Husqvarna R 422Ts Instruction manual

Workshop manual
R 422 Ts
R 422 Ts AWD English

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Contents
Contents ..................................................................1
Safety Instructions .................................................3
General Instructions ............................................3
Special Instructions .............................................3
Risk of sparking ..................................................4
Special Tools ..........................................................5
Laser tachometer ...................................................7
Safety ..................................................................7
Measure speed ...................................................7
Read the last, highest and lowest values ............7
Replace the batteries ..........................................7
Maintenance .......................................................7
Delivery and Dealer Service ................................13
Delivery Service ................................................13
After the First 8 Hours .......................................13
25-Hour Service ................................................13
50-Hour Service ................................................13
100/200-Hour Service .......................................13
300-Hour Service ..............................................14
At Least Once Each Season .............................14
Delivery Procedures ..........................................15
Battery ...............................................................17
Arm Supports ....................................................17
Steering Wheel .................................................17
Towing Eye and Counterweight ........................18
Checking the Engine Oil Level ..........................18
Check the Oil Level in the Hydraulic Tank ........19
Wheels ..............................................................19
Skid Guard ........................................................19
Checking and Adjusting the Cutting Unit ..........20
Test Running .....................................................20
Starting the Engine ...........................................20
Engine Speed Regulator ...................................21
Final Inspection .................................................21
Administration ...................................................21
Design and Function ............................................23
General .............................................................23
Cutting unit ........................................................24
Serial Number ...................................................24
Engine ...............................................................25
Steering .............................................................26
Driving ...............................................................27
Cutting Unit .......................................................28
Repair Instructions ..............................................31
Removing the Engine ........................................31
Fitting the Engine ..............................................33
Fuel Tank ..........................................................35
Changing the Engine Oil ...................................36
Checking and Adjusting the Steering Cables ....37
Replacing the Steering Cables .........................38
Removing/Fitting the Power Steering ...............38
Removing/Fitting the Cable Pulley ....................39
Adjusting the Parking Brake
R 422 Ts AWD ................................................. 40
Adjusting the parking brake
R 422 Ts ........................................................... 40
Adjusting the Hydrostatic Transmission Cable . 41
Checking and Adjusting the Throttle Cable ...... 42
Checking and Adjusting the Choke Cable ........ 42
Replacing the Articulated Steering Bearings .... 42
Removing the Pendulum Shaft ........................ 44
Replacing Bushings ......................................... 45
Fitting the Pendulum Shaft ............................... 45
Drive Axles ....................................................... 46
Front Axle R 422 Ts AWD ................................ 46
Rear Axle ......................................................... 50
Seal Replacement, Outgoing Shafts ................ 53
Replacing the Hydrostatic Transmission Cable 56
Fitting the Hydrostatic Transmission Cable ...... 58
Bleeding the Hydrostatic and Hydraulic
Systems, R 422 Ts AWD ................................. 60
Bleeding the Hydrostatic and Hydraulic
Systems R 422 Ts ............................................ 61
Transmission Maintenance .............................. 62
Adjusting the Lever Housing ............................ 63
Replacing the rear drive belt, R 422 Ts ............ 65
Replacing the Hydraulic Pump's Drive Belt
R 422 Ts AWD ................................................. 68
Replacing the Centre Belt ................................ 70
Replacing the Front Belt ................................... 71
Equipment Frame ............................................. 72
Fitting the Cutting Unit ...................................... 73
Removing the Cutting Unit ............................... 75
The Cutting Unit’s Service Position .................. 76
Placing in the Service Position ......................... 76
Restoring from service position ........................ 78
Adjusting the Unit’s Parallelism and
Cutting Height .................................................. 78
Adjusting the parallelism of the cutting unit ...... 78
Adjusting the Cutting Height Range ................. 79
Checking and Adjusting the Ground Pressure . 79
Changing the Belt on the Cutting Unit .............. 80
Removing Blades with Bearings ...................... 81
Sharpening and Balancing Blades ................... 84
Removing the BioClip plug (Combi) ................. 84
Electrical system ................................................. 85
Wiring diagram R 422 Ts och R 422 Ts AWD .. 85
Ignition and Starter Lock .................................. 91
Hour Meter ....................................................... 91
Fuses ............................................................... 91
Replacing the Light Bulbs ................................ 92
Safety System .................................................. 93
Hydraulic System ................................................ 95
Hydraulic Hygiene ............................................ 95
Hydraulic Oils ................................................... 95
Fixing Oil Leaks ................................................ 95
Workshop Manual for the
R 422 Ts and R 422 Ts AWD

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Keep the Hydraulic Oil Clean ............................96
Working Methods ..............................................96
Component Locations PR 17, PF 21 ................96
Component Locations R 422 Ts .......................97
Component Locations R 422 Ts AWD ..............98
Bleeding the Hydraulic System .........................99
Power Steering .................................................99
Replacing the Lift Cylinder ................................99
Valve Assembly ..............................................100
Pressure Limiting Valve ..................................105
Hose Bundle ...................................................105
Changing the hydraulic oil cooler,
R 422 Ts AWD ................................................107
Replacing the cooling fan ................................107
Appendix: Trouble Shooting Guide

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SAFETY INSTRUCTIONS
Safety Instructions
General Instructions
This workshop manual is written for personnel with
general knowledge about the repair and service of
riders.
The workshop where the rider is to be repaired
must be equipped with safety equipment in
accordance with local bylaws.
No one may repair the rider unless they have read
and understood the content of this workshop
manual.
The machine is tested and approved only with the
equipment originally provided or recommended by
the manufacturer.
This workshop manual contains the following
boxes in relevant places.
Special Instructions
The fuel used in the rider has the following
hazardous properties:
• The fluid and its vapour are poisonous.
• Can cause eye and skin irritation.
• Can cause breathing problems.
• Is highly inflammable.
When using compressed air, do not direct the jet
towards the body. Air can penetrate into the blood
circulation system, which entails mortal danger.
Use eye protection when working with tensioned
springs.
Wear protective earplugs or earmuffs when test
running.
After test running, do not touch the muffler until it
has cooled. Risk of burns. This is especially true if
the rider is equipped with a catalytic converter. The
coatings on and in the catalytic converter element
are hazardous to ingest. Use protective gloves
when working with the converter/muffler.
The blades are sharp and can cause cuts and
gashes. Use protective gloves when handling the
blades.
Use eye protection when working with the cutting
unit. The belt tensioning spring can break, fly off,
and could cause personal injury.
Use eye protection when working with the battery
with the plugs removed. Be especially careful
when handling battery acid. Acid on the skin can
cause serious corrosive injuries. In the event of
spillage on the skin wash immediately with water.
Acid in the eyes can cause blindness; contact
a doctor immediately.
Be careful when servicing the battery. Explosive
gases form in the battery. Never perform
maintenance on the battery while smoking or in
the vicinity of open flames or sparks. This can
cause the battery to explode and cause serious
injuries.
WARNING!
The warning box warns of the risk
of personal injury if the
instructions are not followed.
IMPORTANT INFORMATION
This box warns of material damage if the
instructions are not followed.
!
IMPORTANT INFORMATION
Waste oil and old filters shall be handled
as hazardous waste.

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SAFETY INSTRUCTIONS
Risk of sparking
Sparking can occur when working with the
battery and the thick cables in the starter
motor circuit.
This can cause the battery to explode, fire or
eye injuries.
Sparking in the circuit can not occur once the
battery's power connection cable (usually the
black negative cable) has been
disconnected.
Avoid sparking and its consequences by:
• Wearing protective glasses.
• Make sure that the fuel cap is fitted and
that no flammable liquids are stored in
an open container.
• Do not work on the starter motor circuit
in the vicinity of spilt fuel.
• Disconnect the battery's power
connection cable (usually the black
negative cable) first and connect it last.
• Exercise care with tools so that short
circuiting does not occur.
• Do not short circuit across the starter
relay's connections to run the starter
Risk of sparking

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SPECIAL TOOLS
Special Tools
The following special tools are used when working on the rider.
Special tools for the engine and transmission are specified in resp. Workshop Manuals.
506 66 48-01 Engine belt pulley remover.
506 56 76-01 Allen key 5/16" for loosening the engine belt pulley’s Allen screw (Kawasaki).
506 89 92-01 Counter to aid removing the engine belt pulley.
506 89 93-01 Tool for the centre spring.
535 41 32-01 Punch kit for pendulum shaft bushings.

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SPECIAL TOOLS
The figures show how the special tools are used.
506 66 48-01
506 89 93-01
535 41 32-01
506 56 76-01

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SPECIAL TOOLS
Laser tachometer
Safety
• Laser product class 1.
• Exercise care when the laser beam is on.
• Do not look straight at the beam. Do not
aim the beam towards anyone else’s
eyes, either people or animals.
• Do not aim the laser beam towards pol-
ished surfaces where the beam can be
reflected into someone’s eyes.
• Do not aim the laser beam towards explosive gases.
• Remember when measuring.
• The reflective surface must be smaller than the non-reflective surface.
• If the object to be measured is polished, cover the measurement surface with black tape or paint with
black paint prior to attaching the reflective tape.
• Clean the surface before attaching the tape.
• When measuring at low speed, more accurate measurement values can be obtained if you attach several pieces
of tape equally distributed around the measurement object. Now divide the read measurement value with the
number of pieces of tape to get the correct speed.
Measure speed
1. Move the switch to the RPM position to measure the speed, or TOT to measure the number of revolutions.
2. Attach a small piece of reflective tape (approximately 1 x 1 cm) on the rotating object to be measured.
3. Press and hold down the measurement button on the side of the instrument. Aim the measurement laser beam at
the object and the reflective tape. The display will come on after 1–2 seconds.
4. Hold the measurement button down during the entire measurement. The instrument switches off when the
measurement button is released.
Read the last, highest and lowest values
The instrument automatically saves the last, highest and lowest measurement values during a measurement (i.e. as
long as the measurement button is held down). Press and hold down the memory button (MEM) to read the saved
values. Values are shown on the display after 1–2 seconds.
Measured value Indicated by
Press once Last “LA”
Press twice Highest “UP”
Press three times Lowest “DN”
Replace the batteries
When the symbol for a weak battery is shown on the display, the batteries will soon be spent.
1. Open the battery cover by loosening the crosshead screw that holds the cover in position.
2. Remove the old batteries and insert new ones. Use four, 1.5 volt batteries of the type R6 (AA).
3. Make sure the batteries are turned the right way, otherwise damage can be caused to the instrument.
4. Close the battery cover and secure with the screw.
Maintenance
Clean the tachometer using a soft, damp cloth. Never use any form of solvent to clean it. Never dip it into water or
another fluid.
Do not subject the tachometer to direct sunlight, high temperatures, extreme dust or mechanical impact.
Remove the batteries if the instrument is not to be used for a long period of time.
The tachometer may only be opened by accredited technicians.
RPM
TOT
MEM
DIGITAL TACHOMETER

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SPECIAL TOOLS

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SPECIFICATIONS
Specificatons
R 422 Ts R 422 Ts AWD
Dimensions and weight
Length, base machine, mm/ft with tow hook 2 080/6,82 2 080/6,82
Length with Combi 112, mm/ft with tow hook 2 450/8,04 2 450/8,04
Length with Combi 122 2 550/8,37 2 550/8,37
Width, base machine, mm/ft 900/2,95 900/2,95
Width with Combi 112, mm/ft 1 220/48 1 220/48
Width with Combi 122, mm/ft 1 330/52,4 1 330/52,4
Height, mm/ft 1 160/3.8 1 160/3.8
Operating weight, base machine. kg/lb 305/672 327/721
Wheelbase, mm/ft 1 000/3.28 1 000/3.28
Wheels
Tyre dimensions 195/65-8 195/65-8
Air pressure, front and rear, kPa /bar/PSI 60/0.6/9 60/0.6/9
Engine
Manufacturer Briggs & Stratton Briggs & Stratton
Model 7220 7220
Power
1)
, hp 12,5 12,5
Displacement, cm
3
/cu in 656 656
Fuel, at least octane unleaded 87 (max. methanol 5%,
max. ethanol 10%, max.
MTBE 15%)
87 (max. methanol 5%,
max. ethanol 10%, max.
MTBE 15%)
Tank volume, litres/US Gal 17/18 17/18
Oil, , API SF-SJ SAE 10W/30, 10W/40 SAE 10W/30, 10W/40
Oil volume, litres/US qt 1.7/1.8 1.7/1.8
Oil volume incl. filter, litres/US qt 1,9/2,0 1,9/2,0
Starting Electric start Electric start
Speed, rpm 3000 + 100 3000 + 100
Drive axles
Manufacturer and type Front Tuff Torq VFMU KTM10 SA
Manufacturer and type Rear Tuff Torq RMU K66 Tuff Torq RMU K664
Oil, class SF-CC SAE 10/40 SAE 10/50, Wholly
synthetic
Oil volume, total including hydraulic system,
litres/US qt
3.2/3.4 3.2/3.4

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SPECIFICATIONS
Electrical system
Type 12 V, negative grounded 12 V, negative grounded
Battery 12 V, 24 Ah 12 V, 24 Ah
Main fuse Flat pin, 15 A Flat pin, 15 A
Fuse power outlet Flat pin, 7.5 A Flat pin, 7.5 A
Spark plug EMS PLATINUM EMS PLATINUM
Electrode gap 0,75 mm/0,030" 0,75 mm/0,030"
Bulbs Philips Brilliant Pro 2x12V 20W, type 14613 2x12V 20W, type 14613
Hydraulic System -
Max. working pressure 300 bar/4200 PSI 300 bar/4200 PSI
Max. working pressure steering servo circuit 45 bar/630 PSI 45 bar/630 PSI
Tightening Torques
Drive disc steering 5–10 Nm/3.5-7 lbf. ft. 5–10 Nm/3.5-7 lbf. ft.
Line pulley steering cable 20-30 Nm/14-21 lbf. ft. 20-30 Nm/14-21 lbf. ft.
Belt pulley 35–40 Nm/25-28 lbf. ft. 35–40 Nm/25-28 lbf. ft.
Blades M10 bolt 45-50 Nm/32-36 lbf. ft. 45-50 Nm/32-36 lbf. ft.
Blades M12 bolt 75-80 Nm/53-56 lbf. ft. 75-80 Nm/53-56 lbf. ft.
Blade bearings 20–25 Nm/14-18 lbf. ft. 20–25 Nm/14-18 lbf. ft.
Belt tensioning wheel 15–25 Nm/10-18 lbf. ft. 15–25 Nm/10-18 lbf. ft.
Fitting screws, engine 20–25 Nm/14-18 lbf. ft. 20–25 Nm/14-18 lbf. ft.
Fitting screws, gearbox 20–25 Nm/14-18 lbf. ft. 20–25 Nm/14-18 lbf. ft.
Engine belt pulley 70–80 Nm/50-56 lbf. ft. 70–80 Nm/50-56 lbf. ft.
R 422 Ts R 422 Ts AWD

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SPECIFICATIONS
Cutting Unit
Check List
Parallelism, cutting unit with cutting height in position 1: ± 2 mm/± 0.079"
Checking the cutting height in position 1: 25 ± 2 mm/0,98 ± 0.079"
Distance between support plate and drive belt: 3-6 mm/1/8"-1/4"
Distance between the belt adjuster lever and the belt guide, disengaged unit: 17 ± 5 mm/7/16" ± 3/16"
Play
Brake cable: 1 mm/0.040"
Cable, hydrostatic pedals: 0 mm
Lock, mechanical lifting lever 2 mm/1/16"
Combi 112 Combi 122
Cutting width, mm/" 1 120/44 1 220/48
Cutting heights, mm/" 25-80/0,98-3,15 25-80/0,98-3,15
Blade length, mm/" 420/16,5 450/17,7
Guaranteed noise level, dB(A) 100 102
Width, mm/" 1 220/48 1 330/52,4
Weight, kg/lb 56/123,5 64/141

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SPECIFICATIONS

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DELIVERY AND DEALER SERVICE
Delivery and Dealer Service
Delivery Service
1 Charge the battery for 4 hours at max. 3 amp.
2 Fit steering wheel, seat and any optional equipment.
3 Check and adjust tyre pressure (60 Kpa, 0.6 bar, 9
PSI).
4 Adjust cutting unit:
Adjust lift springs (effective weight of cutting unit
should be 12-15kg / 26.5-33 lb).
Adjust cutting unit so that rear edge is about 2-4 mm
/ 1/8” higher than front edge.
Adjust the cutting unit’s cutting height setting so that
the connection rod is tensed at the lowest cutting
height.
5 Check that the right amount of oil is in the engine.
6 Check that there is oil in the transmission’s oil tank.
7 Connect battery.
8 Fill with fuel and start engine.
9 Check that machine does not move in neutral.
10 Check:
Forward drive.
Reverse drive.
Operation of blades.
Seat safety switch.
Lif lever safety switch.
The safety switch for the hydrostat pedals.
11 Tell customer about:
Needs and benefits of following the service schedule.
Servicing and the influence of this journal on the
second-hand value of the machine.
The transmission guarantee is only valid if the
synchronisation of the front and rear wheels has been
checked and adjusted in compliance with the service
schedule. The system will be damaged if
synchronisation is not carried out.
Range of applications for BioClip.
Complete proof of sale etc.
After the First 8 Hours
1. Change engine oil.
2. Change the oil in the hydraulics and drive
system.
25-Hour Service
1. Clean the engine’s cooling air intake and the
transmission’s air intake.
2. Check the V-belts.
3. Clean/replace the air cleaner’s filter cartridge
(paper filter). (Shorter intervals for dusty
operating conditions.)
4. Clean the fuel pump’s air filter (for dusty
operating conditions).
5. Check the synchronisation between the front
and rear wheels.
50-Hour Service
1. Perform the 25-hour service.
2. Check/adjust the cutting height.
3. Check/adjust the parking brake.
4. Inspect the flame proofing/spark arrestor
(extra equipment).
100/200-Hour Service
1. Perform the 25-hour service.
2. Perform the 50-hour service.
3. Change engine oil.
4. Check whether the engine oil filter needs
changing (every 200 hours).
5. Clean/replace the spark plugs.
6. Change the inline fuel filter.
7. Clean the cooling fins on the engine and the
transmission.
8. Check whether the oil or filter in the hydraulic
tank need changing (every 200 hours).
9. Check whether the hydraulic oil filter needs
changing (every 200 hours).
10. Clean the air filter’s paper cartridge and check
whether it needs changing (every 200 hours).
11. Check nuts and screws for tightness.

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DELIVERY AND DEALER SERVICE
300-Hour Service
1. Inspect the machine. Come to agreement with
the customer as to what additional work is to
be carried out.
2. Perform the 25-hour service.
3. Perform the 50-hour service.
4. Perform the 100-hour service.
5. Clean the combustion chamber and grind the
valve seats.
6. Check the play in the engine valves.
At Least Once Each Season
1. Clean the engine’s cooling air intake
(25 hours).
2. Replace the air filter’s paper cartridge
(200 hours).
3. Change the engine oil (100 hours).
4. Replace the engine oil filter (200 hours).
5. Adjust the cutting height (50 hours).
6. Adjust the parking brake (50 hours).
7. Inspect the flame proofing/spark arrestor,
extra equipment (50 hours).
8. Clean/replace the spark plugs (100 hours).
9. Change the inline fuel filter (100 hours).
10. Clean the cooling fins (100 hours).
11. Check the play in the engine valves
(300 hours).
12. Change the transmission oil (200 hours).
13. Replace the hydraulic oil filter (200 hours).
14. Perform the 300-hour service at an authorised
service representative.
WARNING!
No service operations may be performed on the engine or cutting unit unless:
• The engine is stopped.
• The parking brake is on.
• The ignition key has been removed.
• The cutting unit is disengaged.
• The ignition cables have been removed from the spark plugs.
!

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DELIVERY AND DEALER SERVICE
Delivery Procedures
To our dealers
A well performed pre delivery service is the first
step towards an active after-sales market.
An active after-sales market benefits everyone:
• The customer will be satisfied with their
machine. They know where to turn in order to
get help if problems arise.
• You gain a regular customer, who
recommends you and your company to other
prospective customers.
• In this way, together we build our brand, and
assume joint responsibility for our products
and our customers.
Be thorough with the paper work.
Fill in the guarantee and delivery documents etc.
and ensure that the customer gets the right
operator’s manual for their machine.
Organise a customer register so that in the future,
you can see which machine the customer owns,
as well as the appropriate serial numbers. The
register is of benefit when you order spare parts
and during future marketing activities.
In conjunction with the delivery, you shall also give
the customer the information required to handle
and maintain their machine in a safe manner.
Remember in particular to inform the customer
about:
• Safety regulations.
• Manoeuvre controls.
• Checking oil levels. Topping up oil and the
type of oil required.
• First oil change after the running in period.
• The need and benefit of following the service
schedule and leaving the machine for regular
service.
• Which fuel is to be used.
• Mowing tips to attain good results. Application
areas for mulching.
• The accessories available for the customer’s
type of machine.
• Guarantee rules.
• Your company and whom the customer
should approach if problems arise.

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DELIVERY AND DEALER SERVICE
Packaging and Unpacking
The machine is normally packed using
special packaging when delivered from the
factory. This packaging is comprised of a
wood base with a strong cardboard top
section, all held together with plastic
wrapping.
The base is fitted with pallet feet and the
goods can be handled with a normal forklift
truck from the long side. In order to keep the
goods as flat as possible, two people ought
to help the truck driver. Lift and then drive the
truck carefully.
Break the plastic wrapping and remove the
cardboard packaging.
The machine then stands on the base with
the brakes on and is secured with wooden
blocks.
Check that the machine has not been
damaged during transport when the
packaging is opened. Any damage should be
reported to the transport company as per
routine.
The packaging shall not be returned.
Lifts from the short side, see illustration,
require long pallet forks.
Packed Components:
NumberComponent
1 pc Steering wheel with steering rod
1 pc Allen screw for steering rod
1 pc Lock nut for steering rod
1 pc Operator’s Manual
1 pc Owner’s Manual, Briggs & Stratton
4 pcs Wheels (certain markets)
WARNING!
Handle the transport box carefully.
Keep the goods as flat as possible.
Use long forks to lift from the short
side.
!
Long pallet forks are required

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DELIVERY AND DEALER SERVICE
Battery
Charge the battery with 12 V, max. 3A, for
four (4) hours.
Fit the battery.
Connect the battery with the nuts and bolts
that are attached to the battery. Counter the
bolts when fitting so that the electrodes are
not strained.
• The black cable connects to -.
• The red cable connects to +.
Ensure that the cables do not chafe against
anything.
Fit the cover on the battery and tighten the
strap.
Arm Supports
In those cases where arm supports are
delivered with the machine, it is the dealer’s
responsibility to fit them.
Steering Wheel
• Fit the steering wheel with the steering
rod on the steering column. Choose a
suitable height position.
• Thread the Allen screw into the thread of
the steering column. Work the wheel and
tighten the Allen screw so that it reaches
the bottom of the thread.
• Fit the lock nut to the Allen screw.
WARNING!
Actions with acid contact
External:
Rinse thoroughly with water.
Internal:
Drink large quantities of water or
milk. Contact a doctor as soon as
possible.
Eyes:
Rinse thoroughly with water. Con-
tact a doctor as soon as possible.
The battery emits explosive gases.
Sparks, flames, and cigarettes
must not be present in the vicinity
of the battery.
!
Connecting the battery
Fitting the steering wheel

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DELIVERY AND DEALER SERVICE
Towing Eye and Counterweight
Fit the counterweight on the rear bumper
when supplied separately.
The tow hook is fitted the ”wrong” way at the
factory for transport reasons. Fit the tow hook
to the back of the bumper as illustrated.
Checking the Engine Oil Level
Check the oil level in the engine when the
Rider stands horizontal with the engine
switched off.
Open the engine cover.
Loosen the dipstick and pull it out. Wipe off
the dipstick and fit it again.
The dipstick shall not be screwed into place.
Pull out the dipstick and read the oil level.
The oil level should be between the markings
on the dipstick. If the level is approaching the
”ADD” mark, top up the oil to the ”FULL” mark
on the dipstick.
The oil is topped up through the hole the
dipstick sits in.
Use an engine oil with a viscosity indicated in
the chart, class SF-SJ.
Fitting the tow hook
Dipstick
Oil level
Viscosity chart