Stiga VILLA 2005, VILLA 2001, VILLA 2002, VILLA 2003, VILLA 2004 Workshop Manual
...
WORKSHOP MANUAL
VILLA 2000-2019
Edition Manual Chapter Page
2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 1
1 General instructions
Contents in this chapter
1.1 Introduction ...............................2
1.1.1 Responsibility declaration ......2
1.1.2 How this manual is used .......2
1.1.3 Abbreviations .........................2
1.2 Safety Precautions ...................2
1.2.1 Symbols and general
warnings .................................3
1.2.2 Warm parts ............................3
1.2.3 Moving parts ..........................3
1.2.4 Lifting and blocking up ...........3
1.2.5 Cleanliness ............................3
1.2.6 Tightening torque ..................3
1.2.7 Sharp edges .......................... 3
1.2.8 Replacement parts ................3
1.2.9 Inspection ..............................3
1.3 Guarantee ..................................4
1.3.1 Component guarantee,
chassis .................................. 4
1.3.2 Exeptions ..
1.3.3 Conditions for validity of
the warranties ........................ 4
1.4 Unpacking and assembly ........ 5
1.4.1 Unpacking ........
1.4.2 Battery .................................. 6
1.4.3 Assembly .............................. 7
1.4.4 Final checks .......................... 9
1.5 Service ...................................... 10
1.5.1 First Service ........................11
1.5.2 Intermiadate Service ........... 11
1.5.3 Basic Service ...................... 12
1.5.4 Description of service points. 13
1.6 Technical specifications ........... 16
1.6.1 General tightening torque ...... 16
............................ 4
..................... 5
General
This Manual do not cover repair instructions for the motors. Regarding motors, contact the
respective representative in the actual country.
This Manual
modified or
The manual is divided in the following chapters:
Chapter 1 is this chapter
Chapter 2 Chassis
Chapter 3 Steering
Chapter 4 Hydraulic system
Chapter 5 Belts
Chapter 6 Control Wires
Chapter 7 Electrical system
and its specifications are valid for machines in their original design. In case of
changed machine, i.e. the motor is replaced, the manual accordance is limited.
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2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 2
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.
For example, if you are looking for information on the Accessory Lifter you will find this in
chapter 3, Chassis and Body. On the first page in chapter 3 there is a detailed table of
contents which refers to the correct section, in this case section 3.1.
Always check that you are reading the right chapter for your particular machine before
starting the repair work.
1.1.3 Abbreviations
The following abbreviations are used in this manual:
HST Hydrostatic Transmission PTO Power Take Off
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.
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2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 3
1.2.1 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.
1.2.2 Warm parts
Please observe that engine and exhaust
system picks up a lot of heat during use.
This applies above all to the silencer of
machines equipped with catalytic
converter.
To avoid injuries, allow the machine to cool
before any kind of repairs are made to or
near parts of the engine or exhaust
system.
1.2.5 Cleanliness
Clean the machine before starting repairs.
Dirt that penetrates into sensitive
components can seriously influence the
service life of the machine.
1.2.6 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.
1.2.7 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.
1.2.8 Replacement parts
1.2.3 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.
1.2.4 Lifting and blocking up
Before work under the machine, always
make sure that lifting devices and jackstands are approved for the weight.
Work safe!
Always use Genuine Spare Parts during
service work.
1.2.9 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.
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2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 4
1.3 Guarantee
1.3.1 Component guarantee,
chassis
The guarantee is valid provided
prescribed basic services have been
carried out at an authorised service
workshop during the relevant guarantee
period. The services must be verified in the
service book.
that the
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.
he purchaser is covered b
T
laws of each country. The rights to which
the purchaser is entitled with the support of
these laws are not restricted by this
warranty.
y the national
1.3.3 Conditions for validity of the
warranties
The fully completed warranty card must be
sent to Stiga´s subsidiary or distributor.
In the event of a claim, the service history
must be confirmed with a copy of the
service book.
Neither does the warranty cover:
• Wearing components such as blades,
belts, wheels,battery and cables.
• Normal wear.
• Engine and transmission. These are covered by the respective manufacturer’s
warranties, with separate terms and conditions.
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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: 0,4 bar (6 psi)
Rear: 1,2 bar (17 psi)
When using some accessories it may be
necessary to increase the pressure
somewhat. However, the maximum
permitted pressure is always
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.
Too high pressure Correct pressure
2. Remove the following parts from the
package and put them on the floor.
• The battery (some models).
• The steering wheel.
• The plastic bag, containing owners manuals,
and assembly screws.
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1.4.2 Battery
The battery is a valve regulated type.
Depending on the battery type, load and
assemble the battery, following the actual
instruction below.
Valve regulated battery
This battery needs limited maintenance. Is 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 be-
fore 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 will now be
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
See also the respective installation
manual, delivered with the machine.
After the battery is charged, remove the
motor casing and install it in the machine.
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.
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1.4.3 Assembly
The assembly procedure shall take place in a
clean, well illuminated and dry place.
Assemble the machine as follows:
Assembly of steering wheel
The machine is delivered with two shims, one
with a thickness of 0.5 mm and one with a
thickness of 1.0 mm.
In order to minimise the axial play in the
steering column, the shim washers (0.5 mm)
and/or (1.0 mm) must be installed on the
steering column between the steering column
jacket and the bracket as follows.
1. Install the steering column jacket on the
steering column and secure by knocking in
the tension pin approximately 1/3 of its
length.
2. Pull the steering column jacket and the
steering column up.
3. From the outside, check whether no
washers, the 0.5 mm washer, the 1.0 mm
washer or both washers can be inserted into
the gap. The washer/washers must not be
forced in, as there must be a little axial play.
4. Pull out the cotter pin and dismantle the
steering wheel jacket.
5. Install the washer/washers in accordance
with point 3 above.
6. Install the steering column jacket on the
steering column and secure by knocking in
the tension pin fully. Use a counterhold.
Also make sure that the logo on the steering
wheel is in the correct position.
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Assembly of seat (adjusting wings under)
Release the catch (S) and fold up the seat
bracket.
NOTE! To facilitate installation of the seat,
apply a drop of oil to the four screws before
I
screwing them into the seat.
F
Install the mounting in the rear (upper) holes as
follows:
K
1. Install the shoulder washers (F) on the screws
(K).
2. Insert the screws through the slots in the
bracket. Place a washer (I) between the seat
and the bracket.
3. Tighten the screws in the seat. Tightening
torque: 9±1.7 Nm.
If the screws are tightened more than
9±1.7 Nm, the seat will be damaged.
4. Check that the seat moves easily in the slots
in the bracket.
Install the mounting in the front (lower) holes as
follows:
1. Install the screw knobs (H) on the screws (G).
2. Install a washer (I) on each screw.
3. Insert the screws through the slots in the
bracket and tighten by hand in the seat.
I
H
G
S
4. Fold the seat down and place it in the desired
position.
5. Tighten the screw knobs (H) by hand.
The screw knobs (H) and the seat will
be damaged if tools are used.
Towing plate
Fitting according to customer requirements.
Engine oil
Check the oil level in the engine and top up if
necessary.
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1.4.4 Final checks
Removing from pallet
All the above measures shall have been done
with the machine standing on the pallet. Now,
loosen ev. remaining attachments and roll off
the machine from the pallet.
Accessories
Fit and adjust accessories.
Test driving
Warning!
Do not drive without a work
equipment (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. If the machine is to be
delivered with mower deck or other
accessories, fit these before test driving the
machine.
Steering chain / Steering wire
Check that the steering chain / steering
wire is sufficiently taut. Adjust if
necessary.
Miscellaneous
Give the machine a general inspection.
• Is the machine clean?
• Is there any oil leakage?
• Abnormal noise or rattle?
Receipt
By filling in the guarantee certificate you
guarantee that the delivery service has
been correctly conducted.
Remember to make sure that the
customer receives all the documentation
when the machine is collected / delivered.
HST oil
Check the oil level in the HST’s expansion tank
after test driving, and top up if necessary.
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2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 10
1.5 Service
Every new machine is delivered with a service book. This service book is part of the active
post-market programme and shall be kept in a safe place during the entire lifetime of the
machine. Hand over the service book if the machine is sold in 2:nd hand.
Service should generally be carried out at least every 50 operating hours (exception of the
irst service), although in accordance with the conditions below.
here are three different grades of service events. Every service event consists of a
number of service points as described in the following paragraphs. Every service point has
number which refer to a describing text after the schedules.
Some service points do not coincide with the scheduled service intervals, but shall be
performed in connection with a scheduled service when possible. E.g. some items shall be
performed at every second service and some also between two services. These service
points are described with procedure and interval in the respective “Instruction for use”.
ypical service points wich not coincide with scheduled service intervals are:
• Cleaning/changing air filter in some motors.
• Change of oil in some motors.
• Valve adjustments for some motors.
• Change of spark plug in some motors.
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1.5.1 First S
1.5.2 Int
2008-05-19 Workshop Manual, Stiga Villa/Ready 1 General 11
The first service shall be performed within 5
hours of running and includes the service
points as per the table below.
This service is very important to safeguard
the continuing function of the machine.
Number Service point
1
2
3
4
5
6
21
ervice
Safety check.
Tyres, air pressure.
Engine oil, change.
Machines with filter, replace it
together with the oil.
Oil level in HST, check
(Valid for machines with HST
only).
Belt transmissions, check.
Steering adjustment.
Test driving.
ermediate Service
The intermediate service shall be conducted
between two basic services. That means 50
hours after a basic service.
Number Service point
1
2
3
4
6
8
11
12
The intermediate service is not as extensive
as the Basic Service and can therefore be
conducted by the customer, or by an
authorised Service Workshop. Regardless of
who conducts the service, it must be
documented in the service book.
Safety check.
Tyres, air pressure.
Engine oil, change.
Oil level in HST, check.
(Valid for machines with HST
only).
Steering adjustment.
Air filter, cleaning.
Cooling fins, clean.
Lubrication
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1.5.3 Basic Service
The basic service shall be conducted every 100
hours or once every year, which first occur.
The Basic Service must always be conducted by
an authorized Service Workshop, and
documented with a stamp in the service book.
Number Service item
1 Safety check
2
3
4
5
6
8
*) See also “Safety check”.
**) See also the mover deck manual.
Tires, air pressure
Engine oil, change.
Machines with filter, replace it
together with the oil.
Oil in HST, check.
Belt transmissions, check
Steering adjustment
Air filter for engine, clean/
replace
Number Service item
10
11
13
14
15
16
17
18
19
20
21
22
23
Cooling fins, clean
Spark plug, check/replace
Transmission, check
Speed check
Bearing boxes, check**
Exhaust system, check*
Electrical system, check*
Mower deck, check**
Blades, check**
Power take-off, check
Control check
Valve play***
Test driving
***) See the motor manual.
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1.5.4 Description of service points
1. 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 at the respective machine up to model 2004 are listed in the
tables below. For models 2005 and up, see the respective “Instructions for use”.
Models with manual gearbox
Test Status Action Result
1 PTO activated.
No gear activated.
2 PTO not activated.
A gear is activated.
3 Motor running.
PTO activated.
4 Motor running.
A gear activated.
5 Motor running. Disconnect cable from the
Turn the key and make a
start attempt.
Turn the key and make a
start attempt.
Operator rises from the
seat.
Operator rises from the
seat.
shut off valve.
Motor shall not
start.
Motor shall not
start.
Motor shall
stop.
Motor shall
stop.
Motor shall
stop after a few
minutes.
HST models
Test Status Action Result
1 Brake pedal not pressed.
PTO not activated.
2 Brake pedal pressed.
PTO activated.
3 Motor running.
PTO activated.
4 Motor running. Disconnect cable from the
Turn the key and make a
start attempt.
Turn the key and make a
start attempt.
Operator rises from the
seat.
shut off valve.
Motor shall not
start.
Motor shall not
start.
Motor shall
stop.
Motor shall
stop after a few
minutes.
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2 Tyres, air pressure
Check the air pressure. Adjust if necessary.
The recommended air presure is
designated at the floor mat.
3 Engine oil and oil filter
See “Motors” at page 18. and the
“Instructions for use”, delivered with the
machine, see “Instructions for use” at
page 19. See also the engine manufacturer
manual.
4 Oil, HST
See the “Instructions for use”, delivered
with the machine.
5 Belt transmissions, check
Check the condition of all the belts and belt
tensioners.
11 Spark plug
Remove the spark plug and clean it or
replace if necessary. See also the engine
manufacturer manual.
12 Lubrication
Lubricate the 5 nipples and all moving
parts such as wires and levers. See
section 2.
13 Transmission
Listen for abnormal noise.
Manual models: Check that the drive
function works properly at all gears. Adjust
if required.
14 Speed check
Check that the speed corresponds to the
specified value.
6 Steering, adjustment
See section 3.
7 Not applicable
8 Engine air filter
See the “Instructions for use”, delivered
with the machine. See also the engine
manufacturer manual.
9 Not applicable
10 Cooling fins
Remove protective covers from the engine
and cleans between cooling fins. Use a
brush and compressed air. See also the
engine manufacturer manual.
15 Bearing boxes
Listen for abnormal noise from the
bearings. Check that there are no wear,
play or seizure.
16 Exhaust system
Check that there are no cracks, leakage or
other damages. Check the attachment
devices. See also the engine
manufacturer manual.
17 Electrical system
Check that there are no damaged cables,
contacts or other devices. Check that all
cables are properly secured to the chassis
and with cable holders. Check that there is
no friction between cables and chassis,
which can result in cable damage and
short circuit.
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18 Mower deck
Warning!
The blades are sharp. Always
wear gloves when working with
the blades to avoid injury.
Check if there are collision damages or
wear at the deck body and painting. Align,
repair and touch up the painting as
required.
Check the tightening of the bearing boxes
screws and tighten.
Rotate the blades and check the the shafts
are correct, not bent, no abnormal bearing
noise and no plays.
Check the belts and their tensions, see
section 4.
Check that the lifting mechanism moves
evenly, not jammed and no play and that it
locks in desired position.
20 Power take-off (PTO)
Check that the magnetic clutch (if
applicable) engage the work equipment
rotation in the desired time and that it not
slips during normal load. Replace the
clutch if necessary.
Check that the power take-off belt (if
applicable) engage the work equipment
rotation in the desired time and that it not
slips during normal load. Adjust if
necessary. See section 5.
Check that the power take-off brake (if
applicable) brakes the rotation movement
in the desired time. Adjust if necessary.
See section 5.
21 Control check
Check that all controls function properly,
that there are no jammings or excessive
plays. Adjust if nesaccary. See section 6.
Check the electrical function of the
electrical mower lifter (if applicable).
Check the plastic guide bar between the
blades. Replace if required.
19 Blades
Warning!
The blades are sharp. Always
wear gloves when working with
the blades to avoid injury.
Check that the blades are sharp. Replace if
necessary.
22 Valve play
See the engine manual regarding
procedure and interval.
23 Test driving
Drive the machine during a few minutes
and make the following attentions in
different speeds and turnings in right and
left. Check that all functions work evenly
and proper and without any abnormal
noise.
• Brake function
• Clutch function
•Power take-off
• Steering
Check that there are no abnormal
vibrations.
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1.6 Technical specifications
Tightening torques
6.1 General tightening torque
1.
Unless otherwise stated, the following tightening
torque are applicable for screws and nuts on the
machine:
Thread Torque
M5 5 Nm
M6 9 Nm
M8 22 Nm
M10 45 Nm
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2008-05-19 Workshop Manual, Stiga Villa/Ready 2 Chassis and Body 1
2 Chassis and body
Contents in this chapter
2.1 Lifting mechanism,
manual ..........................................2
2.1.1 General.....................................2
2.1.2 Description................................2
2.1.3 Dismantling...............................2
2.1.4 Repair of lifting lock ..................6
2.1.5 Assembly ..................................6
2.2 Lubrication chassis .................... 8
2.2.1 Steering pivot pins
and beam pivot........................ 8
2.2.2 Control wires............................ 8
2.2.3 Tensioning arms ...................... 9
2.2.4 Steering chain.......................... 9
2.2.5 Bearings................................... 9
General
To facilitate 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. These
equipments are mainly the same for all the machines covered by this manual, but in some
cases configurated in different ways. Where divergences occour between the machines,
particular instructions are given for each particular equipment.
This chapter gives a brief description of the equipments and describes their repair and
replacements.
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2.1 Lifting mechanism,
manual
2.1.1 Description
The work equipment lifting arm is automatic
locked in elevated position by pressing down
the lifting pedal. Next time the pedal is pressed,
the mechanism will release and the arm drops
down.
The locking function is created in the lifting lock.
The principle is described below and shown in
the figure.
A. Locked in lifted position by the ratchet (C).
B. Unlocked. Ratchet (C) is released.
C. Ratchet which is tilted by the pin (D) every
time the pedal is pressed down.
2.1.2 Dismantling
To dismantle the lifting lock it is normally
necessary to dismantle the steering console.
Nevertheless, it is possible for a skilful person
to dismantle the lifting lock without releasing
the steering console.
C
C
D
AB
The dismantling is performed as follows:
1. Dismantle the steering wheel by tapping out
the pin.
If applicable, observe the spacers and the
location when disassembly the steering
wheel.
See section 1.
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2. Remove the screws for the top cover.
If applicable, remove also the following:
• The bullet from the throttle handle by twisting and pulling it simultaneously.
• The ignition switch nut. To aviod damage
at the plastic cover, use a 22 mm ring
wrench.
• The cutting heigth switch by pressing its
locking tabs at the underside.
3. Dismantle the front cover by unscrewing the
two screws at the under side.
4. Unhook the return spring.
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5. Dismantle the lifting pedal located on the lifting arm.
6. Loosen the throttle control as follows:
1. Loosen the lever.
2. Observe where the wire conductor is
fitted to reassemble in the same position.
7. Remove the screws that hold the steering
console at the floor plate, and lift off the
steering console.
8. Remove the screws that hold the lifting fork
at the lifting lock.
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