Husqvarna P524 EFI Instruction manual

Workshop manual
P524 EFI
English
662 - 001 - 23.10.2018

Contents
1 Introduction
1.1 Document description............................................ 3
1.2 Target group...........................................................3
1.3 Revisions................................................................3
1.4 Safety..................................................................... 3
1.5 Servicing tools........................................................3
2 Safety
2.1 General safety instructions.....................................4
2.2 Safety definitions....................................................4
2.3 Special safety instructions......................................4
2.4 Risk of sparks.........................................................4
2.5 Symbols on the product......................................... 4
3 Prepare and do servicing on the product
3.1 Pre delivery inspection........................................... 7
4 Assembly
4.1 Product overview P524 EFI....................................8
4.2 Battery....................................................................8
4.3 Tire pressure.......................................................... 9
4.4 To fill fuel................................................................9
4.5 To start the engine, P524 EFI................................ 9
4.6 To do a check of the engine speed...................... 10
4.7 To do a last inspection......................................... 10
5 Function test
5.1 To do a check of the operation conditions .......... 11
6 Servicing
6.1 Servicing schedule............................................... 12
6.2 Lubrication overview............................................ 15
6.3 Lubrication, general information...........................15
6.4 To lubricate cables............................................... 15
6.5 To lubricate the cutting deck................................ 16
6.6 To lubricate the pedal system.............................. 16
6.7 To lubricate the parking brake cable.................... 16
6.8 To lubricate the chains in the frame tunnel.......... 16
6.9 To lubricate the seat slides.................................. 17
6.10 To lubricate the hydrostatic transmission
cable...........................................................................17
6.11 To lubricate the steering cylinder....................... 17
6.12 To lubricate the joint bearing..............................17
6.13 To lubricate the link rod......................................17
7 Servicing tools
7.1 Servicing tools......................................................18
7.2 Optical tachometer............................................... 18
7.3 Screw fasteners................................................... 19
8 Function overview
8.1 Serial numbers on the product............................. 20
8.2 Engine.................................................................. 20
8.3 Steering................................................................20
8.4 Hydrostatic transmission...................................... 21
8.5 Bypass valves...................................................... 21
8.6 Cutting deck......................................................... 21
8.7 Hydraulic lift for the cutting deck.......................... 21
9 Repair instructions
9.1 Chassis................................................................ 23
9.2 Propulsion system................................................33
9.3 Electrical system.................................................. 38
9.4 Fuel system..........................................................43
9.5 Hydraulic system..................................................44
9.6 Transmission maintenance.................................. 56
9.7 Cutting system..................................................... 63
9.8 Equipment frame..................................................69
9.9 Steering................................................................70
9.10 Belts................................................................... 72
10 Troubleshooting
10.1 To measure voltage........................................... 75
10.2 To measure resistance.......................................75
10.3 To do a check of cables and connectors............75
10.4 Troubleshooting schedule.................................. 75
11 Diagrams
11.1 Wiring diagram................................................... 79
11.2 Hydraulic overview............................................. 80
12 Belt position diagram
12.1 Cutting deck belt................................................ 82
12.2 PTO belt............................................................. 82
12.3 Pump belt........................................................... 83
13 Technical data
13.1 Technical data....................................................84
13.2 Tightening torques............................................. 86
13.3 Product dimensions............................................86
2662 - 001 - 23.10.2018

1 Introduction
1.1 Document description
This manual gives a full description of how to do
maintenance and repair on the product. It also gives
safety instructions that the personnel must obey.
1.2 Target group
This manual is for personnel with a general knowledge
of how to do repair and do servicing. All personnel that
do repair or do servicing on the product must read and
understand the manual.
1.3 Revisions
Changes to the product can cause changes to the
maintenance work and spare parts. Separate
information is sent out for each change.
Read the manual together with all received information
about changes to maintenance and spare parts for the
product.
1.4 Safety
WARNING: All personnel that repair or do
servicing on the product must read and
understand the safety instructions in this
workshop manual.
1.5 Servicing tools
The manual gives information about necessary servicing
tools. Always use original tools from Husqvarna.
662 - 001 - 23.10.2018 Introduction - 3

2 Safety
2.1 General safety instructions
WARNING: Read the warning instructions that
follow before you use the product.
The service center that repairs the product must have
safety devices that obey local regulations. Warnings and
cautions are used to point out specially important parts
of the workshop manual.
2.2 Safety definitions
Warnings, cautions and notes are used to point out
specially important parts of the manual.
WARNING: Used if there is a risk of injury or
death for the operator or bystanders if the
instructions in the manual are not obeyed.
CAUTION: Used if there is a risk of damage to
the product, other materials or the adjacent area
if the instructions in the manual are not obeyed.
Note: Used to give more information that is necessary in
a given situation.
2.3 Special safety instructions
WARNING: The fuel for the product has
dangerous properties:
• The fuel and its fume are poisonous.
• The fuel can cause damage to the eyes and
the skin.
• The fuel can cause breathing problems.
• The fuel is very flammable.
WARNING: Read the warning instructions that
follow before you do work on the product.
• Do not point the airflow at your body when you use
compressed air. Air can go into the blood circulation
and kill you.
• Use eye protection when you do work on springs in
tension.
• Use hearing protection when the engine is on.
• Use protective gloves when you do work on or near
the blades. The blades are sharp and can give cut
injuries.
• Use eye protection when you do work on the cutting
deck. The belt tension spring can break and cause
injury.
• Use eye protection when you do work on the battery
with the caps removed. If battery acid gets into your
eyes or onto your skin, clean immediately with much
water and get medical aid.
• Explosive gases can come from the battery. Do not
smoke near the battery. Keep the battery away from
open flames and sparks.
2.4 Risk of sparks
Sparks can occur when you do work on the battery and
the thick cables. This can cause battery explosions, fire
or eye injuries. Sparks can not occur in the circuit when
the battery ground cable is disconnected.
Obey the following to prevent sparks.
• Use protective goggles.
• Make sure the tank cap is attached correctly.
• Do not keep flammable liquids in open containers.
• Do not do work on the starter motor circuit near
spilled fuel.
• Disconnect the ground cable of the battery first and
connect it last.
• Do not cause short circuits with tools.
• Do not cause short circuit to the starter relay
connections to operate the starter motor.
2.5 Symbols on the product
WARNING: Careless or incorrect use can result in
serious injury or death to the operator or others.
Read the operator's manual carefully and make sure
that you understand the instructions before use.
Rotating blades. Keep body parts away from the cover
when the engine is on.
4 - Safety 662 - 001 - 23.10.2018

Warning: rotating parts. Keep body parts away.
Hot surface.
Do not touch.
Pull the clip to remove the engine cover.
Never use the product if persons, especially children, or
animals, are in the vicinity.
Never cut grass across a slope. Do not cut grass on
ground that slopes more than 10°.
Never carry passengers on the product or equipment.
Operate the product very slowly if no cutting deck is
attached.
Operate the product at full speed when a cutting deck is
attached.
Move forward.
Neutral gear.
Move rearward.
This product is in accordance with applicable EC
directives.
Noise emission to the environment according to the
European Community's Directive. The product's
emission is specified in the Technical data chapter and
on the label.
Always use approved hearing protection.
Stop the engine.
Start the engine.
Warning lamp for engine malfunction.
Warning lamp for low oil pressure.
Engine speed – fast.
Engine speed – slow.
Servicing position for the cutting deck.
Operation position for the cutting deck.
662 - 001 - 23.10.2018 Safety - 5

Cutting height.
Servicing position.
The blades are engaged.
The blades are disengaged.
Oil level.
Stop the engine and remove the spark plug cable before
repairs or maintenance.
Do a check of the engine oil level.
Do a check of the engine oil level.
Parking brake.
Push in the PTO button.
Do not use the safety belt if the
ROPS is disengaged.
Always use the safety belt when
the ROPS is engaged.
Note: Other symbols/decals on the product refer to
certification requirements for some commercial areas.
6 - Safety 662 - 001 - 23.10.2018

3 Prepare and do servicing on the product
3.1 Pre delivery inspection
Complete the sales certificate and the customer records.
Write the serial number in the operator's manual and
confirm the delivery service in the service book.
662 - 001 - 23.10.2018 Prepare and do servicing on the
product - 7

4 Assembly
4.1 Product overview P524 EFI
1 2 3 54 6 7 8 9 10 11 12 13
22 21 19 18 17 16 15 1420
1. Forward drive pedal
2. Rearward drive pedal
3. Light switch
4. Bypass valve to engage or disengage the drive on
the front axle
5. Cutting height lever
6. Lift lever for the cutting deck
7. PTO button, start and stop of the cutting deck
8. Throttle control
9. On/off switch for the power outlet
10. Ignition lock
11. Warning lamp for low oil pressure
12. Warning lamp for engine malfunction
13. Power outlet 12V
14. Cover lock
15. Bypass valve to engage or disengage the drive on
the rear axle
16. Safety belt
17. Fuel tank cap
18. Seat adjustment
19. Type plate
20. Hour meter
21. Parking brake
22. Lock button for parking brake
4.2 Battery
It is not necessary to do maintenance on the battery. It is
the responsibility of the dealer to install the battery.
Use 2 tools when you remove or attach cables on the
terminals.
8 - Assembly 662 - 001 - 23.10.2018

4.3 Tire pressure
We recommend a tire pressure of 100 kPa (1.0 bar /
14.5 PSI) on all 4 tires.
4.4 To fill fuel
WARNING: Gasoline is very flammable. Be
careful and refuel outdoors (see Special safety
instructions on page 4 ).
WARNING: Do not use the fuel tank as a
support area.
The engine runs on unleaded gasoline with a minimum
octane rating of 95 (not mixed with oil). We recommend
biodegradable alkylate gasoline (max. methanol 5%,
max. ethanol 10%, max. MTBE 15%).
Do a check of the fuel level before each use and refuel if
necessary.
You can clearly see the fuel level in the fuel tank. Do not
fill too much. Keep a minimum space of 2.5 cm.
4.5 To start the engine, P524 EFI
1. Make sure that the bypass valves are closed. Refer
to Bypass valves on page 21 .
2. Apply the parking brake.
3. Push in the PTO button to disengage the drive on
the cutting deck.
4. Turn the ignition key to the start position.
5. When the engine starts, immediately release the
ignition key to neutral position.
CAUTION: Do not run the starter for more
than 5 seconds at a time. If the engine does
not start, wait 15 seconds before you try
again.
6. Let the engine run at half throttle for 3-5 minutes
before you apply a heavy load.
CAUTION: If the warning lamp for oil
pressure comes on, stop the engine
immediately and refer to Troubleshooting
schedule on page 75 .
7. Push the throttle control to full throttle position.
CAUTION: To engage the blades when the
engine is at full speed causes strain on the drive
belts. Do not apply full throttle until the cutting
deck is lowered to the mow position.
662 - 001 - 23.10.2018 Assembly - 9

4.6 To do a check of the engine speed
1. Do a check of the engine speed with a Husqvarna
tachometer.
2. Make sure that the maximum speed is correct. Refer
to Technical data on page 84 .
4.7 To do a last inspection
• Do a check of the oil level in the hydraulic tank and
fill if it is necessary.
• Make sure that there are no leaks.
• Make sure that the product is clean.
10 - Assembly 662 - 001 - 23.10.2018

5 Function test
5.1 To do a check of the operation
conditions
The operation conditions are as follows:
• The engine can only be started when the drive of the
blades is disengaged.
• The engine can only be started when the parking
brake is applied.
• The drive of the blades can only operate when the
operator sits in the seat.
Do a check of the operation conditions daily.
1. Try to start the engine with the drive of the blades
engaged. If the operation conditions works, the
engine does not start.
2. Try to start the engine without the parking brake
applied. If the operation conditions works, the engine
does not start.
3. Start the engine, engage the drive on the blades and
lift from the seat. If the operation conditions works,
the blades in the cutting deck stop.
662 - 001 - 23.10.2018 Function test - 11

6 Servicing
6.1 Servicing schedule
The following is a list of maintenance procedures that
must be performed on the ride-on mower. Most points
not described in this workshop manual can be found in
the operator’s manual.
Maintenance Daily Week-
ly
First Maintenance interval
in hours
10 h 40 h 25 h 100 h 200 h 400 h
1. PREPARATIONS
1.1 VISUAL INSPECTION OF THE MACHINE
Check for fuel and oil leakage. X
1.2 CHECK OIL LEVEL
Transmission oil level, top up if necessary. X
1.3 CHECK SAFETY FEATURES AND TRY TO START THE
PRODUCT.
Inspect and test the brakes. X X X X X
1.4 CLEAN / WASH FOLLOWING:
Clean around the muffler. X
Clean the transmission air intake. X
Clean the air filter. X X X X
Clean below the cutting deck. X
Clean and lubricate the belt tensioner bearings. X X
Inside frame tunnel. X
Around engine (thoroughly!). X
Around hydraulic oilcooler. X
Around transmission (thoroughly!). X
1.5 VISUAL INSPECTION (AFTER CLEANING)
Engine’s cooling air intake.
Fuel pump air filter. X X X
Blades. X X X
Check that the PTO belt tension is correct. X X X X
Check that the pump belt tension is correct. X X X X
Check the cutting deck bolts for the belt pulleys, blades, etc. X
Check that the hydraulic hoses and couplings are clean and un-
damaged. X X X
Check joint bearing in articulated unit. X
Check the condition of all pulleys on the machine. X X
1.7 ADJUSTMENTS
Make sure all fastners are properly tensioned (screws, nuts etc). X
1.8 LUBRICATE
Driver’s seat. X
Bearing surfaces on cutting unit. X X X
Lubricate the articulated bearing. X X X X
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Maintenance Daily Week-
ly
First Maintenance interval
in hours
10 h 40 h 25 h 100 h 200 h 400 h
Lubricate according to the lubrication chart. X X X X X
Hydrostatic cable with links. X X X X
Parking brake wire. X X X X
Throttle control. X X X X
Choke control. X X X X
Pivoting wheel. X X X X
Belt adjuster. X
2. ENGINE
2.1 SERVICE MAINTENANCE SCHEDULE FOR ENGINE FROM
OEM
Check that the spark plug is clean and properly gapped X X
Clean the combustion chamber X
2.2 FUEL SYSTEM
Check the fuel hose. Replace if necessary. X X X
Change the fuel filter. X X X X
2.3 AIR INTAKE SYSTEM
Replace the air filter’s prefilter. X X X
Replace the air filter’s pre-filter and paper filter. X
2.4 COOLING AND STARTER SYSTEM
Inspect the cooling fins on the hydrostatic transmission. X X X X
Clean the engine and transmission. X X X X
2.5 EXHAUST SYSTEM
Examine the muffler and heat deflector X X X X
2.6 OIL SYSTEM
Replace engine oil* (SAE 10W/40). X X X X
Change the oil filter X X
2.7 ELECTRICAL AND IGNITION SYSTEM
Replace the spark plug. X X X X
Check lights. X
3. TRANSMISSION, CONTROLS AND DRIVE SYSTEM
3.1 INSPECT AND ADJUST IF REQUIRED:
Front and rear wheel rotation speed. (Only AWD) X X X
Check the oil level in the transmission and top up if necessary
(SAE 10W/50) X
Air pressure in the tyres X X X X
Parking brake. X
3.2 REPLACE:
Suction filter in the hydraulic tank. X X
Hydraulic oil filter. X X
662 - 001 - 23.10.2018 Servicing - 13

Maintenance Daily Week-
ly
First Maintenance interval
in hours
10 h 40 h 25 h 100 h 200 h 400 h
Hydraulic oil. X
Replace the pump belt. X
Replace the cutting deck drive belt. X
Oil in the gearbox (SAE 10W/40) / (SAE 10W/50 Synthetic only
for AWD). X X
3.3 LUBRICATE:
Belt adjuster. X X
Joints and shafts. X X X X
According to the lubrication schedule. X X X X X
4. CUTTING EQUIPMENT
Check/adjust the cutting height setting. X X X
Replace the cutting deck blade belts. X
Inspect the cutting deck. X
14 - Servicing 662 - 001 - 23.10.2018

6.2 Lubrication overview
1
1 1
2
3
45
6
4
1. Rear axle bearing
2. Link rod
3. Articulation bearing
4. Front axle bearing
5. Steering cylinder
6. Lift chain axle
6.3 Lubrication, general information
• Remove the ignition key to prevent accidental
movements during lubrication.
• Use engine oil when you lubricate with an oil can.
• When you lubricate with grease, use a chassis or
ball bearing grease that prevents corrosion. Remove
unwanted grease after lubrication.
• Lubricate 2 times a week if you operate the product
daily.
• Do not spill lubricant on the drive belts or the
grooves of the belt pulleys. If you do spill, clean with
alcohol. If the friction between the drive belt and the
pulley is not sufficient after you clean with alcohol,
replace the drive belt.
CAUTION: Do not use gasoline or other
petroleum products to clean drive belts.
6.4 To lubricate cables
• Lubricate the 2 ends of the cables and move the
controls to the end positions.
• Attach the rubber covers on the cables after
lubrication.
• Cables with casing must be lubricated regularly to
prevent malfunction.
a) Remove the cable and hang it vertically.
662 - 001 - 23.10.2018 Servicing - 15

b) Lubricate the cable with thin engine oil until the
oil starts to release from the bottom. Replace the
cable if the oil does not release from the bottom.
Note: You can fill a small plastic bag with oil and seal
the plastic bag against the cable casing with tape. Let
the cable hang vertically from the bag until the next day.
6.5 To lubricate the cutting deck
1. Remove the front cover.
2. Lubricate the joints and the bearings with engine oil.
6.6 To lubricate the pedal system
1. Remove the 4 screws and remove the frame plate.
2. Push and release the pedals and lubricate the parts
that move with engine oil.
3. Lubricate the cables for the forward and rearward
drive pedals with engine oil.
6.7 To lubricate the parking brake cable
1. Remove the 4 screws and remove the frame plate.
2. Remove the left side cover.
3. Remove the rubber casing on the parking brake
cable.
4. Lubricate the ends of the parking brake cable with
engine oil.
5. Lubricate the parking brake cable with engine oil.
6. Press the parking brake pedal 3 times and lubricate
the parking brake cable again.
7. Attach the left side cover and the frame plate.
6.8 To lubricate the chains in the frame
tunnel
1. Remove the screws and remove the frame plate.
2. Lubricate the chain in the frame tunnel with engine
oil or chain lubricant spray.
16 - Servicing 662 - 001 - 23.10.2018

6.9 To lubricate the seat slides
1. Tilt the seat forward.
2. Lubricate the seat slides with engine oil.
6.10 To lubricate the hydrostatic
transmission cable
1. Lubricate the joints and bearings of the hydrostatic
transmission cable with engine oil.
2. Remove the rubber sleeve and lubricate the
hydrostatic transmission cable with engine oil.
3. Press the forward drive pedal 5 times and lubricate
the hydrostatic transmission cable again.
4. Attach the rubber sleeve.
6.11 To lubricate the steering cylinder
The steering cylinder has 2 grease nipples, one on each
end.
• Lubricate with a grease gun until grease comes out.
6.12 To lubricate the joint bearing
1. Lubricate the joint bearing of the articulation with a
grease gun until grease comes out.
6.13 To lubricate the link rod
1. There are 2 grease nipples, one on each side of the
link rod. Lubricate with a grease gun until grease
comes out.
662 - 001 - 23.10.2018 Servicing - 17

7 Servicing tools
7.1 Servicing tools
Note: Special tools for engine and transmission can be
found in the related workshop manual.
1
4
7
3
6
5
2
1 Laser tachometer 502 28
80-01
2 Adjustment tool for wheel speed 578 92
62-01
3 Counterhold – Belt pulley 506 89
92-01
4 Puller – Spring N/A
5 Puller – Belt pulley 506 66
48-01
6 Battery charger (EU) 509 06
82-01
7 Tachometer 502 71
14-01
7.2 Optical tachometer
7.2.1 Laser safety
WARNING: The optical tachometer is a class 1
laser product. Read the warning instructions
that follow before you use it.
• Be careful when the laser beam is on.
• Do not look into the laser beam.
• Do not point the laser beam at shiny surfaces. It can
make a reflection into your eyes.
• Do not point the laser beam at the eyes of a person
or animal.
• Do not point the laser beam at explosive gases.
7.2.2 To measure rpm with tachometer
Attach more than one piece of tape on the surface to get
the accurate result when measuring at low speed. Put
the tape with the same distance between the pieces.
Then divide the read value with the number of tape
pieces to get the accurate rpm.
1. Make sure the area of reflection is smaller than the
area without reflection. If the object to be measured
is shiny. Put black tape or black paint on the
measured surface before the reflection tape is
attached.
2. Clean the surface to be measured before attaching
the reflection tape.
3. Put a small piece of reflection tape (approximately
1x1 cm) on the object to be measured.
4. Put the switch to the RPM position for measuring
rpm or TOT for measuring the number of
revolutions.
5. Press and hold the measuring button on the side of
the instrument. Point the measuring laser beam at
the object and the reflection tape. The display
automatically illuminate after 1-2 seconds.
6. Release the measuring button to stop the measuring
procedure.
7.2.3 To read the tachometer values
The tachometer automatically saves the last, highest
and lowest values for the measure while the button is
pressed.
• Press and hold the memory button (MEM) to see the
saved results. The value is shown on the display
after 1-2 seconds.
a) The first push on the memory button shows the
last value, identified with "LA" on the display.
b) The second push on the memory button shows
the highest value, identified with "UP" on the
display.
c) The third push on the memory button shows the
lowest value, identified with "DN" on the display.
7.2.4 Maintenance of the tachometer
• Clean the tachometer with a soft, moist cloth.
• Do not use solvent for cleaning.
• Do not put the tachometer into water or other liquids.
• Keep the tachometer from sunlight, high
temperature and dirt.
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• Do not cause mechanical chock to the tachometer.
• Remove the batteries if the tachometer is not used
for long periods.
7.3 Screw fasteners
Some screws and nuts are locked with Eslok® Nylon
180°. The threads of those screws have a red layer.
Remove and attach the screws a maximum of 3 times
before you replace them.
Always obey the tightening torque in the table when
there are no other instructions in the text.
Wrench Di-
mension
Hex Key Thread Tightening
torques
8 mm 4 mm M5 6 Nm
10 mm 5 mm M6 10 Nm
– 3 mm M6 10 Nm
13 mm 6 mm M8 24 Nm
– 4 mm M8 18–20 Nm
17 mm 8 mm M10 47 Nm
17 mm – M10 12.9 70 Nm
18–19 mm 10 mm M12 81 Nm
24 mm – M16 110 Nm
30 mm – M20 200 Nm
32 mm – – Hydraulic
couplings.
Refer to Hy-
draulic cou-
plings, pipes
and hoses
on page
45 .
Always tighten screws (A) that are attached to the frame
(B) before attaching a locknut (C) on the opposite side.
Do not tighten the locknut (C) with too high a torque. If
you tighten the locknut with too high a torque, the
tension of the screw in the frame decreases. The screw
will then come loose during operation.
A
B
C
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8 Function overview
8.1 Serial numbers on the product
The product serial number is on the printed type plate
(A) above the right footrest plate. The type plate gives
the designation, the type number from the manufacturer
and the serial number (s/n) of the product.
The engine serial number (B) is on the right side of the
engine.
The transmission serial number (C) is behind the wheels
on the right side of the product.
The hydraulic pump serial number (D) is on the right
side of the hydraulic pump.
• The type designation is above the bar code and
starts with the letter "K".
• The serial number is above the bar code and has
the prefix "s/n".
• The type number from the manufacturer is below the
bar code and has the prefix "p/n".
The type designation and serial number are necessary
to complete an order for spare parts.
B
C
D
C
A
8.2 Engine
The 2 cylinder, overhead valve engine on this product
has Electronic Fuel Injection (EFI).
Use only original spare parts to repair the engine. The
warranty is not applicable if other parts are used.
Information about engine repairs is not given in this
workshop manual. Information about adjustments and
engine repairs can be found in the manuals from the
manufacturer of the engine. You can get the engine
manual from an approved servicing dealer or download
it from the web site of the engine manufacturer. The
serial number of the engine is necessary to get the
correct manual.
8.3 Steering
The product has hydraulic power steering and
articulated steering. The movement from the steering
wheel moves to the rear axle through a hydraulic
cylinder. This makes the product easy and accurate to
steer.
The control unit is connected directly to the steering
wheel and moves the steering cylinder in and out. The
steering cylinder is connected between the chassis and
the rear axle. It is possible to steer if the engine stops
but the steering wheel is heavy to turn. There is 1
hydraulic tank for all hydraulic functions on the product.
20 - Function overview 662 - 001 - 23.10.2018