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Stiga PARK 120 2016, Workshop Manual

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Summary of Contents for PARK 120 2016

Page 1: ...Workshop manual PARK 120 PARK 220 2016 2020...

Page 2: ...l instructions 3 2 Frame and Covers 15 3 Steering wheel 23 4 Hydraulic system 28 5 Belts 31 6 Control cables 43 7 Electrical system 51 8 Mower Decks 66 by STIGA No use of the illustrations or duplicat...

Page 3: ...4 2 Battery 9 1 4 3 Final inspections 10 1 5 Maintenance 11 1 5 1 General safety checks 12 1 5 2 Electrical safety check 12 1 6 Technical data 14 1 6 1 Machine dimensions 14 1 6 2 General tightening...

Page 4: ...r par 2 1 To facilitate consultation of the manual each chapter is dedicated to a specific component There is a table of contents at the beginning of each chapter The cover on the other hand holds a g...

Page 5: ...repair operations must be carried out by expert maintenance mechanics who are familiar with all the safety and accident prevention regulations and have read the procedures described in this manual B...

Page 6: ...f in compliance with the relative legislation in force make sure no one can inadvertently carry out actions which could compromise the safety of the mechanic working on the machine D Tools required Al...

Page 7: ...ts must be kept and made available to the Manufacture together with any replaced parts in the event of complaints from the Customer 1 2 4 Reporting faults Please report any faults which may recur with...

Page 8: ...an external manufacturer and is built to precise technical specifications which distinguish it from similar products made by the same manufacturer The serial number indicated on the label 1 makes it p...

Page 9: ...egulated battery This type of battery requires minimum maintenance It has no caps or electrolyte level controls Warning Never wear metal rings bracelets necklaces or other similar jewellery when worki...

Page 10: ...ttery charger make sure it is a genuine STIGA battery charger The battery will be damaged if other battery chargers are used 1 4 3 Final inspections Interventions before start up Before starting the m...

Page 11: ...adjustment 5 50 12 Steering adjustment Lubrication of the bearings in the articulation 5 50 12 2 3 Lubrication of the shaft on the front wheels and quick connections 50 12 2 3 Engine air filter clean...

Page 12: ...seated Parking brake disengaged Try to start the engine The motor does not start Driver seated Parking brake engaged Try to start the engine The engine starts Engine on cutting device disengaged park...

Page 13: ...ies Check that none of the cables rub against the frame as this could lead to damaged cables and short circuits Check the tightness of the battery terminals 7 Check controls Check that all the control...

Page 14: ...D mm 741 741 E mm 770 770 E1 mm 991 1023 1 6 2 General tightening torques Tightening torques for screws and nuts unless otherwise specified Thread Torque M5 6 Nm M6 10 Nm M8 24 Nm M10 47 Nm 1 7 User g...

Page 15: ...the engine cover 16 2 1 2 Fitting new screw mounts to the engine cover 16 2 1 3 Removing the front covers 17 2 1 4 Removing the belt cover at the centre of the machine 20 2 2 Replacing the link arm 21...

Page 16: ...he engine cover New screw mounts can be mounted on the rear frame if the previous screw mounts are faulty B A C D Remove the faulty screw mount as follows 1 Use a 8 5 mm drill Drill down to the thread...

Page 17: ...the steering wheel A B 1 Slacken the wing nut 2 Lift the steering wheel to uncover the two pins 3 Tighten the wing nut 4 Remove the two pins A from the sleeve B 5 Remove the steering wheel Removing t...

Page 18: ...e pedal screw C Also remove the plastic knob D by pulling it straight up F E 3 Remove the lift pedal screw E Also remove the plastic knob F by pulling it straight up G I H 4 Remove the ignition switch...

Page 19: ...vers remain attached to the casing 7 4 3 Removal of the cover under the seat A 1 Remove the cover A NOTE operate with great care to avoid breaking the tabs on the cover The locking tabs are at the top...

Page 20: ...4 Removing the belt cover at the centre of the machine B C A D F 2x E 2x 1 Remove the engine cover for details 2 1 1 2 Remove the spring A to tension arm from the frame 3 Unscrew the bolt B 13 mm wren...

Page 21: ...ear side of the frame and on the front frame near the arm to ensure it does not roll over Keep it lifted using a jack or wooden planks B A 1 Unscrew the bolt A 17 mm wrench 2 Unscrew the bolt B 17 mm...

Page 22: ...urs of operation as well as after every wash View from the top 2 3 3 4 4 1 Object Action Points Centre point Lubricate with oil on the centre point 1 Steering pulleys Lubricate the pulley hubs with an...

Page 23: ...ly 25 3 1 3 Adjustment 26 3 1 4 Replacing the bushes on the steering shaft 27 General description The machine is fitted with a mechanical steering system Steering power is transmitted by a cable chain...

Page 24: ...the steering wheel 3 1 1 Disassembly Before commencing disassembly operations make a note of the route taken by the cable chain system so that the new components can be installed in the exact same wa...

Page 25: ...ear wheels Check that the wheels are straight and that the mid dle marked link is positioned at the centre of the chain gear wheel if this is not the case take to the straight position 4 Install the t...

Page 26: ...the front pulley 3 Apply a force of 5 7 kg The distance E between the cables should be approximately 45 mm 4 Test drive the machine with the wheels straight and check that the steering wheel is in th...

Page 27: ...he steering wheel remove the pin A 2 Remove the steering chain and cables For further details see 3 1 1 3 Remove the front covers For the relative description see 2 1 3 4 Remove the pin B 5 Take hold...

Page 28: ...air 29 4 4 HST oil 29 4 4 1 General 29 4 4 2 Oil change 30 4 5 Transmission removal 30 4 6 Changing engine oil 30 4 6 1 Checking the engine oil level 30 This chapter contains a brief description of th...

Page 29: ...smitted to the motor by an oil flow Since both the oil flow and the flow direction is controlled by the drive pedal the machine can move both forwards and backwards with a stepless gear ratio 4 3 Repa...

Page 30: ...g a jack or strong wooden planks Warning Check that the machine is supported effectively and safely B 4x A A 5 Remove the rear wheels A 6 Unscrew the 4 screws 4 which hold the transmission in place To...

Page 31: ...iption 34 5 2 2 Drive belts D 35 5 2 3 Operating equipment C clutch belt 36 5 2 4 Operating equipment belt B 40 All the mechanical power provided by the engine is transmitted to the various power user...

Page 32: ...gap between the belt and the bottom of the groove The belt rests its sloping sides against the walls of the pulley There must be a gap between the belt and the bottom of the groove Same requirements...

Page 33: ...reinforced rubber Bending in two directions Designed to bend around the pulley in one direction only Most belts installed on machines have tensioning rollers which act on the outer side of the belt T...

Page 34: ...front pulley 3 The belt is kept tensioned by the tensioning pulley 2 installed on a spring loaded tensioning arm Belt B Belt B is dedicated to transmission from the articulated point to the double fro...

Page 35: ...belt D off the pulley 9 connected to the drive shaft 4 Remove the belt D from the pulley 7 and extract it upwards over the top of the fan Assembly 1 Install the belt D from the front side onto the pul...

Page 36: ...the belts are positioned see 5 2 Disassembly 14 C 13 6 12 2x 1 Remove the engine casing 2 1 1 2 Remove the belt D from the transmission 5 2 2 3 Remove the upper belt casing 12 two screws 4 Remove the...

Page 37: ...olds the cable to the clutch 7 Disconnect the connector 15 from the clutch cable 17 16 8 Remove the clutch stopper 16 by unscrewing the two screws 17 C 10 5 9 Remove the belt from the double pulley 5...

Page 38: ...ge 38 Assembly 14 C 13 6 12 2x 1 Insert the belt C from the front side in the groove on the double pulley and then fitting it on the drive shaft pulley 2 Replace the upper belt casing 12 two screws 17...

Page 39: ...14 13 C 6 Install and tighten the central top bolt 14 and the tensioning arm on the belt C Please note that the tensioning pulley must be positioned on the inside of the belt 7 Install the spring 13...

Page 40: ...ly 18 14 B 12 5 C 19 2x 2x 13 1 Remove the engine casing 2 1 1 2 Remove the spring 13 on the tensioning arm which is dedicated to the equipment clutch belt C 3 Unscrew the central top bolt 14 and move...

Page 41: ...e centre upwards and then slip off the belt B 9 Slip the belt off the front double pulley 3 Assembly 5 3 20 1 Insert the belt from the front and start by fitting it in the top groove 3 of the double p...

Page 42: ...ace the upper belt casing 19 two screws 7 Install and tighten the central top bolt 14 and the tensioning arm on the belt C Please note that the tensioning pulley must be positioned on the inside of th...

Page 43: ...tment 47 6 4 Brake cable 47 6 4 1 Disassembly 47 6 4 2 Assembly 48 6 4 3 Adjustment 48 6 5 Accelerator cable 49 6 5 1 Disassembly 49 6 5 2 Assembly 49 6 5 3 Adjustment 50 General description All mecha...

Page 44: ...d or elbow unions The cables can only transmit traction force The return force is generated by the springs For a higher transmission of pushing and traction forces components such as levers brackets e...

Page 45: ...2 Using a screwdriver or similar tool remove the ball pin B from its seat C 3 To reassemble the various parts repeat the operations in reverse order The ball pin B must be inserted into its seat C usi...

Page 46: ...f how the cables and cables ties are connected to ensure that the new components are rein stalled in exactly the same way 5 Remove the elbow connectors from the cable Caution The bodies of the elbow c...

Page 47: ...ecessary adjust the rear elbow connector located on the pump 6 4 Brake cable Danger NEVER use the machine if the brakes are faulty Caution The parking brake must not be used as an operating brake and...

Page 48: ...to reassemble 3 Install new cable ties 4 Adjusting the cable 6 4 3 6 4 3 Adjustment Danger NEVER use a machine with faulty brakes Caution Check that the cables are slack when the parking brake is not...

Page 49: ...the seat B 4 Disassemble the accelerator control B 5 Pull the accelerator control back and the cable until it comes out from under the plastic cover 6 Detach the cable unit from the accelerator contro...

Page 50: ...ent 120 220 A A 1 Adjust the cable sheaths on the terminals until the accelerator lever reaches the end of stroke position 2 Tighten the clamps A of the sheaths 3 Check the following Operation of the...

Page 51: ...ng switch controls 62 7 4 5 Connections 63 7 4 6 Removing the battery 63 7 5 Control panels 64 7 6 Wiring diagram 65 General description The electrical system has two primary functions To maintain the...

Page 52: ...circuit when a prohibited action is to be carried out The wiring diagram must be read for full understanding of the electrical system of a special machine model All power apart from the starting circ...

Page 53: ...t be charged All cables shall be OK All connections shall be OK The conditions for carrying out a procedure must be met For example if the engine is to be started the operator must be sitting on the s...

Page 54: ...ake switch NOT Change the ignition switch YES Is there voltage at the start relay NOT Change the parking brake switch YES Is there ground at the start relay YES Change the start relay NOT Change the s...

Page 55: ...ace ignition switch Change the battery Is the engine electrical connections OK NOT Repair the fault YES Replace the charge regulator The engine does not stop Does the engine stop when the work equipme...

Page 56: ...ge the seat switch Black You can not start the blades Is it possible to start the blades if you short out the connector cables to the lifting switch YES Change the lifting switch NOT Is it possible to...

Page 57: ...ic cables 7 3 1 Description In this section the workshop manual will display the cables for both machines to increase the understanding of the electrical system and also explain what the various conne...

Page 58: ...e PTO switch Brake pedal Lift pedal Start relay PTO relay Safety relay 1 Charging 2 Ignition 3 Fuel valve Engine Ground on engine MAG clutch Start relay Battery charging 3 2 1 8 6 5 4 7 A1 B M S G 1 2...

Page 59: ...G 1 2 PTO relay Safety relay Start relay MAG clutch Start relay Battery charging 1 2 3 1 Charging 2 Ignition 3 Fuel valve Engine 3 2 1 8 Ground on engine Cutt heigt switch PTO switch 6 5 4 7 3 2 1 8 6...

Page 60: ...ets necklaces or other similar metal items when working with the machine electrical system It can lead to short circuits or fires 7 4 1 Relay positions The relays are located under the engine cover in...

Page 61: ...of the fuse that may be installed If a higher current fuse is installed there is a risk of fire damage to the machine The machine is equipped with one fuse The fuse is located under the machine engine...

Page 62: ...igure The switches are pressed into place in their respective rectangular holes in the control panel To change a switch follow the procedure below 1 Remove the relevant protection to make the switch a...

Page 63: ...nnectors may require special tools for removal Warning No metal from the cable may be visible outside the screw connection Too long stripped cables can cause short circuits or fires 7 4 6 Removing the...

Page 64: ...s A Torx T30 3 Remove the battery To reassemble the various parts repeat the operations in reverse order 7 5 Control panels A1 A2 Switch A1 The switch can be used to smoothly set the cutting height of...

Page 65: ...Edition 2016 Workshop Manual PARK 120 PARK 220 Chapter 7 Electrical system Page 65 7 6 Wiring diagram...

Page 66: ...permanent lubricated ball bearings All decks are provided with a quick coupling to simplify the lifting up procedure for cleaning and inspection and The decks are also provided with an electrical or...

Page 67: ...ility test a lawn mower can be subject to An iron pipe is placed right into the blades during operation The blade can be deformed but it may not under any circumstances come off or split This test ver...

Page 68: ...lades and remove the blades 3 After removing the blades check whether the shafts are damaged This is best done by rotating the shafts to see if they are out of true 8 2 2 Assembly C B B C 45 Nm 1 Fit...

Page 69: ...A use a 17 mm spanner to hold the blades 90 5 Reinstall the blades at 90 to one another NOTE The blades can be turned 1 3 of a turn in their mountings Select positions so that the blades are offset 90...

Page 70: ...g between gear wheels and blade shaft See Synchronising blades 8 5 2 Check the two blade shaft bearings as follows Grab the pulley and force it in the radial direction No radial play shall be felt Gra...

Page 71: ...per the table below in the middle of the belt The belt shall move 10mm or 12mm in according to the table If not loosen the bearing housing and repeat step 1 2 above until the movement is 4 OK Timing...

Page 72: ...e figure A The blades A can be turned 1 3 of a turn in their mountings Select positions so that the blades are offset 90 from each other If the blades are not synchronised one or more of the following...

Page 73: ...ket on the machine 2 Remove the shaft stop washers A 3 Extract the pins B and remove the drive unit To reassemble the various parts repeat the operations in reverse order 8 7 Replacement of the spring...

Page 74: ...STIGA S p A Via del Lavoro 6 31033 Castelfranco Veneto TV Italy www stiga com...

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