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Primo 2008
Workshop Manual
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Stiga Primo 2008 Workshop Manual

Edition Manual Chapter Page 2005-05-04 Workshop Manual, Stiga Park 1 General instructions 1
Workshop
manual
Primo 2008
1 General instructions
Contents in this chapter
General
This Workshop Manual is intended for Stiga Primo model 2008. This Manual do not cover repair instructions for the motor. Regarding the motor, see the
motor manual. This Manual and its specifications are valid for machines in their original design. In case of modified or changed machine, i.e. the motor is replaced, the manual accordance is limited.
The manual is divided in the following chapters:
Chapter 1 is this chapter Chapter 2 Chassis Chapter 3 Steering Chapter 4 Belts Chapter 5 Electrical system Chapter 5 Cutting deck
1.4 Unpacking and assembly......... 5
1.4.1 Unpacking.............................. 5
1.4.2 Battery ................................... 6
1.4.3 Assembly............................... 7
1.4.4 Final checks........................... 9
1.4.5 General tightening torque...... 10
1.5 Instructions for use .................. 10
1.6 Raising....................................... 11
1.6.1 Raising back.......................... 11
1.6.2 Raising front........................... 11
1.7 Turning upsidedown................. 12
1.7.1 Preparing............................... 12
1.7.2 Draining the petrol ................. 12
1.7.3 Seat with its plate................... 12
1.7.4 Motor hood............................. 13
1.7.5 Motor oil................................. 13
1.7.6 Petrol tank.............................. 13
1.7.7 Turning................................... 13
1.7.8 Restoring the machine on its
wheels.................................... 13
1.1 Introduction................................2
1.1.1 Responsibility declaration.......2
1.1.2 How this manual is used ........2
1.2 Safety Precautions ....................2
1.2.1 Before service or maintenance2
1.2.2 Symbols and general
warnings.................................3
1.2.3 Warm parts.............................3
1.2.4 Moving parts...........................3
1.2.5 Lifting and blocking up............3
1.2.6 Cleanliness.............................3
1.2.7 Tightening torque ...................3
1.2.8 Sharp edges...........................3
1.2.9 Replacement parts.................3
1.2.10 Inspection.............................3
1.3 Guarantee...................................4
1.3.1 Guarantee period ...................4
1.3.2 Exeptions................................4
1.3.3 Conditions for validity of the
warranties...............................4
1.1 Introduction
1.1.1 Responsibility declaration
In spite of the great care we have taken there may be errors in this publication. The author cannot be made liable for incorrect or missing information. GGP SE reserves the right to regularly change product specifications without prior notice. All the information in this book is based on the information available at the time of production. Illustrations and photographs may be arranged schematically, which implies that one picture may cover several models and therefore not correspond exactly with all models.
1.1.2 How this manual is used
To make this manual easy to understand we have divided the machine into its main systems and components. These parts are now the different chapters in the book. Each chapter is divided up into sections. There is a quick-guide on the cover of this book, which refers to the different chapters. In each chapter there is a detailed table of contents so that you can easily and quickly find what you are looking for.
1.2 Safety Precautions
This manual has been written primarily for trained mechanics working in a well-equipped workshop. Nevertheless, the manual contains such detailed information that it can also be of use to owners who wish to carry out simple service and repairs on their machine. A basic knowledge of repairs, tools and repair instructions is, however, always a prerequisite for first-rate results.
A qualified mechanic should always be consulted if the owner does not have sufficient knowledge to carry out repairs.
During the warranty period all service must be carried out by an Authorised Workshop for the warranty to be valid.
The following basic points should be observed if the machine is to function perfectly:
• Follow the service schedule.
• Be on the alert for sudden vibrations or abnormal noise to avoid major breakdowns.
• Always use Genuine Spare Parts
• Follow the descriptions in this manual carefully. Do not take any short cuts.
1.2.1 Before service or maintenance
Before service or maintenance is carried out, the mesures below shall be performed:
• Prevent the machine from rolling by always applying the parking brake.
• Prevent unintentional starting of the engine by removing the ignition key.
• All service and all maintenance must be carried out on a stationary machine with the engine switched off.
1.2.2 Symbols and general
warnings
Warning! This symbol indicates a risk of
personal injury or damage if the instructions are not followed.
Note! This text indicates a risk of damage to the material or risk of unnecessarily complicated work if the instructions are not followed.
1.2.3 Warm parts
Please observe that engine and exhaust system picks up a lot of heat during use.
T o avoid injuries, allow the machine to cool before any kind of repairs are made to or near parts of the engine or exhaust system.
1.2.4 Moving parts
The machines are all equipped with v-belt transmissions. Always stop the engine and remove the starter key before inspections or repairs are carried out. Always use extreme caution when testing systems with moving parts to avoid injuries.
Always use Genuine Spare Parts during service work.
1.2.5 Lifting and blocking up
Before work under the machine, always make sure that lifting devices and jack­stands are approved for the weight. Work safe!
1.2.6 Cleanliness
Clean the machine before starting repairs. Dirt that penetrates into sensitive components can seriously influence the service life of the machine.
1.2.7 Tightening torque
Unless otherwise stated the tightening torque in the tables in the section Technical specifications must be used for the different sizes of screws. This does not refer to self-tapping screws, which are mainly used for the assembly of body parts.
1.2.8 Sharp edges
Watch out for sharp edges, especially when working with the mower deck. The blades can be very sharp. Always wear gloves when working with the blades.
1.2.9 Replacement parts
Always use Genuine Spare Parts during service work.
1.2.10 Inspection
Each part dismantled in conjunction with service work must be inspected. Examine for: wear, cracks, out of roundness, straightness, dents, discolouring, abnormal noise and jamming.
1.3 Guarantee
1.3.1 Guarantee period
For consumer use: two years from date of
purchase.
1.3.2 Exeptions
The extended warranty does not cover damage due to the following:
• Neglect by users to acquaint themselves
with accompanying documentation.
• Carelessness.
• Incorrect and non-permitted use or
assembly.
• The use of non-genuine spare parts.
• The use of accessories not supplied or
approved by the manufacturer.
Neither does the warranty cover:
• Wearing components such as blades,
belts, wheels,battery and cables.
• Normal wear.
• Engine and transmission. These are cov-
ered by the respective manufacturer’s warranties, with separate terms and con­ditions.
The purchaser is covered by the national laws of each country. The rights to which the purchaser is entitled with the support of these laws are not restricted by this warranty.
1.3.3 Conditions for validity of the
warranties
The fully completed warranty card must be sent to Stiga´s subsidiary or distributor.
1.4 Unpacking and assembly
Every Stiga machine has undergone an extensive control programme before delivery. The machines are delivered as completely assembled as possible. Thanks to this the assembly on delivery is rapid and easy. The correct and careful assembly of the machine on delivery is a simple way of ensuring satisfied customers!
Note! The machine shall remain placed on the pallet during the unpacking and assembly.
1.4.1 Unpacking
Open up the crate and release the part as follows:
1. Check the air pressure in the tyres. The pressure is designated on the floor mat. The air pressure in the tyres is of critical importance for the performance and handling of the machine. The correct air pressure for mowing is: Front: 1,2 bar (17 psi) Rear: 1,2 bar (17 psi)
Too high pressure in the tyres leads to that the machine drives poor due to:
• A small surface in contact to the ground.
• Hard tyre = less flexibility = self cleaning char­acteristic deteriorate.
2. Remove the following parts from the package and put them on the floor.
• The steering wheel.
• The backrest.
• The plastic bag, containing owners manuals, and assembly screws.
Too high pressure Correct pressure
1.4.2 Battery
The battery is a valve regulated type.
Valve regulated battery
This battery needs limited maintenance. It has no electrolyte levels or plugs.
Warning! Do not wear rings, metallic bracelet,
chain round the neck or similar metal objects when working with the battery. It can cause short-circuit, burns and fire.
Warning! The battery must be fully charged
before being used for the first time. The battery must always be stored fully charged. If the battery is stored while discharged, serious damage will occur.
Charging with the engine The battery can be charged using the engine’s
generator as follows:
1. Install the battery in the machine as shown below.
2. Place the machine outdoors or install an extraction device for the exhaust fumes.
3. Start the engine according to the instructions in the user guide.
4. Allow the engine to run continuously for 45 minutes.
5. Stop the engine. The battery is now fully charged.
Charging using battery charger When charging using a battery charger, a
battery charger with constant voltage must be used.
The battery can be damaged if a standard type battery charger is used.
Installation of battery
Connect first the red cable to plus (+) and then the black cable to minus (-).
If the cables are disconnected/ connected in the wrong order , there is a risk of a short-circuit and damage to the battery.
If the cables are interchanged, the generator and the battery will be damaged.
The engine must never be driven with the battery disconnected. There is a risk of serious damage to the generator and the electrical system.
1.4.3 Assembly
The assembly procedure shall take place in a clean, well illuminated and dry place.
Assemble the machine as follows:
Steering wheel
Install the steering wheel as follows:
1. Install the steering column jacket on the steering column using a drift or similar so that the holes in the steering column jacket and steering column align with each other.
2. Tap in the supplied tension pin from the other side using a hammer.
Backrest
Install the backrest as follows:
1. Fold the seat up towards the steering wheel.
2. Install the backrest with the screws (O) without tightening.
3. Set the backrest to the desired position.
4. Tighten the screws. Tightening torque: 20­24 Nm.
If the screws are tightened more than 24 Nm, the seat will be damaged.
N O
Seat
Adjust the seat backwards/forwards to a comfortable driving position.
The seat can be folded and adjusted front-rear. To adjust the seat, slacken of f the three screws (P), set the seat to the desired position and tighten the screws.
Tightening torque: 20-24 Nm.
If the screws are tightened more than 24 Nm, the seat will be damaged.
The seat is equipped with a safety switch that is connected to the machine’s safety system. This means that certain dangerous activities are not possible when there is nobody sitting on the seat.
Backrest
The backrest can be adjusted laterally and vertically . T o adjust the backrest, slacken off the screws (O), set the backrest to the desired position and tighten the screws. Tightening torque: 20-24 Nm.
If the screws are tightened more than 24 Nm, the seat will be damaged.
Battery
Fold the seat up and install the battery leads. See also“1.4.2”.
Engine oil
Check the oil level in the engine and top up if necessary.
A
P
ON
1.4.4 Final checks
The final check consists of test driving and safety check as described below.
Test driving
Warning! Do not drive without the mover deck
attached. Risk for turning over.
Drive the machine for a few minutes. Test all the functions. Pay special attention to the safety functions. The mower deck must be fitted before test driving the machine.
Listen to abnormal noise or rattle during the test driving.
Safety check
Check the safety functions. It is often appropriate to do this check in conjunction with test driving. The following items shall be checked at all machines:
• No leakage on fuel lines and connections.
• No mechanical damages to the electrical cables. All insulation intact.
• The muffler shall be undamaged and its screws tightened. No exhaust leakage in con­nections.
The electrical check items are listed in the tables below.
Test Status Action Result
1 PTO activated.
No gear activated.
Turn the key and make a start attempt.
Motor shall not start.
2 PTO not activated.
A gear is activated.
Turn the key and make a start attempt.
Motor shall not start.
3 Motor running.
PTO activated.
Operator rises from the seat.
Motor shall stop.
4 Motor running.
A gear activated.
Operator rises from the seat.
Motor shall stop.
1.4.5 General tightening torque
Unless otherwise stated, the following tightening torque are applicable for screws and nuts on the machine:
1.5 Instructions for use
Some procedures, e.g. changing motor oil, motor filter etc., are refered to the instruction for use, delivered with the machine.
The instruction of use is written in 16 languages and divided in two parts. The first part always contains the languages SV, FI, DA, NO, DE, EN, FR and N.
Tightening torques
Thread Torque M5 5 Nm M6 9 Nm M8 22 Nm M10 45 Nm
1.6 Raising
Jacks must only be placed in the designated area. Placing the jack in other locations will damage the machine.
The machine must only be raised on hard, stable and horizontal surfaces. Otherwise there is a risk of the machine dropping.
The machine must never be loaded with further weight when it is raised. Nobody must sit on the machine when it is raised.
1.6.1 Raising back
For certain maintenance work, the rear part of the machine must be raised slightly so that the required rear wheel can be removed. Raise the machine as follows:
1. Position the machine on a hard, stable and horizontal surface.
2. Raise the machine using a jack, see the fig.
1.6.2 Raising front
Note! To raise the machine at the front, the cutting deck must be removed.
Raise the machine at the front as follows:
1. Place the machine on a flat, solid and horisontal ground.
2. Disassemble the cutting deck. See chapter 6.
3. Raise the machine with help of a jack and apply the yokes according to the figure.
For location of jack and yokes, see the figure.
1
1
2
2
1.7 Turning upsidedown
Some service measures are facilitated by turning the machine upsidedown on a work bench.
1.7.1 Preparing
Before the machine is turned, the following items must be disassembled:
• Cutting deck, see chapter 6
• Draining the petrol
• Seat with its plate
• Motor hood
• Motor oil
• Petrol tank
1.7.2 Draining the petrol
Petrol is highly inflammable. Always store fuel in containers that are made especially for this purpose.
Only handle petrol outdoors, and never smoke during petrol handling. Never handle petrol together with a warm or running engine.
1. Place the machine outdoors.
2. Drain the petrol tank by loosening the hose at the fuel cock. Close the hose and insert it in a suitable container until the tank is empty.
3. Start the engine and let it run until it the carburettor is empty and the engine stops.
1.7.3 Seat with its plate
1. Fold up the seat and remove the screws (A).
2. Lift up and remove the seat with the seat plate.
A
A
1.7.4 Motor hood
1. Open the motor hood.
2. Person 1 holds the hood on one side and person 2 holds the other side and removes the screws (B).
3. Lift carefully up the hood and place it on a soft surface.
1.7.5 Motor oil
Drain the motor oil. See the owners manual.
1.7.6 Petrol tank
Loosen the screws holding the crossbar (C) and remove the crossbar.
Loosen the screw (D) holding the tank and battery cage and remove the tank and battery cage with battery.
1.7.7 Turning
Prepare a work bench to place the machine on. Two persons lif t the machine, one person at the
rear and one at the front. Lift and turn the machine 180°. Place it carefully
on the work bench.
1.7.8 Restoring the machine on its
wheels
To restore the machine on its wheels, perform the instructions above in the opposite order.
BB
CD
2 Chassis and body
Contents in this chapter
General
To facilita te the driving, handling of work equipment and to make it comfortable for the driver, the machines are equipped with a various number of aid equipments.
This chapter gives a brief description of the equipments and describes their repair and replacements.
This chapter also contains information about how to repair the plastic chassis including material and threads.
2.3 Lubrication chassis .................... 4
2.3.1 Drive chain............................... 4
2.3.2 Steering cable.......................... 4
2.3.3 Tensioning arms, movable joints5
2.3.4 Throttle cable........................... 5
2.3.5 Bearings................................... 5
2.1 Repair of the chassis...................2
2.1.1 Repair of cracks........................2
2.1.2 Repair of threads......................2
2.2 Wheel............................................3
2.2.1 Adjusting the drive chain (U) ....3
2.1 Repair of the chassis
There are two types of chassis repair:
• Repair of cracks i.e. after interferences etc.
• Repair of threads.
2.1.1 Repair of cracks
Consult the dealer for detailed information.
2.1.2 Repair of threads
A number of screws are threaded direct into the chassis. The screws used are shown in the figure to the right.
Threads for those screws can be repaired as follows:
1. Order a repair kit for threads. See the spare parts list.
2. Drill out the defect thread in the chassis with a 7 mm drill.
3. Screw the thread adapter (A) from the repair kit into the hole with the recess first. The recess is intendet to cut the thread in the plastic material. The thread adapter is screwed in with a screw in its internal thread.
4. Use a csrew M5x25 (B) from the repair kit and fit the actual item.
A
B
2.2 Wheel
For certain maintenance work, it is necessary to remove a rear wheel.
Dismantling:
1. Raise the machine according to chapter 1.
2. Remove the cover disc (A).
3. Use a 17 mm wrench and remove the screw (B) with disc.
4. Pull the wheel from the axle.
Assembly:
1. Slide the wheel onto the axle.
2. Install the screw (B) with disc.
3. Tighten the screw to 40-45 Nm.
2.2.1 Adjusting the drive chain (U)
Check/adjust the belt tension each season as follows:
Check:
1. Raise the machine and remove the right­hand rear wheel. See 6.4.
2. The chain (15:U) must have 5-10 mm of play. Any required adjustment, see blow.
Adjustment
:
Adjust the play by moving the tensioner wheel as follows:
1. Slacken off the nut (15:T) and set the tensioner wheel to the desired position.
2. Tighten the nut and check the play. Adjust again if required.
3. Tighten the nut to 40-45 Nm when adjustment has been completed.
AB
5-10 mm
T
U
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