connection 7. Screws for circuit board

2. Cable with connections 8. Circuit boards
3. Cable with connections 9. Cable with connection
4. Cable with connections 10. Cable with connection
5. Cable with connections 11. Cable with connection
6. Starter module

40 – English
 Electrical System

4. Make sure the two clip nuts (4) are not lost.
IMPORTANT!
5. Dismantle the nut (3) and seal from the ignition
The sensor has a thin wall with a fine thread switch (1).
and the thread strip if tightened too tight.
6. Remove the ignition switch through the steering
wheel console.
9. Tighten the lock nuts. Tightening torque 20 Nm.
7. Loosen the connector from the ignition switch
10. The sensor has an LED built in. Test the sensor
by pulling straight out.
by turning on the ignition and checking that the
LED comes on when the parking brake arm or 8. Assemble in reverse order.
other magnetic tool is held within 2-3 mm from
9. Pull out the plastic nut on the ignition switch
the sensor.
carefully.
Ignition Switch, Changing 10. Check the function.
1. Remove the ignition key (2).
2. Dismantle the front cover of the steering wheel
console (2). 1
3. Loosen the headlight insert (1) and move out 2
of the way.

1 2 3

8095-234
4

1. Ignition switch 3. Nut

2. Ignition key 4. Clip nut
8095-300

1. Lamp insert 2. Cover

English – 41
Electrical System

Hour Meter, Changing Temperature Gage, Changing

Tools Dimension Quantity 1. Dismantle the front cover of the steering wheel
console (2).
Torx T20 1
2. Loosen the headlight insert (1) and move out of
1. Dismantle the front cover (2) from the steering the way. Make sure the two clip nuts are not lost.
wheel console.
2. Loosen the headlight insert (1) and move out of 1 2
the way. Make sure the two clip nuts are not lost.

1 2

8095-300
1. Headlamp insert 2. Cover
8095-300

3. Remove the strap (1) with nuts (4) and

1. Headlamp insert 2. Cover lockwashers (3).
4. Lift up the temperature gage (2) out of the
3. Loosen the cables from the hour meter (3). steering wheel console.
4. Loosen the hour meter by compressing the 5. Loosen the connector from the temperature
holder and pressing it through the steering gage by pulling straight out.
wheel console (1). 6. Assemble in reverse order.
5. Assemble in the reverse order.
IMPORTANT!
Take great care when tightening the strap.
The strap may be damaged if the temperature
gage is in the wrong position.
1

2 1 2
3

3
4
8095-236

1. Strap 3. Lock washer

1. Steering wheel console 3. Hour meter
2. Temperature gage 4. Nut
2. How to connect

42 – English
 Hydraulic System

HYDRAULIC SYSTEM
Hydraulic Hygiene
Keep the hydraulic system clean. Remember to:
• Clean thoroughly before opening the filler cap or disconnecting anything.
• Use clean vessels with topping up oil.
• Use only clean oil that has been stored in sealed containers.
• Do not reuse drained oil.
• Change the oil and filter according to the intervals specified in the Service Schedule.
A system that is contamination-free is required to give a functioning hydraulic system without shutdowns.
Particles are generated during operation that can cause both wear damage and malfunctions. The system has
filters to separate these particles. The filter is dimensioned to trap the generated particles, but if dirt enters the
system from outside the filters will rapidly clog so that they do not work as intended. If there is dirt in the
system, further contaminants will be generated, creating a vicious circle. This will result in breakdowns and
the need for large resources to clean the system.
The particles that cause the most damage are the same size as the play between the moving parts and the
components. Normal play in pumps and valves is from 3-5 µm and up (1 µm = a thousandth of a mm).
In connection with this, it can be noted that one particle of size 40 µm can only just be seen with the human eye.
Each particle of dirt is an abrasive that generates more contaminants, which will eventually result in permanent
damage. The number of particles will increase each time the hydraulic system is opened. After a few hours in
operation most of the particles that have entered are trapped in the filters. Therefore, avoid opening the
hydraulic system unless really necessary because each intervention increases the risk of contamination even
when the work is carried out in a professional manner.

Rectify Oil Leaks

Cavitation is caused by air entering can cause internal damage to pumps and engines. Air can enter the
system where there is an oil leak. That is why it is so important that oil leaks are rectified as soon as possible.
Keep Hydraulic System Fluid Clean
You must be completely sure that when opening a can of oil for the hydraulic system, the area around the filler
cover is absolutely free from dust, dirt, cotton waste and water. If a vessel, funnel or hose is required to fill the
system, make sure they are clean.
Use only the type of oil specified in the lubrication schedule. Make sure levels are checked at established
intervals and maintained correctly.

Working Methods
Cleanliness also applies to components that are removed or are going to be fitted. Remember that an
exchanged component will probably be examined with test equipment at a workshop. It is important that the
component is in the same condition when examined as it was when it was taken from the machine. Otherwise
the actual fault can not be established and the test equipment will be contaminated. It is also possible that
submitted component is not faults and is therefore returned without action.
The points below should be taken as routine procedures when working on hydraulic systems:
• Clean roughly as necessary.
• Protect the area where the work is to be done against dust and other impurities in the air. Plastic cloth and
the like can be used.
• Wash very thoroughly with white spirit or the like. Only washing the parts that are directly affected will not
suffice. Even areas from where dirt can fall onto the point of entry while work is in progress must be cleaned,
just as the tools being used. Use a suitable brush to wash with, wipe dry and then wash again if necessary.
Finally shower off the area being dismantled, hose connections and the like with pure white spirit.
• Apply appropriate protection immediately after all pipes and hoses have been removed. Components
(also exchanged) as well as hoses and pipes should be protected.
• All components included in pipe fixtures shall be replaced or cleaned in pure white spirit and blown clean
with compressed air before being refitted.
• Maintain cleanliness when measuring pressure. Shower both parts of quick couplings with white spirit
before connecting. Make sure any protection is clean before returning it.

English – 43
Hydraulic System

Hydraulic Couplings, Pipes and Hoses

Aluminum hydraulic pipes must always be loosened at both ends when dismantling.
It is essential to use two tools, of which one is used as a counterhold, both when loosening and tightening
hoses, so that the hose is not exerted to tensional stress or rotation when tightening. Elbow nipples can fail
or cracks occur when loosening or tightening without counterhold.
When assembling hydraulic lines, first tighten until the tapers make contact, i.e. as far as can be tightened
easily. Then tighten a further one and a half flats. Any further tightening should be avoided. See Tightening
Torques.
Always check and note how hose, lines, pipes, etc. are tightened throughout the machine before loosening
or dismantling. They must always be refitted with the same tightening force as originally.
Always check when assembling hoses and lines, that they go clear of locations where they can be exerted
to chafing and wear.
Always check after refitting hoses, lines, pipes, etc., that there is no leakage.

Hydraulic System

4
10

6
7 8

9
8095-254

1. Power steering 5. Front transmission 9. Rear transmission

2. Valve block working hydraulics 6. Hydraulic tank 10. Hydraulic system cooler
3. Hydraulic pump 7. Hydraulic filter with valve block
4. Lift cylinder 8. Control cylinder

44 – English
 Hydraulic System

Suction Filter, Changing

Tools Dimension Quantity
Socket wrench 8 mm 1
Torque wrench 1
U-grip for 32 mm 1
torque wrench

Tilt the seat back.

Release the hydraulic line (1) from its connection
to the tank (3).
Remove the screws (2) and lift up the connection.
Remove the suction filter (5) from its connection.
Wash the parts with white spirit and blow clean with
compressed air inside and out.
Fit a new suction filter on the connection. Torque,
60 Nm.
Assemble in the reverse order. Use a new gasket.
Tighten the nuts moderately so the gaskets are not
damaged.

4
5

6
8095-226

1. Hydraulic hose 4. Adapter

2. Screw 5. Suction filter
3. Tank connection 6. Gasket

English – 45
Hydraulic System

Hydraulic Pump, Changing

8095-275
1. Drive axle 3. Hydraulic pump
2. Hex screws 4. Pump arm

Tools Dimension Quantity

Allen Key 8 mm 1
Combination 13 mm 1
wrench
Combination 16 mm 1
wrench
Combination 22 mm 1
wrench
Combination 27 mm 1
wrench
Combination 32 mm 1
wrench
Socket wrench 19 mm 1
Socket wrench 22 mm 1
Socket wrench 27 mm 1
Torque wrench 1

WARNING!
Heavy objects are released when
dismantling the hydraulic pump.

46 – English
 Hydraulic System

Dismantling 8. Loosen the pump arm (6) from the pump with
two screws (7).
1. Dismantle the driver's seat. See Removing
Driver's Seat. 9. Dismantle the hydraulic pipes (2), (5) to the
hydraulic pump and plug the hole and
2. Dismantle the protective cover under the seat.
connections. The pipes must be loosened at
3. Place a vessel under the hydraulic pump to both ends.
collect oil spill.
10. Loosen the banjo coupling (1) and the hydraulic
4. Clean according to the general instructions. hoses (3) and (4) from the hydraulic pump. Plug
holes and connections. Inspect the copper
5. Turn the drive shaft so that two hex screws (1)
washers on the banjo coupling (1) and change if
are visible in the belt pulley mounting.
necessary.
6. These screws clamp a sleeve over the pump's
11. Dismantle the pump by pulling it forward.
spline shaft. Loosen the screws max. two turns.
The pump is now free from the drive shaft.
7. Remove the two retaining screws (2) holding 1
the pump to the partition wall.
7
2

3
5 4
6

8095-269
1
8095-294

1. Banjo coupling 5. Hydraulic pipe

2. Hydraulic pipe 6. Pump arm
1. Hex screw 2.  artition wall retaining
P
screw 3. Hydraulic hose 7. Screw
4. Hydraulic hose

Assembling
1. If the pump is being changed, the adapters and
connections must be transferred to the new
pump. Check the condition of O-rings and other
components. Torque tighten adapters as
illustrated. Torque tighten the banjo coupling
adapter on the opposite side to 32 Nm.

1
1
8095-320

1 2

1. Adapter torque 60 Nm 2. Adapter torque 50 Nm

English – 47
Hydraulic System

2. Place the pump in its location and position it.

Torque tighten the two retaining screws (2)
holding the pump to the partition wall to 47 Nm.
3. Turn the drive shaft so that two hex screws (1)
are visible in the belt pulley mounting and
tighten them.

1. Hex screw 2. 8095-294

 artition wall retaining
P
screw

4. Assemble the hydraulic pipes (2), (5) and

tighten the cap nuts as instructed.
5. Connect the hydraulic hoses (3), (4) and torque
tighten the cap nuts as instructed.
6. Before assembling the banjo coupling, top up
the pump with oil.
7. Assemble the banjo coupling (1) with two
copper washers and torque tighten to 32 Nm.
8. Connect the pump arm (6) to the pump and
tighten with the screws (7).
9. Start the machine and check for any leakage.
10. Assemble the protective cover.
11. Assemble the driver's seat.
12. Test run the machine and check that there is
no oil leakage.
13. Top up with oil in the hydraulic system if
necessary.

1
7
2

3
5 4
6
8095-269

1. Banjo coupling 5. Hydraulic pipe

2. Hydraulic pipe 6. Pump arm
3. Hydraulic hose 7. Screw
4. Hydraulic hose

48 – English
 Hydraulic System

Rear Transmission, Changing

8095-274

Tools Dimension Quantity

Torx T20 1
Combination 14 mm 1
wrench
Combination 16 mm 1
wrench
Combination 17 mm 1
wrench
Combination 22 mm 1
wrench
Combination 32 mm 1
wrench
Socket wrench 17 mm 1
Socket wrench 18 mm 1
Socket wrench 22 mm 1
Socket wrench 27 mm 1
Allen Key 10 mm 1
Torque wrench 1

English – 49
Hydraulic System

Dismantling 8. Loosen the rear end of the connecting rod (1)

by dismantling the screw (3) with nut (5).
1. Raise the machine and support it under the frame.
Make sure not to misplace the bushing (4).
Refer to the illustration for the permitted area.
2. Dismantle the rear wheels and wheel hubs from
the transmission. See Removing Hub.

1 1

2
6
8095-322

8095-318
1.  rea allowed for
A 2.  rea forbidden for
A 5 4 3
supporting supporting
1. Connecting rod 5. Nuts
2. Screw 6. Plate
3. Dismantle the cover over the rear transmission.
3. Screw 7. Nut
4. Place a vessel under the transmission to collect
4. Bushing
oil spill.
5. Clean according to the general instructions.
6. The hydraulic hoses can be mixed up. Mark the WARNING!
lines so that they are reconnected on the correct Heavy objects are released when
connections. dismantling the transmission.

7. Loosen the hydraulic lines (1), (2) and (3).

Fit sealing plugs to prevent leakage and 9. Dismantle the transmission by removing the
contamination. retaining screws.

1
8095-322

2
3
1. Hydraulic hose 3. Hydraulic hose
2. Hydraulic hose

50 – English
 Hydraulic System

10. If the transmission is being changed, the

devices for adjusting the wheel speed (1) and
damper for the rear wheels speed (2) must be
transferred to the new transmission as below:

IMPORTANT!
Do not get the components mixed up. It is a
good idea to dismantle and reassemble one
adjustment device at a time before work on
the next adjustment device commences.

1 2

3 8095-319

1. Wheel speed adjustment 2.  ear wheel speed

R
damper

11. Dismantle the device for rear wheel speed

damper by removing the screw (1) and nut (6).
Note the position of the spring (4) and washer (5).
12. Dismantle the link head (3) with nut (2).
13. Dismantle the device for adjusting the wheel
speed (13) by removing nut (12) and screw (8).
14. Dismantle the plates (10) only if any measures
need to be taken (e.g. cleaning).
15. If the transmission is being changed, dismantle
the hydraulic connection adapters.

1. Screw
2. Nut
1 3. Link head
4. Spring
5. Washer
13
6. Nut
7
7. Nut

12 8. Screw
9. Link head

2 10. Plate

11 11. Bushing
10 3 12. Nut

8 4 13. Wheel speed adjuster

8095-338

9 5
6

English – 51
Hydraulic System

Assembling 3. Assemble the hydraulic hoses and torque

tighten as instructed.
1. Assemble in reverse order. Start by refitting any
remove hydraulic adapters. Torque tighten the 4. Insert the screw (1) for the rear wheel speed
adapter on top (1) to 32 Nm. The two other damper through the link head (3). Assemble
adapters (2) and (3) are tightened to 50 Nm. the spring (4), washer (5) and nut (6).
5. Assemble the wheel speed adjuster (13) with
1 nut (7) and other components.
6. Check the oil level and top up if necessary as
specified in Technical Data.
7. Carry out all measures for adjusting the wheel
speed according to Service Actions.
8. Run the machine and check for any leakage.

8095-322
2 1
3

1. Hydraulic adapter 3. Hydraulic adapter

2. Hydraulic adapter 13
7
2. Assemble the transmission with its three 12
retaining screws.
1
1 2
11
10 3
13
13 4
9 78
7 5
6
12
12

22
11
11
10
10 33
8 44 8095-338
8
8095-338

9
9 5
5
6
6
1. Screw 8. Screw
2. Nut 9. Link head
3. Link head 10. Plate
4. Spring 11. Bushing
5. Washer 12. Nut
6. Nut 13. Wheel speed adjuster
7. Nut

52 – English
 Hydraulic System

Front Transmission, Changing

8095-272

Tools Dimension Quantity

Groove joint 1
pliers
Combination 18 mm 1
wrench
Combination 22 mm 1
wrench
1
Combination 27 mm 1
wrench
Combination 32 mm 1
wrench 2
Allen Key 10 mm 1
Torque wrench 1
Socket wrench 22 mm 1
Socket wrench 27 mm
8095-322

Dismantling
1. Raise the machine and support it under the frame.
Refer to the illustration for the permitted area. 1. Area allowed for supporting
2. Dismantle the front wheels and wheel hubs from 2. Area forbidden for supporting
the transmission. See Removing Hub.

English – 53
Hydraulic System

3. Loosen the lock nut (2) and dismantle the 7. Dismantle the hydraulic pipes (4), (6) at both ends.
parking brake cable (3), tension spring (6), split
8. Loosen the hydraulic hose (5) from the
pin (4) and clevis pin (5) on the end of the
transmission.
transmission.
9. Fit sealing plugs to prevent leakage and
4. Place a vessel under the transmission to collect
contamination.
hydraulic oil spill.
5. Clean according to the general instructions. WARNING!
Heavy objects are released when
6. Drain the hydraulic tank if sealing plugs for the
dismantling the transmission.
hydraulic lines are not available.

2 10. Remove the three screws (3), (7) with washers

1 (2), (8) and one nut (1), which hold the front
transmission to the frame and lower the
3 transmission.
4
6 5 11. If the transmission is being changed, dismantle
8095-232
the hydraulic connection adapters (4), (5), (6).

1. Arm 4. Split pin

2. Lock nut 5. Clevis pin
3. Parking brake cable 6. Tension spring

2
3
4

5
6
8

8095-323
7
1. Nut 5. Hydraulic hose
2. Washer 6. Hydraulic pipe
3. Screw 7. Screw
4. Hydraulic pipe 8. Washer

Assembling
1. Assemble in reverse order. Start by refitting the
hydraulic adapters. Torque tighten the adapter
on top (4) to 32 Nm. The two other adapters (5)
and (6) are tightened to 50 Nm.
2. Assemble the hydraulic hose and the hydraulic
lines and torque tighten according to
instructions.
3. Assemble the parking brake cable.
4. Check the oil level and top up if necessary as
specified in Technical Data.
5. Run the machine and check for leakage and the
function of the parking brake.

54 – English
 Hydraulic System

Filter Holder, Changing Assembling

Tools Dimension Quantity 1. Install in reverse order.
Allen Key 8 mm 1 2. If the adapters are to be refitted, they must be
Combination 17 mm 2 torque tightened to 50 Nm except pos. 5 in the
wrench illustration, which is tightened to 60 Nm.
Combination 22 mm 2 3. Assemble the hydraulic hoses and torque
wrench tighten as instructed.
Combination 27 mm 1
4. Check the oil level in the hydraulic system and
wrench
top up if necessary.
Combination 32 mm 1
wrench 5. Start the machine and check for any leakage.
Socket wrench 13 mm 1 Fill with oil if necessary.
Socket wrench 22 mm 1
Socket wrench 27 mm 1
Torque wrench 1

Dismantling
1. Fold up the seat.
2. Dismantle the protective plate under the seat.
3. Loosen the hydraulic hoses and plug the lines
and connections.
4. Dismantle the hydraulic pipes at both ends and
plug the lines and connections.
5. Dismantle the two retaining screws (1) holding
the filter holder (3) and remove the holder.
6. If the filter holder is being changed, the adapters
must be dismantled and reused after inspection.
7. Clean thoroughly as instructed.

IMPORTANT!
If there is not enough room, the adapter
can be torque tightened to the filter holder
after the hose has been torque tightened
to the adapter. In this way, the adapter can
be turned into position for better access to
torque tighten the hose.

5
2
3
8095-292

1.  ilter holder retaining

F 3. Filter holder
screw
4. Hydraulic oil filter
2. Connections
5. Connection 60 Nm

English – 55
Hydraulic System

Valve Block Working Hydraulics, Changing Steering Servo, Changing

Tools Dimension Quantity Tools Dimension Quantity
Combination 13 Socket wrench 8 1
wrench Socket wrench 13 1
Combination Allen Key 5 1
wrench Allen Key 6 1
Combination Combination 14 1
wrench wrench
Socket wrench Combination 16 1
wrench
Torque wrench Combination 17 1
Torx wrench
Combination 19 1
Dismantling wrench
Combination 22 1
1. Dismantle the side cover.
wrench
2. Dismantle the valve lever (1). Loosen the lock Torque wrench 1
nut (2) first and then screw out the valve lever. U-grip for torque 17 1
wrench
3. Place a container under the valve block to U-grip for torque 22 1
collect the waste oil. wrench
4. Loosen the hydraulic lines from the valve block Torx T30 1
connections (5). Fit protective plugs. Dismantling
5. Dismantle the three retaining screws (3) holding 1. Drain the hydraulic system.
the valve block (4) and remove the block.
2. Dismantle the steering wheel hub (5) by
6. Clean thoroughly as instructed. carefully prising it loose with a screwdriver.
7. If the valve block is being changed, remove the 3. Dismantle the steering wheel (4), secured using
adapters from the block. one screw (6) under the steering wheel hub (5).
Retain the key (5) and the washer (7). Dismantle
the cover (2) over the steering servo housing.
1

2 IMPORTANT!
3 Do not use force, use a puller if the steering
wheel is stuck hard.

4
4. Unscrew the four screws holding the cover (2) in
front of the steering servo housing.

5
6
8095-291

4
1. Valve lever 4. Valve block
2. Lock nut 5. Hydraulic connections 5 6
3. Screw 6. Plastic cover 7

Assembling
1. Assemble in the reverse order. The adapters
are torque tightened to the block with 50 Nm. 3
2
8095-284

1
2. Assemble and torque tighten the hoses as
instructed.
1. Power steering 5. Steering wheel hub
3. The block screws (3) are tightened to 24 Nm.
2. Cover 6. Screw
4. Start the machine and check the function. 3. Key 7. Washer
5. Check for any leaks in the hydraulic system and 4. Steering Wheel
top up with oil if necessary.

56 – English
 Hydraulic System

5. Unscrew the two screws holding the headlamp

insert (2). Do not misplace the two loose clip IMPORTANT!
nuts on the lamp insert console. Make sure the O-rings remain mounted in the
6. Lift out the headlamp insert. adapter on the steering servo.

1 2 IMPORTANT!
Connections can be interchanged. Mark the
hydraulic hoses so that they are reassembled
on the correct connections. NB! The
connections on the steering servo are marked
with letters.

1. Headlamp insert 2. Cover 8095-300

7. Dismantle the headlamp console (6).

8. Loosen all electrical connections.
9. Dismantle the ignition switch (2).
10. Dismantle the cover (5).
11. Place a container under the steering servo
to collect the spill oil.
12. Clean according to the general instructions,
see Hydraulic System.
13. Mark up how the hydraulic lines are connected.
14. Loosen the hydraulic lines from the steering
servo (1). Fit protective plugs.

4 5
3
2 6

7
8
1

9 9
8095-301

1. Screw 5. Headlamp console

1. Ignition switch 6.  emperature gage
T
connection
2. Light switch connection
7. Clip nut
3. Warning lamp connections
8. Console retaining screw
4. Cover

English – 57
Hydraulic System

1. Dismantle the steering servo and plate (2). Steering Cylinder, Replacement
2. Dismantle the plate from the steering servo. Tools Dimension Quantity
Socket wrench 13 mm 1
Combination 14 mm 1
wrench
Combination 19 mm 1
wrench
Side cutters 1
1 4 5
Torque wrench 1
U-grip for torque 19 mm
3 wrench

Dismantling
1. Start the engine and turn the steering wheel full
2 lock to the right.
2. Turn off the engine.
7 6
3. Dismantle the two hydraulic hoses (3), (4)
8095-302

from the steering cylinder.

1. Power steering 5. Connection T 4. Put protective plugs in the hydraulic hoses and
protective cover on the steering cylinder (5).
2. Plate 6. Connection P
3. Connection R 7. Connection L
2 3
4. Connection E 4
1

Assembling
1. Assemble in the reverse order.
2. Hoses in the steering servo (1) are torque
tightened as follows:
5
• Figure pos. 6 connection P - 24 Nm

8095-341
• Figure pos. 4 connection E - 24 Nm
• Figure pos. 5 connection T - 14 Nm 1. Shaft with locking lug 4. Hydraulic connection
2. Cable ties 5. Control cylinder
• Figure pos. 7 connection L - 14 Nm
3. Hydraulic connection
• Figure pos. 3 connection R - 14 Nm
• Torque tighten the steering wheel to 24 Nm. 5. Loosen the rear end of the steering cylinder (3)
3. Check steering servo function after finishing the by dismantling the shaft with the locking lug (1).
measure.
4. Check for possible leakage.

1 2

3
8095-288

1. Shaft with locking lug 3. Control cylinder

2. Screw

58 – English
 Hydraulic System

6. Dismantle the shaft with the locking lug (1) from 5. Fit a new cable tie on the cable at the front shaft
the steering cylinder's front fastening and cut off locking lug.
the cable tie. Remove the steering cylinder.
6. Tightening torque for screws and hydraulic
7. Note how the adapter for the rear hydraulic connections as instructed.
connection (4) is turned in relation to the
7. Bleed the steering cylinder by starting the
steering cylinder.
engine and making repeated steering wheel
movements to full lock left and right.
2 3 4 8. Check for any leakage from the steering
1 cylinder hydraulic connections.
9. Lubricate the steering cylinder through the
grease nipples.
10. Check the hydraulic tank level.

Steering Cylinder, Changing Joint Bearing

5
Tools Dimension Quantity
8095-341 Socket wrench 13 m 1
Combination 19 mm 1
1. Shaft with locking lug 4. Adapter
wrench
2. Cable ties 5. Control cylinder Circlip pliers SGH 1
3. Hydraulic connection Press tool 1

Dismantling
8. Dismantle the adapter from the steering cylinder 1. Dismantle the steering cylinder (1).
and fit a protective cover. See Steering Cylinder, Changing
Assembling 2. Dismantle the circlip (2).
1. Assemble the adapter (4) onto the steering 3. Press out the steering cylinder joint bearing (3).
cylinder (5). Screw down the adapter until it The joint bearing must be pressed towards the
bottoms. circlip side.

1 2 3
2 3 4
1

8095-342

5
8095-341

1. Control cylinder 3. Joint bearing

2. Circlip
1. Shaft with locking lug 4. Adapter
2. Cable ties 5. Control cylinder
4. Clean the bearing seat.
3. Hydraulic connection
Assembling
1. Apply a thin layer of lubricant on the walls of the
2. Unscrew the adapter until it reaches the noted bearing seat.
position.
2. Press in the joint bearing from the circlip side.
3. Hold the adapter and tighten the lock nut. Press only on the outer bearing race.
Tightening torque for lock nut is 45 Nm.
3. Fit the circlip and check that it lies correctly in its
4. Reassemble the steering cylinder in the reverse groove.
order. 4. Assemble the steering cylinder in the reverse
order. See Changing Steering Cylinder,
Assembling

English – 59
Hydraulic System

Lifting Cylinder, Replacement Assembling

Tools Dimension Quantity 1. Assemble in the reverse order.
Combination 19 mm 1 2. Bleed the lift cylinder by lowering and lifting the
wrench lift arms repeated times with the engine started.
Circlip pliers SGA 1 3. Check for any leakage from the lift cylinder
Screw driver 10 mm 1 hydraulic connections.
Jack assembly 1 4. Lubricate through the grease nipples.
Dismantling 5. Check the hydraulic tank level.
1. Start the engine and raise the lift arms.
2. Turn off the engine.
3. Remove the service cover.
4. Place a jack assembly under the lift arm beam
and lift the beam carefully to unload the gas
spring.
5. Dismantle the gas spring's (1) front retainer
spring (2) and clevis pin (3), and lower the gas
spring.
6. Dismantle the lift cylinder hydraulic connections
(6), (7).
7. Plug the hydraulic connections with a protective
cover protective plug.
8. Dismantle the circlips (5) from the air cylinder
mountings and press out the rear pin (6).
9. Slowly lower the jack assembly with the lift arm
beam.
10. Take out the front pin and remove the lift
cylinder (8).

1
8

7 6 5 4 3 2
8095-348

1. Gas spring 5. Circlip

2. Retainer spring 6. Hydraulic connection
3. Clevis pin 7. Hydraulic connection
4. Cotter pin 8. Lift cylinder

60 – English
 Cutting deck

CUTTING DECK 5. Remove the grease nipple (4).

Bearing Housing Blade Bearing, Changing 6. Lock the blade with a wooden block.
7. Loosen the flanged nut (1) on the belt pulley
Tools Dimension Quantity about 1.5 turns.
Torx T30 1 8. Put a 24 mm socket with extender on the
Socket wrench 24 mm 1 loosened nut.
Socket wrench 18 mm 1 9. Tap the extender so that the belt pulley (2)
Socket wrench 13 mm 1 comes free from the blade mounting. Heat if
necessary.
Breaker 1
10. Remove the flanged nut and the belt pulley.
Torque wrench 1
Combination 7 mm 1 11. Remove the flat key (3) and dust shield (5).
wrench
1
Dismantling 2
1. Disconnect the cutting deck.
2. Remove the protective covers (8) over the belt.
4
3. Prise off the belt from the pulley in question.
3 5
4. Assemble the cutting deck and place in service
position.

8095-340
4 3 2 9 5 6
1. Flange nut 4. Grease nipple
2. Belt pulley 5. Dust shield
1 3. Flat key

12. Remove the four nuts (1) with screws holding

the bearing housing (2).
13. Remove the bearing housing.
14. Put the blade in a vice.
4 15. Dismantle the screw (4) for the blade. Remove
8 7 the screw and the blade washer (3) with blade.

1. Cotter pin 6.  ttachment point for

A IMPORTANT!
service position
2. Link joint The blade washer is convex. Always turn the
7. Service strut
3. Cutting deck mounting convex side against the screw head.
8. Protective cover
4. Cutting height setting
9. Gear Assembling
5. Propeller shaft with
quick couplings
1. Clean the contact surfaces on the blade, blade
washer, bearing housing and belt pulley.
2. Assemble in the reverse order.

2
8095-347

3 4
1. Nut 3. Blade washer
2. Bearing housing 4. Screw

English – 61
Cutting deck

3. Tightening torque for the blade screw and belt 12. Remove the four nuts (1) with screws holding
pulley nut is 110 Nm. the bearing housing.
4. Lubricate the bearing through the grease nipple 13. Remove the bearing housing (2).
before taking the cutting deck into service.
14. Put the blade in a vice.
Bearing Housing, Changing Bearing 15. Dismantle the screw (4) for the blade.
Remove screw, blade washer (3) and blade.
Tools Dimension Quantity
Torx T30 1 16. Press the blade mounting (9) out of the bearing
Socket wrench 13 mm 1
housing.
Socket wrench 18 mm 1 17. Knock or press the pack box (4), spacers (5), (8)
Socket wrench 24 mm 1 and bearing (6).
Breaker 1 Assembling
Torque wrench 1
Press tool 1 1
Combination 7 mm 1
wrench
2
Dismantling
1. Disconnect the cutting deck.

8095-347
3 4
2. Remove the protective covers over the belts.
3. Prise off the belt from the pulley in question. 1. Nut 3. Blade washer

4. Assemble the cutting deck and place in service 2. Bearing housing 4. Screw
position.
5. Remove the grease nipple (4).
6. Lock the blade with a wooden block.
7. Loosen the flanged nut (1) on the belt pulley
about 1.5 turns.
8. Put a 24 mm socket with extender on the
loosened flanged nut.
9. Tap the extender so that the belt pulley (2)
comes free from the blade mounting. Heat if
necessary.
10. Remove the flanged nut and the belt pulley.
11. Remove the flat key (3) and dust shield (5).

1
2

4
3 5
8095-340

1. Flange nut 4. Grease nipple

2. Belt pulley 5. Dust shield
3. Flat key

62 – English
 Cutting deck

1. Clean the contact surfaces on the blade, blade

washer, bearing housing and belt pulley.
2. Clean the inside of the bearing housing.
3. Lubricate the bearing seats, blade mounting
and pack boxes with a thin layer or lubricant.
4. Assemble bearing (6), spacers (5), (8) and
packing boxes (4). Press only on the outer
bearing races.
5. Press the blade (9) into position.
6. Assemble in the reverse order.
7. Tightening torque for the blade screw and belt
pulley nut is 110 Nm.
8. Lubricate the bearing through the grease nipple
before taking the cutting deck into service.

IMPORTANT!
The blade washer is convex. Always turn
the convex side against the screw head.

1 1. Grease nipple
2 2. Flange nut
3 3. Dust shield

4 4. Packing box

5 5. Spacer

6 6. Bearings
7. Bearing housing
7 8. Spacer
9. Blade attachment
8 10. Blade washer
6 11. Screw
4

10
8095-339

11

English – 63
Technical Data

Technical Data
P 520D P 525D
Dimensions
Length without cutting deck, cm/in 208 / 81.9 211 / 83.07
Width without cutting deck, cm/in 111 / 44.1 114 / 44.88
Height, cm/ft 129 / 50.8 133 / 52.4
Operating weight without cutting deck, 625 / 1378 665 / 1466
kg/lb
Wheelbase, cm/in 106 / 41.7 106 / 41.7
Tire dimension 18 x 8.5 x 8 20x10x10
Air pressure rear - front, kPa/bar/PSI 150/1.5/22 150/1.5/22
Engine
Make/Model Kubota D902 Kubota D1105
Rated output, kW (see note 1) 14.5 17.8
Stroke, cm /cu.in
3
898 / 54.8 1123 / 68.5
Idle speed, rpm 1800 ± 50 1750 ± 50
Full throttle rpm (See note 6) 3300 3200
Start Electric starter Electric starter
Fuel, minimum octane rating unleaded min 45 cetane 2.0-4.5 cSt @ 40°C min 45 cetane 2.0-4.5 cSt @ 40°C
0.835-0.855 kg/l sulfur<0.2w% 0.835-0.855 kg/l sulfur<0.2w%
Tank capacity, liters/USqt 25 / 6.6 25 / 6.6
Oil, API class CD or better SAE 10W/40 SAE 10W/40
Oil capacity with filter, liters/USqt 3.3 / 3.5 3.3 / 3.5
Oil capacity without filter, liters/USqt 3.0 / 3.2 3.0 / 3.2
Electrical System
Type 12V, negative ground 12V, negative ground
Battery 12V, 62 Ah 12V, 62 Ah
Main fuse A 125 125
Supply fuse circuit board, A 50 50
Bulbs, halogen 2x12V 20W 2x12V 20W
Cooling system capacity, l/USqt 3.7 / 3.9 3.7 / 3.9
Antifreeze 50% glycol 50% glycol
Hydraulic system (See note 2)
Max. working pressure, bar/ (psi) 120 / 1740 120 / 1740
Hydraulic tank volume, l/USqt 8 / 8.5 8 / 8.5
Hydraulic system volume, l/USqt 13 / 13.7 13 / 13.7
Transmission
Make Kanzaki KTM 23 Kanzaki KTM 23
Oil, class API SM, ACEA A3/B4 (See SAE 10W/50 Fully synthetic SAE 10W/50 Fully synthetic
note 2)
Oil capacity, front transmission, 0.9 / 0.24 0.9 / 0.24
l/USgal
Oil capacity, rear transmission, l/USgal 0.9 / 0.24 0.9 / 0.24
Max. hydraulic pressure, bar/psi 275 / 3989 275 / 3989
Drive
Forward speed, km/h 0-15 0-18.5
Reverse speed, km/h 0-12 0-14
Note. 1: The power rating of the engine is the average net output (at the specified rpm) of a typical production engine of the model,
measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine
installed in the final machine will depend on the operating speed, environmental conditions and other variables.
Note. 2: The same type of oil is used in both the hydraulic system and the transmission.

64 – English
 Technical Data

Technical Data - Sound and Vibration Levels

P 520D P 525D
Combi 132 Combi 155 Combi 132 Combi 155
Noise emissions (see note 3)
Noise power level, measured dB(A) 102 105 102 105
Noise power level, guaranteed dB(A) 103 105 103 105
Noise levels (see note 4)
Noise pressure level at user's ear, dB(A) 88 90 88 89
Vibration levels (see note 5)
Vibration level in steering wheel, m/s2. 1.7 1.7 1.7 1.7
Vibration level in seat, m/s2 0.7 0.7 0.7 0.7

Note. 3: Emission of noise to the surroundings measured as sound power (LWA) in accordance with the EU directive 2000/14/EC.
Note. 4: Sound pressure level according to EN 836. Reported data for the noise pressure level has a typical dispersion (standard deviation)
of 1.2 dB(A).

Note. 5: Vibration level according to EN 836. Reported data for the vibration level has a typical dispersion (standard deviation) of 0.2 m/s2
(steering wheel) and 0.8 m/s2 (seat).

Technical Data - Fluids

Engine oil Antifreeze
Choose oil with viscosity according to the Only use a glycol based antifreeze that is approved
temperature ranges in the figure. Do not mix different by the applicable norms BS 6580:1992 or ASTMD
oil types. 3306-89 or AS 2108-1977 (indicated on the
packaging).

Glycol Water Freezing point

60 % 40 % -47 °C / -53 °F
50 % 50 % -37 °C / -35 °F
40 % 60 % -25 °C / -13 °F

Technical Data - Cutting Deck

Cutting deck Combi 132 Combi 155
Cutting width, cm/inch 132 / 52 155 / 61
Cutting heights, 7 positions, mm/inch 25-127 / 0.98-5.0 25-127 / 0.98-5.0
Blade length, mm/inch 490 / 19.3 563 / 22.2
Width, mm/inch 1340 / 52.8 1594 / 62.8
Weight, kg/lb 100 / 220 131 / 289
Bevel gear oil SAE 80W/90, capacity 0.4 l SAE 80W/90, capacity 0.4 l

English – 65
 PTO-SWITCH

ON
12V UTTAG
Switch +12V OFF

1 2 C1
C
A
C2

66 – English
B1
B

1
2
B
B2
MAIN FUSE
A1
A
C 50A

+
BATTERY
-

Blue
Red
Red
Red
Orange
Red
Orange

Yellow

1
2
1
2
1
2
3
4
STARTMOTOR

Blue

Red
Blue
Blue

Red
Red
B+

1
2
3
4
5
6
Brown
Housing GENERATOR
L
J4 J3 J10 EXTRA POWER 1 AND 2 J15
IG
SOLENOID

1
1
1
1
JX P
R

1
2
1
2
1
2
3
4
1
2
3
4
5
6
W
Black
B Housing J6
Brown 1 1
Yellow 2 2 SC2 SC3 SC4 SC5
Blue 3 3 EXTRA POWER 1 GND EXTRA POWER 2 GND KEY SWITCH
Orange 4 4 J2 Yellow Housing
GENERATOR Black 5 5
1 A Brown Brown A
Pink 6 6
J1 2 B Yellow Yellow B
3 C Yellow Yellow C
1 IG Start
4 D Orange
2 Blue
5 E ROAD KIT POWER
L 6 F Blue Orange D On

E
PRINTED CITCUIT BOARD KEY CONNECTOR F Off
2
1

KEY Blue
START MOTOR J11 Red Housing
J7 1 1 Green Green
FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 2 2 Red
1
3 3 Pink
IGNITION EXTRA LIGHT EXTRA POWER EXTRA POWER +12V SOCKET ROAD KIT GEN/SOLENOID FRONT LIGHT
20A ROADKIT 10A 10A 10A 10A 5A 4 4 Purple
5A 5A
5 5 White
6 6 Grey
TM1
Pink 4 4
LAMP
GLOW PLUG Orange 3
1 +12V 3

Purple 2
SENSOR 2
TEMP

Electric connection box Blue 1

White J9 GND 1
TEMP SENSOR 1
Housing J7 1 1 2 TEMP C KUBOTA
1
OIL

Green 1 1 2 2 3 TEMP-METER KUBO

Green 2 2 3 3 4
Green 3 3 4 4 5
GLOW

Green 4 4 5 5 6
Purple 5 5 6 6 7
Grey 6 7 7
BATT

6 8
LIGHT

OIL SWITCH 8 8
1
P.T.O

CON5
BRAKE

1 2 1 Red
AF4 AF3 AF1 AF1
SMD2920P100 SMD2920P100 SMD2920P100 SMD2920P100 INDICATE C6304

START MODULE
Typ Typ Typ Typ Light switch
CON6
1 Pink

ROAD KIT
1 = ALWAYS POWER J17 J14 J13
2 = FLASH LEFT 1 1 IGNITION POWER Blue
2 2 1 1 FLASH LEFT 1
3 = FLASH RIGHT Pink
3 3 2 2 FLASH RIGHT 2
4 = REAR LIGHT 4 4 3 3 TAIL LIGHT 3
4 4 4
1
2

5 = HAZARD LIGHT 5 5 HAZARD LIGHT

6 6 5 5 HORN 5
6 = HORN 7 7 6 6 ROAD LIGHT ON 6
7 = ROAD LIGNT ON 8 8 7 7 GND 7
9 9 8 8 8
8 = CABINPOWER ON 10 10
9 = WORKING LIGHT FRONT

1
2
3
1
2
1
2

10 = GND

J8 J5 J12
1
2

CON1
HOUR METER 1 White
1

2 CON2 2 1
1 Gray
CABIN

1
2
3
1
2
1
2

1 = ALWAYS POWER
J16 Light connectors
1 2 = FLASH LEFT
Grey
Blue

ALWAYS POWER
Green
Green

Blue
Black
2

Brown
REAR LEFT 3 = FLASH RIGHT
3
FLASH RIGHT
4 2 1

1
2
3
REAR LIGHT 4 = REAR LIGHT
5
HAZARD LIGHT
1
2

6
HORN 5 = HAZARD LIGHT
7
ROAD LIGHT ON
8
CABIN POWER ON 6 = HORN
9
WORKING LIGHT F
10
GND 7 = ROAD LIGNT ON 1 2

8 = CABINPOWER ON
9 = WORKING LIGHT FRONT
10 = GND
P-BRAKE SENSOR PTO CLUTCH SEAT SWITCH
WIRING CABIN
115 73 58-26
2014W42