Stiga T 102 Series Workshop Manual Download Page 81

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WORKSHOP MANUAL

T...102/122 - TC...102/122

Map of functional units

Validity

General informations

Related topics

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ELECTRICAL DIAGRAMS

CHAPTER

REVISION

FROM ...

PAGE

7.20

2018

1 of 1

AVV

+Bt Mot.Avv

GND

c d e

a
b

BK
BK

19a 19b

NC - 3

NO - 2 C

NO - 2

NC - 3

BK
BK

Engines: B&S - GGP - Kawasaki

Electronic Card

Engine

2a Generator

2b Starter

2c Engine stop

2d Carburettor

2e Oil

Battery

Starter relay

Key ignition switch

Brake microswitch

Grasscatcher microswitch

Microswith operator present

Neutral microswitch

Grass-catcher full microswitch

Recharge connector

Lights switch

Light

Blade microswitch (if fitted)

Clutch switch

Clutch

Fuel tank

19a

10 A Fuse

19b

25 A Fuse

Reverse consent button

Reverse gear microswitch

CABLE COLOURS

Black

Blue

Brown

Grey

Orange

Red

Violet

Yellow

White

Summary of Contents for T 102 Series

Page 1: ...rformed by individuals or inadequate facilities The Manufacture reserves the right to make any im provements to the product of a technical or commercial nature that may be necessary There maybe theref...

Page 2: ...f the re lationship between the manufacturer and the ser vice centres A close collaboration between the manufacturer and the service centres is conclusive for solv ing problems in the most effective w...

Page 3: ...NT Specific procedures or information necessary to avoid damage to the machine or equip ment WARNING Non observance will result in the risk of injury to oneself or others DANGER Non observance will re...

Page 4: ...burettor 6 9 INDEX OF FUNCTIONAL UNITS Engine Fuel Tank Validity General informations Different fittings are foreseen for this machine which can imply the use of different engines with in the same Thi...

Page 5: ...l is recommended for information regarding servic ing disassembly and replacement of compo nents Related topics 1 1 Identification of components RELATED TOPICS Adjustments and tuning Brake adjustment...

Page 6: ...semblies Removal of the collector channel 5 3 Removal of the cutting deck 5 7 Repairs Replacement of the blades control belt 6 6 Replacement of the blades connection belt 6 7 Replacement of the suppor...

Page 7: ...ng allowance adjustment 4 6 Steering geometry adjustment 4 7 Removal of external parts and main assemblies Repairs Dismantling of the steering components 6 3 Validity General informations Related topi...

Page 8: ...xcept for instructions provided for each specific outfitting recognisable accord ing to the type of dashboard installed on the ma chine Related topics RELATED TOPICS Adjustments and tuning Removal of...

Page 9: ...ED TOPICS Information and Verifications Troubleshooting of the electrical system 7 1 7 11 Cutting in of the safety devices 7 2 7 12 Safety microswitches operation check 7 3 7 13 Terminal board supply...

Page 10: ...eet when requests are made un der guarantee and are indispensable for spare part orders 2 Transmission Rear axle The hydrostatic transmission unit is made up of a block including the rear axle This un...

Page 11: ...the parts in ca se of any subsequent disputes with Customers D Fault notification The Manufacturer welcomes any notifications of faults that recur with particular frequency It gives the oppor tunity...

Page 12: ...lute the environment with oil petrol or other waste and dispose of all waste in ac cor dance with the laws in force A Qualification of operators All maintenance disassembly and repairs must be car rie...

Page 13: ...ut actions that may physically endanger those working on the machine D Necessary equipment All the operations can be carried out with the tools nor mally used in a good garage Some operations require...

Page 14: ...2 Blocks H 32 mm for adjusting the cutting deck 3 Bush for assembly of blades bearings 4 Stopper for assembly of wheel bearings 5 Pulley extractor 6 Pulley centre distance checking template 7 Blades c...

Page 15: ...bles A Front Once the parking brake has been en ga ged the ma chine can be lifted using a jack which pushes on the underside of the frame placing a wood block 1 be tween the base of the jack and the f...

Page 16: ...coming mi saligned and failing to work correctly A Fitting snap rings One side of the Benzing snap rings 1 has a round ed edge and the other a sharp edge For maximum grip the rounded part needs to be...

Page 17: ...r hold so they should never be reused On assembly make sure it is inserted in the right di rection and push the fastener 7 onto the pin using a pipe or socket spanner 8 with the right diameter so that...

Page 18: ...wo ways A Tuning the machine whenever possible B Proposing a regular maintenance pro gramme to the Customer to be carried out at prearranged intervals for example at the end of the summer or prior to...

Page 19: ...n the tank Top up Dirty or old fuel Empty the fuel tank and add fresh fuel Clogged carburettor filter Check and clean Black exhaust fumes Excessively oily carburetion Check the starter and command cab...

Page 20: ...rake is not adjusted correctly Check and adjust 4 2 Hydrostatic unit failure Check the Manufacturer s Instruction Manual The machine will not move in either direction Pulley splines broken Replace Hyd...

Page 21: ...ded In short this means that the blades are suitable for the shape of the casing and to the number of revolutions to provide the best possible cutting result 3 Cutting deck Problem Probable cause Solu...

Page 22: ...ma chine as follows A 113 115 mm for mod 102 A 90 91 mm for mod 122 NOTE The hook position of the spring 2 on the plate 3 is different for the model 102 hole 3a and the model 122 3b the only hole on t...

Page 23: ...asured from the inside of the washers When the adjustment has been made tighten the nut 1 NOTE Never go under these amounts to avoid over loading the brake unit WARNING When the adjustments have been...

Page 24: ...nformations If it seems that the forward drive is not working pro perly after a long period of use or after repla cing the belt this may be caused by a change in the length of the belt A loose belt re...

Page 25: ...l in the forward neutral and re ver se positions make sure that the push button clicks at every position change before the wheels start moving A Adjusting the pedal in the neutral position Adjustment...

Page 26: ...riginal position was lost during cut ting deck replacement and the correct distance from the engine pulley must be reset Check the tyre pressures If one or more tyres have been replaced or you find di...

Page 27: ...to obtain the same meas urement so that the outlet is perfectly centred with respect to the collector channel then fully tighten the nuts 8 and locknut 9 NOTE It is very important that distance B is...

Page 28: ...g up the two reference points punched on them Check that the movement is not caused by loose linka ge nuts and tighten all the nuts of the tie rods and ball joints If the movement is due to the ring g...

Page 29: ...oints 1 of the wheel connection rod 2 If a different distance is found dismantle one or both the joints and screw or unscrew them on the rod 6 as much as necessary On assembly fully tighten the locknu...

Page 30: ...ing di rection of the central screw 1a 1b of each blade To check the alignment of the blades one of them must first be re moved and refitted af ter having re mo ved the shaft key 2 to permit independe...

Page 31: ...the rotation of the other A Removing and reassembling For removing a blade it must be firmly held and the cen tral screw 1 undone bearing in mind that the screw on the left blade 1a is unscrewed anti...

Page 32: ...m the rounded side removing as lit tle material as possible The blade is to be replaced when the cutting edge has worn down to 10 mm Using the appropriate equipment check the ba lance to make sure tha...

Page 33: ...d disconnect the connector to the lights 1 The hood can be secured in two ways A Fixing with springs Unhook the two fastener springs 2 and pull out the pins 3 REMOVAL OF FRONT HOOD CHAPTER REVISION FR...

Page 34: ...uits are not caused first discon nect the black cables earth then the red cable posi tive and remove the battery 2 Remove the caps 5 from the springs and undo the screws inside 6 Remove the seat after...

Page 35: ...L T 102 122 TC 102 122 On reassembly ensure that the two side tabs 11 of the cover are correctly inserted into the housings in the footboards REMOVAL OF THE WHEEL COVER CHAPTER REVISION FROM PAGE 5 2...

Page 36: ...uits are not caused first di sconnect the black cables earth then the red ca ble positive and remove the battery 2 Remove the caps 5 from the springs and undo the screws inside 6 Remove the seat after...

Page 37: ...L T 102 122 TC 102 122 On reassembly ensure that the two side tabs 11 of the cover are correctly inserted into the housings in the footboards REMOVAL OF THE WHEEL COVER CHAPTER REVISION FROM PAGE 5 2a...

Page 38: ...convey or at each cutting deck height variation REMOVAL OF THE COLLECTOR CHANNEL Validity General informations Removing the collector channel gives access to the small side wheels of the drive belt t...

Page 39: ...his point it is possible to remove the dashboard which is fixed to the frame by four self threading screws 3 and 4 NOTE The screws 3 are covered by pla stic caps on some models On reassembly on some m...

Page 40: ...remove the steering wheel 1 Unscrew nut 5 and dismantle the ignition key block 6 without disconnecting the electric cables to pre vent reassembly errors Models with cruise control Loosen the screw 7 a...

Page 41: ...ectrical con nections and the starter cable where present The dashboard 13 can be removed at this point it is fix ed to the chassis by two upper screws 14 co vered by plastic caps and three lower scre...

Page 42: ...smission belt for easier access to the parts involved this is done by slackening the stretcher Disconnect the connector 5 unhook the check spring 6 from the clutch side and undo the central screw 3a r...

Page 43: ...of differ ent length and in different positions so it is best to label them so that no errors are made on reassembly On reassembly fully tighten the screws for the en gi ne and the pulley to the amoun...

Page 44: ...e pulley 3 so overcoming the resistance of the stretcher on the jockey pulley Validity General informations The rear axle Transaxle is made up of a single maintenance free sealed unit which includes t...

Page 45: ...erse for re as sem bly avoiding to fully tighten the nut 16 so that cor rect movement of lever 18 is guaranteed REMOVAL OF THE REAR AXLE Tuff Torq K46F CHAPTER REVISION FROM PAGE 5 6 0 2018 2 of 2 Che...

Page 46: ...r blade shafts With some practice and experience it is possible to do this work with the deck still in position Related topics 4 5 Aligning the cutting deck 5 3 Removal of the collector channel REMOVA...

Page 47: ...ecessary to check the pressure and to check the alignment of the cutting deck ATTENZIONE Replace distorted wheel rims as they could impair the tyre s hold B Wheels The wheels are held by a snap ring 1...

Page 48: ...the opposite side and struck with a hammer around various points of the in ner circumference of the bearing The new bearing must be fitted with the help of a pla stic mallet or of a bronze pad 3 that...

Page 49: ...ce Unhook the spring 1 and lift the steering column 2 just enough to be able to draw out the pinion 3 A Dismantling the steering pinion and ring gear Remove the tie rod 6 unscrew the nut 4 and take ou...

Page 50: ...the correct a lign ment and regular ro tation of the steering wheel column When reassembled Check the steering geometry During assembly please note that to replace both the ring gear teeth and pinion...

Page 51: ...annel It is advisable to slacken the transmission belt to work on the parts involved more easily This is done by slackening the stretcher Dismantle the drive pulley 1 and the stretcher pulley 2 fixed...

Page 52: ...The small side wheels 1 are fixed to the frame by a nut 2 with a spacer 3 between which is of differ ent height 3a or 3b depending on the assembly po si tion When reassembling you should bear in mind...

Page 53: ...on to obtain greater access then dismantle the upper casing 4 and almost totally undo the nut 5 without dismantling the jockey pulley 6 so that the belt can be re moved Keeping the blade locked undo t...

Page 54: ...oad the spring 2 Dismantle the upper casing 3 undo screw 4 and di smantle the control pulley 5 undo the articulation screw 6 and remove the stretcher plate 7 Remove the protection casing 8 slackening...

Page 55: ...n reassembly check that the washer under the pin 11 is not damaged and that the outer pin rol lers run freely Use the specific tool 15 to check the piston 16 for the belt give values and the force app...

Page 56: ...ice and experience it is possible to dismantle the deck supports without removing the cutting deck Remove the blade control belt Remove the blade connection belt Remove the blades and take off the hub...

Page 57: ...g to the support axes must meet perfectly in the centring step 15 cut into the up per part of each support Reassemble the blades Reassemble the blade connection belt Reassemble the blade control belt...

Page 58: ...with the wire On reassembling put the accelerator lever in the MI NIMUM position connect the end of the cable 2 to the terminal 3 on the engine after having mo ved the cursor 5 in the same MINIMUM pos...

Page 59: ...ht 10 A fuse blown Replace fuse 10 A Battery terminal crossed Check connections CHAPTER REVISION FROM PAGE 7 1 0 2018 1 of 3 TROUBLESHOOTING OF THE ELECTRICAL SYSTEM Validity General informations In t...

Page 60: ...have the correct gap 5 The starter continues to turn after engine has started and does not stop when the key is removed Mechanical difficulties with the contact breakers of the starter relay Replace t...

Page 61: ...eck all the micros witches and the relative wiring 11 The 10 A fuse cuts in Short circuit or overload on the power side of the card ignition block starter relay headlamps and recharger connector Find...

Page 62: ...A STARTING START position The engine DOES NOT start when Operator Absent Grass Catcher Blades Engaged Drive Engaged Parking Indication on the Dashboard B WHILE CUTTING The engine STOPS start when Ope...

Page 63: ...t with the contacts of circuit board connector 3 and the contact 6 CN2 of the card CHAPTER REVISION FROM PAGE 7 3 1 2018 1 of 1 Validity General informations Related topics SAFETY MICROSWITCHES OPERAT...

Page 64: ...0 20 with the black ferrule on ter minal 17 and the red one on terminal 18 of the CN4 connector 1 of the wiring The key in the ON position The reading shows the battery voltage which should never go b...

Page 65: ...TOR SOLENOID VALVE OPERATION CHECK All the connectors must be connected to make this check When the key is set to ON a click must be heard from the carburettor solenoid valve coil CHAPTER REVISION FRO...

Page 66: ...ridge between the terminals 11 CN3 and 18 CN4 of the wiring connectors 1 the click of the relay bobbin should be heard and the starter mo tor should come into action only with B S and Tecumseh engines...

Page 67: ...part of the clutch due to exci tation of the electric winding If this does not occur check the wiring and the o peration of the control push button and ensure that the card is operating correctly The...

Page 68: ...off Fuel warning light Terminals 6 4 on Neutral warning light Earth 8 off C Self resetting protection operation check For this test put everything in the same situation as in point A On connecting te...

Page 69: ...d Carburettor 2e Oil 3 Battery 4 Starter relay 5 Key ignition switch 7 Brake microswitch 8 Grasscatcher microswitch 9 Microswith operator present 10 Neutral microswitch 11 Grass catcher full microswit...

Page 70: ...contact Check and clean the connections c after several minutes use Poor or missing earth contact on the charge regulator Check the earth connections and the screws fastening the regulator Overvoltage...

Page 71: ...rter continues to turn after engine has started and does not stop when the key is removed Mechanical difficulties with the contact breakers of the starter relay Replace the starter relay Starter works...

Page 72: ...heck all the micros witches and the relative wiring 12 The 10 A fuse cuts in Short circuit or overload on the power side of the card ignition block starter relay headlamps and recharger connector Find...

Page 73: ...ING The engine STOPS start when Operator Absent Absent Absent Seated Grass Catcher Missing Fitted Blades Engaged Engaged Engaged Engaged Drive Engaged Reverse Consent Button Released Parking Engaged I...

Page 74: ...3 4 12 13 14 15 16 17 18 19 20 11 3 4 5 6 7 8 9 10 1 2 CN2 CN1 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 2 3 4 12 13 14 15 16 17 18 19 20...

Page 75: ...on terminal 11of the con nector 1 of the wiring The key in the ON position The reading shows the battery voltage which should never go below 11 Volts 1 2 3 4 12 13 14 15 16 17 18 19 20 11 3 4 5 6 7 8...

Page 76: ...this check When the key is set to ON a click must be heard from the carburettor solenoid valve coil 1 2 3 4 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 CN2 CN1 Validity General informations Rel...

Page 77: ...nd 4 of connector CN1 of the wiring 1 the relay bobbin must be heard to click and the starter must start If the bobbin clicks but the starter does not start make a bridge 2 with a large section cable...

Page 78: ...he clutch due to excitation of the electric wiring If this is not so check the operation of the cabling and control switch The clutch must be replaced if engagement does not take place after these che...

Page 79: ...2 output cabling terminals When one of the two keys is pressed the instrument reading shows the battery voltage positive or nega tive this value must never fall below 11 5 Volts If no power is detect...

Page 80: ...ut this o pe ration Use a screwdriver to remove the flat battery 1 Only use 3 Volt 24 mm batteries of types CR 2450 or CR 2430 When fitting the new battery make sure that the end marked faces towards...

Page 81: ...OR BK NC 3 NO 2 C VI VI NO 2 NC 3 C BL BL 24 23 BK BL BL BK BK BK BR BR BK BK BK BK BK BK BK BK BK NO 15 BL BL Engines B S GGP Kawasaki 1 Electronic Card 2 Engine 2a Generator 2b Starter 2c Engine sto...

Page 82: ...t means that the regulator is charging too much and must be replaced The job of the voltage regulator is to supply a flow of current to the battery at a constant voltage of about 14 15 Volts cutting i...

Page 83: ...ge at least 12 24 hours after recharging A General information In a sealed dual battery the electrolyte for each el ement is carefully measured out during manufacture and sea led at source in order to...

Page 84: ...to func tion correctly it is important to follow the exact assem bly positions by re ferring to the drawings that indicate the various usages of each type A Free B Activated Validity General informat...

Page 85: ...m 6 Screw for blade 45 50 Nm Every section in this manual gives values for all the com ponents involved in each operation B Adjustments TIGHTENING TORQUES AND ADJUSTMENTS SUMMARY CHAPTER REVISION FROM...

Page 86: ...8 1 of 1 BELTS ASSEMBLY Validity General informations Tightening torques 6 4 Replacement of the drive belt 6 6 Replacement of the blades control belt 6 7 Replacement of the blades connection belt 1 Dr...

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Stiga T 102 Series, Workshop Manual

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