Vari BDR-595 E EuroAdela Instructions For Use Manual

Drum mower

BDR-595 E

EuroAdela

Instructions for use

BDR-595 E EuroAdela

2

Contents

1 Basic information...............................................................................................................3

2 EC-Conformity Statement.................................................................................................. 4

3 Introduction........................................................................................................................5

3.1 Warning..........................................................................................................................5

4 Operation safety ................................................................................................................. 6

4.1 Safety regulations...........................................................................................................6

4.2 Declared and guaranteed noise and vibration values ..................................................... 7

4.3 Safety pictographs..........................................................................................................7

5 Machine: Its use, technical specification and description..................................................9

5.1 Use of the machine.........................................................................................................9

5.2 Technical specification................................................................................................... 9

6 Instructions for use...........................................................................................................10

6.1 Machine assembly........................................................................................................10

6.2 Putting into operation...................................................................................................12

6.3 Starting the mowing disk..............................................................................................13

6.4 Machine travel..............................................................................................................13

6.5 Machine stop................................................................................................................ 15

6.6 Working with the machine...........................................................................................15

6.6.1 Working engagement of the machine...................................................................15

6.6.2 Mowing grass stands............................................................................................16

6.6.3 Problems at cutting............................................................................................... 16

7 Maintenance, care and storage........................................................................................ 17

7.1.2 Engine oil replacement......................................................................................... 18

7.1.3 Table of machine lubrication................................................................................18

7.2 Tightening of bolted connections................................................................................. 19

7.3 Replacement and sharpening of working knives..........................................................19

7.4 V-belt replacement and adjustment of tightening pulley............................................. 20

7.5 Setting-up litz wires of pulley, brake and machine travel gear clutch.........................22

7.6 Driving problems: Diagnostics.....................................................................................24

7.9 Machine storage ...........................................................................................................26

7.10 Disposal of packaging and machine after service life expiration............................. 26

8 Instructions for ordering spare parts.................................................................................27

8.1 Machine casing......................................................................................................... 29

8.2 Handlebars................................................................................................................ 31

8.3 Mowing disk drive ................................................................................................... 33

8.4 Wheel driving gear...................................................................................................36

8.5 Gearbox.................................................................................................................... 38

Text and illustrations 2003 VARI,a.s.

Publication No. VL-079-2003

BDR-595 E EuroAdela

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1 Basic information

,Ask your dealer to provide unpackaging of the machine and briefing.

Fill in the following table with data on your machine. The data are important for ordering

spare parts.

It is advisable to have a copy of this page with all data on the machine purchase for the

case of loss or theft of the original record.

Type

BDR-595 E

Trade name

EuroAdela

Engine type

HONDA GCV160

Machine Serial No./Year of
Manufacture

/

Engine Serial No.
Date of delivery (sale)

Supplier

Address

Telephone/Fax/E-mail/Internet

Your notes:

Manufacturer reserves the right of technical modifications and machine innovations not
impacting function and safety of the machine. The alterations may not reflect in these
instructions for use.

BDR-595 E EuroAdela

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2 EC-Conformity Statement

EC-CONFORMITY STATEMENT

according to Act No. 22/1997 Gaz.

(as amended)

,Manufacturer:

VARI,a.s., Opolanská 350, 289 07 Libice nad Cidlinou, Czech Republic

Identification No.: 00660574

issues the following Statement at its own responsibility

,Machine

a) Name:

Drum mower

b) Model:

BDR-595 E

c) Brand:

-

d) Serial No:

00001-99999

,Regulations to which the conformity was assessed:

Government Decree No.170/1997 Gaz. , Government Decree No.169/1997
Gaz., Government Decree No.9/2002 Gaz. (all Government Decrees as
amended), Directive 98/37/ES – Attachment No.1

,Person authorized for testing:

a) Name: Státní zkušebna zemědělských, potravinářských a lesnických strojů
b) Seat: Třanovského 622/II, Praha 6 - Řepy
c) AO: 206 , accredited testing laboratory no.: 1054
d) Final report No.: 22 508 of 5 March 2003

,Harmonized technical norms, national technical standards and specifications:

ČSN EN 292-2+A1, ČSN EN 12733, ČSN CISPR 12

,

Technical documentation set containing the assessment of product compliance with the

regulations:

No. STD/043/2003

,Manufacturer confirms that:

The above machine based on his concept and design, as well as the model introduced by us
into circulation, comply with relevant basic safety requirements of the government decrees.
Should there be machine alterations not approved by us, this Statement becomes void.
The product is safe under conditions of its common use specified by manufacturer.
Manufacturer has adopted measures to ensure conformity of all products introduced onto
the market with technical documentation and basic requirements.

,In Libice nad Cidlinou Date: 28 March 2003

signed by person authorized to act on our behalf:
Name: Jiří Belinger - CEO

Signature: Stamp:

BDR-595 E EuroAdela

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3 Introduction

Dear customer and user,
Thank you for the trust you have shown by purchasing our product. You have become owner
of machine from a wide range of machines and attachments made by ,a.s. as a system of
gardening, farming, small agricultural and communal technology.

Drum mower BDR-595 E EuroAdela meets with its design the latest European safety

standards and directives for this category of mowing machines. Construction of the protective frame
with screen around the entire mowing disk circumference does not prevent perfect cutting of the grass
and its continuous swathing on the right side of the machine. Thanks to this frame with the screen
which provides protection from possible fly-away stand fragments, the drum mower can also be used
inside towns and villages (while adhering to instructions listed under 4.1 Safety regulations). The
drum mower can also be favourably used at places where cutting of the high-grown grass must not
result in damage to young trees, shrubs, etc. such as in forest nurseries, orchards, ...

Please read the Instructions for use carefully. Following them properly, you will get our

product performing reliable work for years.

3.1 Warning

User is obliged to get acquainted with the Instructions for use and to follow all instructions for

machine operation so that the user’s and other persons’ health and property do not suffer any harm.

Safety instructions contained in this manual do not describe all situations or conditions
possibly occurring in practical use. Safety factors such as common sense, diligence and
scrupulousness are not included; it is assumed, however, that all persons authorized for machine
operation or maintenance do possess the intelligence.

The machine can be operated only by persons in good mental and physical condition. For the
professional use of the machine the machine owner is obliged to ensure a work safety training and
provide instructions on machine control for operators and to keep records on these trainings and
briefings. In addition, the machine owner is obliged to make a so called categorization of
operations according to the relevant national legislation.

Should some instructions in the manual be unintelligible, you are encouraged to contact your

dealer or directly the manufacturer of the machine. The contact address and telephone/fax connection
are to be found at the end of the manual.

Instructions for use supplied with the machine are an integral part of the machine. They have
to be available at any time, placed at a well accessible place with no risk of their damage. In the case
that the machine is sold to another person, the Instructions for use must be given to the new machine
owner. If the above conditions are not met, the manufacturer bears no responsibility for incurred
risks, accidents and injuries resulting from the machine operation.

The manufacturer bears no responsibility for damages caused by unauthorized and incorrect
use of the machine and for damages caused by any machine modifications not authorized by the
manufacturer.

To prevent injuries of operators and other people occurring in the vicinity of the machine, it is
absolutely crucial to follow safety regulations marked in the Instructions for use with the following
warning safety symbol:

,

As soon as you meet with this symbol in the

manual, read the attached instructions

carefully !

BDR-595 E EuroAdela

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4 Operation safety

4.1 Safety regulations

,This international symbol indicates important messages concerning safety. When you see

the symbol, be aware of a possible injury to yourself or to other persons and read attached
instructions carefully.

,The machine operator must be over 18 years of age. He (she) is obliged to get familiar

with the instructions for use of the machine and is supposed to be informed of the general
principles of work safety.

,Prior to carrying out any activities in the near vicinity of the machine, switch the engine

off and wait until the mowing disk stops moving! Before leaving the machine alone,
switch off the engine!

,Never let the engine running at maximum speed or idling for a long time with the

mowing disk drive clutch and travel wheels drive clutch being switched off! Components
of the machine drive (V-belt, belt pulley, clutch pulley, etc.) might get damaged!

,Prior to each employment of the machine, check its parts (working mechanism or its

casing in particular) for possible damage or loosening. Possible defects must be rectified
without any delay. Repairs are to be made only with original spare parts.

,Before using the machine, the stand must be cleared of solid bodies such as stones, wires,

loose construction debris, etc., which could be flinging up or which might damage the
machine. If these cannot be removed, don’t work the places.

,The machine is equipped with the rotating working tool. Maximum circumferential speed

is 60.3 m.sec-1. Therefore, see to it that other persons move at a safe distance from the
machine when it is in operation with regard to a possibility of mown stand or solid
objects flying away

,With respect to exceeded recommended values of noise and vibrations, you are warned to

observe the following instructions when working with the machine:
a) Protect your hearing by using suitable protective aids specified in CSN EN 352-1

(shell ear protectors) or CSN EN 352-2 (plug ear protectors). Require the aids from

your dealer.

b) Work with the machine should be interrupted after max. 20 minutes for min.10

minutes. During these breaks, the machine operator must not be exposed to the effect

of another source of noise or vibrations.

,Machine operators should use working aids authorized to CSN EN 166 or CSN EN 1731

(tight-fitting garments, sturdy shoes, working gloves and protection glasses). Keep a safe
distance given by the handle.

BDR-595 E EuroAdela

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,Don’t start the engine in enclosed spaces! Pay an increased attention when handling the

machine since the exhaust silencer remains hot after the engine has been switched off;
make sure there are no leakages and spills on engine parts when refuelling. If they
happen to occur, dry out the stained parts or wait until the petrol evaporates.

,When the machine is in operation, all other persons (children in particular) and animals

have to be outside the machine’s working space. The machine operator can continue
working only after they have been shown out to a safe distance of min. 50 meters (see
Pictograph 6).

,Removal of any protective equipment and machine casings is forbidden.

,Safe slope accessibility of the machine is 10°. Maximum inclination of engine at work is

20° for a longer time and 30° for a shorter time (up to 1 minute).

,All kinds of machine repair, adjustment, lubrication and cleaning are to be made with the

machine switched off and spark plug cable disconnected.

4.2 Declared and guaranteed noise and vibration values

Declared emission level of acoustic pressure A at the operator’s site L

pAeq,T

= 84 dB

(according to ČSN EN 836+A1/A2, Attachment H and ČSN EN ISO 11 201)
Guaranteed level of machine’s acoustic performance L

WA

= 100 dB (according to

Government Decree No..9/2002 Gaz. )
Declared aggregative value of accelerated vibrations transmitted onto the operator’s hand-arm
ahv = 8,1 + 3,2 [m.s-2] (according to ČSN EN 836+A1/A2, Attachment G and ČSN EN 1033).

4.3 Safety pictographs

User is obliged to maintain pictographs on the machine legible and to provide for their

replacement in case of their damage.

10

At work, keep the maximum permitted-safe slope accessibility of the machine

11

Switching on the mowing disk drive: „0“ = Mowing disk standing still; , „1“ = Mowing
disk turning

12

Switching on the machine travel: „0“ = Machine standing still; , „1“ = Machine moving

Pictograph no. Safety information description

1

Label with manufacturing data

2

Guaranteed level of machine’s acoustic performance

3

Instructions for use to be thoroughly studied prior to machine use

4

During machine maintenance, conductor should be disconnected from the spark plug

5

Putting one’s hands or feet into the mowing disk working space is prohibited – Danger
of injury

6

Entry prohibited for other persons and animals. Keep minimum safe distance from the
machine.

7

Danger of injury by fly-away material fragments, chips, objects, etc.

8

Arrow for the tool direction of rotation - right

9

Putting one’s hands into the V-belt space is prohibited – Danger of squeezed limbs.

BDR-595 E EuroAdela

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L

wA

2.

1.

3. 4. 5.

6. 7.

8.

11.

12.

9. 10.

BDR-595 E EuroAdela

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5 Machine: Its use, technical specification and description

5.1 Use of the machine

Drum mower Model BDR-595 EuroAdela has been designed and manufactured to the

latest knowledge in the field of small gardening and farming machinery, its design meeting
the most recent European safety standards binding for this machine category. It also excels in
easy maneouvrability and problem-free maintenance.

The mower is meant for cutting thin-walled stalky grass stands of medium height up to
max. 80 cm on well-kept (i.e. annually mown) surfaces. The mown surfaces must be without
any solid articles in the stand and greater terrain roughness. The mower is not meant for park
treatment of grass stands neither for cutting stands with even a minimum representation of
woody plants arisen from self-seeding.

,Engagement width has to be at all times accommodated to the density of

mown stands

5.2 Technical specification

BDR-595 E EuroAdela Unit Value

Length (incl. protective screen) mm 1745
Width (incl. protective screen) mm 978
Height (incl. protective screen) mm 1120
Weight kg 61
Max. engagement width cm 56
Mowing disk speed (at max. engine rotations) min-1 2068

Circumferential speed of knives (at max. engine

rotations)

m.s-1 60.3

Travel speed (at max. engine rotations) km.hr-1 2.7
Area performance (according to stand type) m2/hr 800-1400
Gear box oil filling litres 0.15
Oil grade API GL - 4, GL – 5

SAE 90, 80W - 90

Engine type Unit Value

HONDA GCV 160

-- -­Cylinder volume cm3 160
Drilling x Lift mm 64x50
Max. output at RPM kW/rpm 4.1/3600 (5.5HP)
Max. torque at RPM N.m/rpm 11.4/2500
Maximum engine speed adjustment rpm 3200 (+/-100)
Tank volume litres 1.1
Petrol (leadless) oct.no. 91-95
Oil filling litres 0.55
Oil SAE 15W-40
Spark plug -- NKG BPR6ES

-- BRISK LR15YC

BDR-595 E EuroAdela

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6 Instructions for use

6.1 Machine assembly

Ask your dealer to provide machine unpackaging and briefing.

Grip points for unpackaging the machine from the box: Front – Mowing disk; Rear – the

„U“ tube of the machine frame.

Should you do the machine assembly yourself, please follow the below instructions:

Note: Washer size (e.g. Ø6.4mm) is always presented as the diameter of washer hole.

1. Take the machine out from the box and all parts from the packages.

2. Slip the front part of screen frame (1a) into the rear part of screen frame (1b) and connect
them by means of M6x16 bolts (2) with small flat washers Ø6.4mm (3).

3. Put the assembled screen frame on a flat surface (table, floot, etc.) and slip the screen (4)
onto the longitudinal beam on the front part of screen frame with its back side out. Bolt
the screen (4) to the assembled apron frame by means of two bolts M6x16 (2) with
washers Ø6.6mm (5) and self-locking nuts M6 (6) with small flat washers Ø6.4mm (3).
Provide the bolt heads with plastic caps (7). Then sling the screen sides over the screen
frame so that they are in the position illustrated in Fig. 2a.

4. Turn the handlebars (8)so that the handrails point to the rear of the machine. Attach the
handlebars (8) onto the frame tubes at a required height by means of bolts with squares
(9), small flat washers Ø8.4mm (10) and plastic rosebits with internal tread (11). Fix the
Bowdens to the tubes of handlebars by means of two plastic tightening tapes.

Driving wheels

Engine

Handleba

Mowing disk drive gear

lever with brake

Accelerator lever (adjustment

of engine speed)

Machine travel gear

clutch lever

Plastic rosebit to

adjust handlebars

height

Upper

Figure 1: Drum mower BDR-595 E EuroAdela

Starter grip

Side apron

Front grip handrail (e.g. for
lifting the machine etc.)

Rear grip points

(for steering, lifting

or loading the
machine)

Apron

BDR-595 E EuroAdela

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5. Put the apron with frame into the cut-out in the upper casing (13). Then put the casing
with the apron frame on the machine and bolt it with two nuts M8 (14) with large flat
washers Ø9mm (10). Provide the nuts with plastic caps (19). The apron frame will be
screwed to the machine under engine front with M6x20 bolts (20) with small flat washers
Ø6.4mm (3). Provide the heads of M6x20 bolts with plastic caps (7).

6. Then bolt the apron to the upper casing by means of bolts M6x16 (2) with large flat
washers Ø6.6mm (5) and self-locking nuts M6 (6). Provide the M6x16 bolt heads with
plastic caps (7).

7. Bolt the mud guards (17) to the upper casing (13) by means of bolts M6x16 (2), self­locking nuts M6 (6) and large flat washers Ø6.6mm (5).

Apron around the
mowing disk

Figure 2a :
Apron assembly

BDR-595 E EuroAdela

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6.2 Putting into operation

,The machine can be delivered without working fillings of the engine (as

depending on varied national regulations)!

,First read the instruction for engine use thoroughly! You can prevent a possible

damage to the engine.

1. Check oil in the engine and/or fill the engine with the prescribed oil type and volume.
Fill the tank with the prescribed amount and type of petrol.

9

Figure 2b: Machine assembly

8

BDR-595 E EuroAdela

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2. Move the accelerator lever into the front position (CHOKE). Start the engine by pulling
on the manual starter (instructions for starting see the guidelines for engine use).

3. Let the new or cold engine running for about 30 seconds on the choke (accelerator lever
in the CHOKE position); then move the accelerator lever into the position MAX and let
the engine running in this position for about 30 seconds.

,Don’t leave the machine alone when doing this.

6.3 Starting the mowing disk

,When starting the engine, the two levers on the handlebars must be in the off

position.

1. Start the engine. When doing this, follow the instructions presented in the operating
manual for engine use.

2. Set-up maximum engine rotations by accelerator lever on the right handrail. (Should the
engine be cold, let it warm up at maximum speed for about 1 minute.)

3. Grasp the left handlebar grip. Then slowly press the mowing disk drive gear lever on the
right handlebar grip with your right hand.

,Press the lever slowly up to two thirds of the stroke so that the mowing disk can

start rotating and the engine does not stall.

The start of the mowing disk is accompanied with a partial slippage of the V-belt and

with the related phenomena such as whistling, rattling, etc. which usually disappear after the
belt has started properly moving.

4. After the mowing disk has started turning, press the lever completely to the handrail and
hold firm.

Note: In a new or cold engine, engine stalling may occur at several first mowing disk

drive starts. The phenomenon will disappear after the engine has got warmer. If the disk
drive cannot be started even after the engine has got warm, follow the table presented in
chapter 7.6 for diagnostics.

6.4 Machine travel

The travel gear is to be switched on by a lever on the left handrail. Press the lever down
to the handrail and the machine starts immediately moving forward. You have to start slowly
walking as soon as you have pressed the lever down and the machine has started its travel.

,The machine may start moving with a slight jerk; be prepared for that.

BDR-595 E EuroAdela

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Note: all four main positions of accelerator lever are locked by means of a simple hollow-lug
system in the lever body.

Mowing disk drive clutch

lever and brake lever

Machine travel

clutch lever

Accelerator lever

(engine speed

adjustment)

Bowden cable of

machine travel

Mowing disk brake

Bowden cable

Bowden cable of

tightening pulley of

the mowing disk

drive V-belt

Right

Left handrail

STOP position of accelerator lever –
Engine not running

MIN

(turtle) position of accelerator

lever – Engine running idle

MAX (hare) position of accele

rator lever

– Engine running at maximum speed

CHOKE

position of accelerator lever (for cold

engine start only) – Engine running on choke

Figure 3: Handlebars and accelerator lever

BDR-595 E EuroAdela

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6.5 Machine stop

,Prior to performing any activities in the near vicinity of the machine, switch off the

engine and wait until the mowing disk stops! Always switch the engine off before
leaving the machine.

,Never let the engine running at maximum speed or idling with the mowing disk

drive gear clutch released and with the released clutch of travel wheels drive gear
for a long time! Machine drive components (V-belt, belt pulley, clutch pulley, etc.)
might get damaged!

If you wish to stop the machine travel, release the lever on the left handlebar grip. The
machine travel will stop but the mowing disk is still rotating. The mowing disk drive will
switch off immediately after you have released the lever on the right handlebar grip. The
mowing disk will be stopped by safety brake.

Engine is to be switched off by pushing the lever into the STOP position.

,In the case of any critical situation, release your hold on the handlebars

immediately. The levers will return to their zero position, the machine and the
mowing disk will come to a stop (while engine is still running at adjusted rotations;
this is why it is to be switched off by pushing the lever into the STOP position as
soon as possible!)

6.6 Working with the machine

6.6.1 Working engagement of the machine

,Prior to the machine use, the stand must be cleared of solid bodies such as stones,

wires, loose construction debris, etc., which could be flung or might otherwise
damage the machine. Should these be impossible to remove, avoid working the
places.

,Mowing engagement width has to be at all times accommodated to stand density!

On the upper surface of the apron, there is a
yellow strip placed on the right side to indicate
the maximum working engagement of the
mowing disk on the right. Edge of the to-be­mown stand should not exceed the boundary
given by the strip (see Figure).

Warning: When mowing, make sure that the
lower disk is permanently pushed against the

Strip on the apron

To-be-mown stand

BDR-595 E EuroAdela

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ground and does not rebound. Disk rebounding results in uneven stand mowing

6.6.2 Mowing grass stands

Set the engine to maximum speed, let the mowing disk rotate at maximum speed
(starting the mowing disk see chapter 6.3) and get the machine into motion (see chapter 6.4)
facing the stand to be cut. The mown grass is thrown away by the mowing disk to the right
side onto the screen which forms a swath. Grass leaves the space under the screen from in
front of the right wheel.

The only correct way how to proceed at cutting the grass stand is to have the to­be-mown grass at all times on the left side of the machine (see Figure).

It is adviseable to drive the machine along the slope contour lines for cutting.
Keep in mind, however, that the maximum machine tilt permitted is 20° (long-term)
and 30° (short-term)!

If the stand is very dense, grown through, rotten or lodged, the machine working
engagement width must be reduced accordingly so that the mowing disk rotations are not
being excessively reduced and the cutting quality impaired.

6.6.3 Problems at cutting

Choking of the space under the upper casing and apron with grass can show as follows:

a) Engine markedly loosing speed but not stalling: machine travel to be switched off

immediately (lever on the left handrail); drive in reverse gear just a bit with a
simultaneous slight lifting of the machine front (by pushing down on the handlebar
handrails). The casing space will do itself a partial clearance of excessive grass matter.
Then drive the machine against the stand again (see chapter 6.4).

,Be very careful while lifting the machine and at reverse driving!

b) Engine loosing speed and stalling: release the both levers on the handlebars, lift the

machine front part by pushing down on the handlebars and drive a bit in reverse. Clear
the space under the upper casing and spread the cut grass across the ground. Start the
engine, switch on the mowing disk drive (see chapter 6.3) and once again drive the
machine against the stand (see chapter 6.4).

,The engine must always be switched off when clearing the space under the upper

casing and screen!

,Tilt the machine always only backwards onto the handlebars. Be very careful while

moving in the space beneath the lifted machine! Secure the machine against
spontaneous motion!

,Be very careful while cleaning the space under the upper casing and screen. Cutting

edges of knives are sharp. You should wear protective gloves or you can also use a
piece of branch etc.

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7 Maintenance, care and storage

To ensure a long-term satisfaction with our product, it must be given proper care and
maintenance. Regular maintenance of the machine will prevent its early wear ensuring at the
same time a correct functioning of all its parts.

Follow all instructions for intervals of machine maintenance and adjustment. It is adviced
that you keep records on the number of machine working hours and on the conditions in
which the machine was working (for service purposes). Similarly as the current maintenance,
the post-season maintenance should be entrusted to one of our authorized service workshops
if you are not certain of your own technical skill.

,Regarding the machine weight, its maintenance and adjustment are to be made by a

team of two persons.

7.1 Machine lubrication

7.1.1 Gear oil replacement and refilling

,When replacing oils, follow the basic hygienic principles, regulations and laws

on environment protection.

The gearing works in an oil bath. Oil condition should be checked once a month (oil

plugs see Fig. 4).

Minimum grade of gear oil according to API should be GL-4, GL-5; according to SAE:

90 or 80W-90.

Oil replacement in a new machine is to be made after the first 5 hours of operation and
then after 100 working hours or after the season. This will ensure that the gears will not
suffer excessive wear. The exchange interval can be extended up to 130 hours (the running­in time of 5 hours must be adhered to) in higher oil grades (API GL-5, SAE 80W-90).

Czech oils fully meeting the requirements are MOGUL TRANS 90 or MOGUL TRANS
80W-90.

Oil replacement should be made when the gearbox is warm, oil can be drained easily.

1. Clean around the oil plugs. Underlay the machine and secure it so that a space is created

under the machine for a vessel to collect oil.

2. Loosen the pour-in plug on the rear wall of the box and the drain plug in the bottom of

the gearbox (spanner No. 19).

3. After the oil has been drained, screw back the drain plug in the bottom of the box. Fill the

gearbox with the new oil (it is adviced to use a funnel with flexible tubing). Oil level
should reach to the lower edge of the hole. Then screw the pour-in plug back. If the seals
under the plugs are damaged, replace them with new ones.

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7.1.2 Engine oil replacement

See the guidelines for engine operation. To drain the oil, the machine should be either
inclined onto the side with the pour-in neck with oil gauge, or the engine should be
dismounted from the machine (see chapter 7.4 a,b,d).

7.1.3 Table of machine lubrication

Both swivel seatings of rotary lever in
the gearbox

min 1x a

month

yes

silicon oil in

atomizer

5.1

Tightening pulley arm pin (after
disassembling upper casing)

min 2x

yes

grease,

engine oil

5.2

Brake lever seating near the front belt
pulley (accessible after upper casing

disassembly)

min 2x yes

grease,

engine oil

5.3

Machine lubrication

During the

season

After the

season

Lubricant Figure

All cables

- input points to Bowdens

- output points from adjustment

bolts

min 2x
min 2x

yes
yes

silicon oil in

atomizer

-

Plug to pour oil into the

gearbox

Plug to drain oil from the gearbox

Figure 4: Oil plugs

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7.2 Tightening of bolted connections

Check the bolted connections for proper tightening. Check tightening of bolts

fastening the knives in the upper disk and bolts fastening the lower disk onto the flange prior
to any machine use.

7.3 Replacement and sharpening of working knives

If the cutting edges of working knives show wear or a damage to knives results in

machine vibrations, the cutting edges must be renewed or the knives replaced.

,The machine must be standing on a firm support plate and must be secured so that

the knife can be easily accessible and an unexpected spontaneous machine motion
cannot occur.

,Be very careful when dismounting the knives. Their cutting edges are sharp. Protect

your hands with working gloves.

,The engine must be switched off and the cable end connector to the spark plug

disconnected!

1. Turn the screen sides over to back or disassembly the screen with the frame

Figure 5.2: Tightening pulley arm pin

Figure 5.1: Rotary clutch lever

Figure 5.3: Brake lever seating

BDR-595 E EuroAdela

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2. Hold the upper disk so that it does not turn and dismount the knife bolted connection by
using the barrel spanner No. 16 and flat wrench No. 17.

3. Take the knife and parts of knife seating out of the mowing disk. Level the blade and
sharpen the knife cutting edges. Inclination of the sharpened blade should be 30° with
respect to the lower plane of the knife.

,Should some of knives be bent or showing a considerable wear, you must always

replace all knives in the mowing disk!

4. Screw back the bolt with the filler, knife and flat washer. Than screw on the nut.

5. Hold the bolt head with the barrel spanner No. 16 and tighten the nut. All knives must
freely rotate on the bolts. The knives have blades on both sides; when one side is worn
out, the knife can be reversed and the blade of the other side can be used. When replacing
the knife, replace also all damaged parts of the knife clamping (see Fig. 6).

Note: Manufacturer does not answer for damages caused by the machine if the knives

were repaired by unskilled persons without the use of the original spare parts. There is a
“VARI“ stamp on the knife, which identifies the manufacturer and is at the same time a
control mark indicating that the knife is an original spare part.

7.4 V-belt replacement and adjustment of tightening pulley

The V-belt should be replaced according to its wear (cracked sides, torn belt, sides worn
out down to belt carrier fibres, belt pulled out of shape) or after about 100 hours of operation
at the maximum. In this machine, the belt stretched to maximum is considered a belt in which
the distance between the internal belt surfaces is lesser than 7 mm (with the pressed lever of
mowing disk drive clutch) – see Fig. 7.

The replacement procedure is as follows:

Nut M10
Order no.189 561

Washer
Order no. 189 587

Knife
Order no. 189 060

Washer 10.5

Order no. 131 518

Bolt M10x30
Order no. 189 545

Figure 6: Knife clamping on the mowing disk

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a) Drain petrol from the engine tank. Dismount the accelerator lever (2x spanner No. 8)

from the handlebars. Bowden cable should never be dismounted from the control on the
engine!

b) Unscrew three safety nuts (spanner No. 13) on the engine flange and pull the engine out

from the machine frame upwards. Never use force to pull the engine out from the frame!

,Warning: It is not advised to dismount the engine together with the underlying

support plate if not necessary. Should the disassembly of the engine support plate or
gearbox from the machine frame occur, axial alignment of gearbox shafts and
engine must be ensured at reverse assembly. It is therefore adviceable to entrust the
operation to an authorized service shop with the original and manufacturer­approved centring fixture.

,Never put the engine on the side. Oil might get into the exhaust or into the air

cleaner. The best engine seating is with the lower flange dwelling on two lintels
which are at least 7 cm high.

c) Dismount the apron with the frame and upper casing (flat side spanners No. 8, 10, 13).

Dismount the pillar in front of the driven belt pulley (see Fig. 5.3) (spanner No. 10). Take
the old V-belt off the both belt pulleys and replace it with a new one. Original V-belt
marking is OPTIBELT X13x1300Ld 6T6K (Ld = calculated length). It is also possible
to use an equivalent V-belt made by other manufacturers at a size of A13x1270 Li
(Li=internal length) or ½“ x 52“La (La=external length). However, the belt must be
made without rubber on sides! Only this belt model will guarantee that the knife drive
start is continuous at engaging the clutch.

,Should a different belt model be used, the machine manufacturer does not bear any

liability for correct and full functioning of the gear!

d) Put the engine back in its place. Pins in the driven part of the clutch slid on the gearbox

must fall into holes in the driven pulley. Bolt the engine with three safety nuts with flat
washers and screw the accelerator lever back onto the handlebars.

e) Install the V-belt into the groove in the belt pulley on the engine.

f) Check the operation of the tightening pulley and adjustment of guide lamination. With

the lever on the right handlebar grip being completely pressed down, the pulley must
ensure a sufficient belt tension (spring on the cable being extended by about 10 mm as
compared with the normal condition). Possible corrections are to be made by means of
the adjustment bolt No. 2 (see Fig. 8). With the lever switched off, the pulley must be
inclined away from the longitudinal machine axis by 0 - 5° (at maximum) = with the belt
convex side being approx. 1.5 – 2.0 cm from the bottom of the tightening pulley (see Fig.

7) and the cable in the Bowden of the tension pulley must exhibit no slackness. In the
case that the adjustment bolt is completely screwed out and it is necessary to tighten the
V-belt, the spring on the cable can be hooked into the front hole on the arm of the
tightening pulley (see Fig. 7 bottom, note: this connection can be used already from the
manufacturer) and the belt tension can be adjusted once again. Guide lamination on the
right side of the machine must be parallel to the belt and at a maximum distance of 1 – 2
mm from the belt convex side.

g) Mount back the post in front of the driven belt pulley, the upper plastic casing and the

apron with the frame.

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7.5 Setting-up litz wires of pulley, brake and machine travel gear

clutch

In order to guarantee low operating forces on levers which control drive switching, it is
advisable to lubricate cables in Bowdens at least 2x during the season with some oil available
in atomiser (e.g. SILKAL, MD Spray, WD40). Correct functioning of the machine also
requires the correct adjustment of drive controls.

The cable in the brake Bowden must always exhibit a slight slackness (with the
mowing disk drive clutch lever and brake released) so that the brake performance is
sufficient. In order to achieve the brake cable slackness in the Bowden, the adjustment bolts
must be screwed into the chassis or handlebars cross-beam during the adjustment.

The cables in the pulley Bowden and in the Bowden of machine travel gear clutch must
be without slackness, slightly tense. In order to tense the cables, the adjustment bolts must be
screwed out of the chassis or handlebars cross-beam.

Driven belt pulley

Driving belt

pulley (engine)

Tightening pulley

V-belt

Guide pin

Left guide
sheet

Guide pin

Right guide
sheet

Figure 7: Adjustment of tension pulley and maximum extension of V-belt

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Safety nuts in all adjustment bolts should be tightened by using two flat side spanners
No. 10 or No. 9. If there is no more step to be used in the adjustment bolt, it is possible to
displace the hook on the cable into another hole in the metal sheet lever on the handlebars (or
on the travel gear clutch lever on the gearbox and on the arm of the tightening pulley – see
Figures 7 and 8) so that the pre-stress of cables can be again regulated by the adjustment bolt.

Hole for a possible
connection of cable hook

Brake Bowden and

adjustment bolt no. 1

Pulley Bowden and

adjustment bolt no. 2

Machine travel gear clutc

h

Bowden and adjustment bolt

no. 3

Figure 8: Bowdens and adjustment bolts

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7.6 Driving problems: Diagnostics

Problem Reason Remedial action

Tightening pulley does not
stress the belt sufficiently

Set-up tightening pulley by
means of adjustment bolt

No. 2 (see Fig. 8)
Cable fallen out from the
tightening pulley lever

Put the cable back

V-belt fallen behind the
tightening pulley or down
from the belt pulley

Put the belt back

V-belt is torn Replace the belt with a new

one

Mowing disk
does not turn

Excessive belt extension
(see Fig. 7)

Replace the belt with a new

one
Brake cable is stressed Adjust the cable so that it is

slightly slack with the lever

on the right handrail

released; screw on the

adjustment bolt No. 1 (see

Fig. 8)
Brake cam lever is
insufficiently greased

To be oiled

Brake
performance is
insufficient

Worn lining Contact the service shop

Wheel travel
gear clutch does
not switch off

Incorrectly adjusted control
cable

No rumbling must be heard

from the gearbox when

manually turning the travel

wheel in counter-travel

direction (wheel gear

switched off). Keep

screwing on the adjustment

bolt No. 3 until the

rumbling sound disappears.

Wheel travel
gear clutch does
not engage

Another gear defect Contact the service shop

BDR-595 E EuroAdela

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7.7 Table of service operations

Operation During season After season

Gearbox oil check 1x/month yes*
Engine oil check before each use **
Engine air filter check before each use check
Check of knives for fastening and
intactness

before each use

***

check

Upper and lower disk intactness check before each use

***

check

V-belt stress check after 2 hours;

further on after
each 20 hours or
as required

check

V-belt condition check as required check

****

Cleaning of wheel hubs and exchange
of lubricating grease

- yes

Cleaning of machine from impurities
and debris

after each use yes

* The first exchange after 5 hours, then after 100 – 130 hours (according to oil grade);
**

Oil exchange intervals see Operating manual for engine;
*** In the case of damage (even at cutting) – cracks, bending, breakage etc. – repair
required immediately!
**** or exchange after about 100 hours.

7.8 Washing and cleaning of the machine

,At cleaning and washing the machine, proceed to observe valid regulations and

legislation on the protection of water courses and other water resources against
pollution or contamination with chemical substances.

,Never wash the engine with a stream of water! Electric equipment might fail when

starting the engine.

All dirt, debris and plant residues should be removed from the machine after the end of
the season. Check the intactness of working knives, grind the cutting edges (or replace the
knives if necessary) and conserve the knives with conservation oil. Travel wheels should be
dismounted from the axle once in a season, cleaned and the hubs inside filled with a new
filling of plastic lubricant.

,The engine must be switched off and the cable termination to the spark plug

disconnected!

Wheel disassembly, lubrication and assembly procedure:
a) Underlay the machine so that the wheels can freely turn. The machine must be secured

against spontaneous motion.

b) Take out the split pin and screw off the slotted nut by using spanner No. 24. Remove the

wheel from the axis.

c) Clean the wheel hub inside, wheel hub flange with balls and the free wheel from

impurities and old grease.

BDR-595 E EuroAdela

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d) Fill the hub inside with new grease (e.g. for water pumps) lubricating at the same time

also the flange with balls and free wheel surfaces.

e) Slide the free wheel on the wheel axis. The pin driven into the wheel axis must lean

against the inclined surface on the free wheel (see Fig. 9). Put the wheel onto the axis,
screw the nut to the stop; then release it by one split pin groove and secure the connection
with a new split pin. The wheel must freely turn with no great axial clearance.

f) Check of correct free wheel assembly: Press the machine travel gear clutch lever, turn the

driving wheel by hand in the direction of forward travel. The free wheel must be clicking.

7.9 Machine storage

Prior to any longer storage, clean the machine from all dirt, debris and plant residues.

Repair damages on painted machine parts.

When putting the machine out of operation for a longer time, it is advisable:

a) to conserve knives on the mowing disk;
b) to drain petrol from the engine fuel tank and from the carburetter (more

instructions see guidelines for engine operation).

Prevent access of unauthorized persons to the machine. Protect the machine from
weather impacts but don’t use air-tight protection due to a possibly increased corrosion under
it.

7.10 Disposal of packaging and machine after service life

expiration

After unpacking the machine, you are obliged to provide for the disposal of packaging
with the use of secondary raw-materials according to Waste Law No. 185/2001 Gaz. (as
amended) and with respect to the decrees of local town or municipal authorities.

Split pin

Slotted nut M16

Washer ↵ 17 mm

Wheel 3.00-8“

Figure 9: Free wheel (on left wheel, mirrored on the right wheel)

Shaft-Wheel axis

Spring

Free wheel

Pin

BDR-595 E EuroAdela

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The following procedure is recommended for machine disposal after the end of its service

life:

1. Dismount all parts from the machine that can still be used.

2. Dismount plastic machine parts and parts of non-ferrous metals. The stripped machine

remainder and the dismounted parts are to be liquidated according to Waste Law No.
185/2001 Gaz. (and its possible further amendments) and with respect to the decrees of
local town or municipal authorities.

Instructions for ordering spare parts

The following data are to be used for easier identification when ordering the spare parts:

1. Machine type, engine type, machine serial number and year of manufacture;

2. Ordering number given by manufacturer and its name in the component list;

3. Number of ordered pieces separately for each item;

4. Precise address, telephone number, fax number or e-mail address;

5. If you are not certain about the correct identification of the component, send the
damaged component either to the nearest service shop or to the manufacturer;

6. All components should be ordered in the nearest service shop or at your dealer’s.

In the case of any confusions concerning the spare parts or technical issues, the VARI a.s.
commercial, customer-service or technical departments are prepared to answer all your
inquiries.

Contact to manufacturer

VARI, a.s. Telephone: [phone]
Opolanská 350 Fax: [phone]
Libice nad Cidlinou ([phone]
CZECH REPUBLIC e-mail: [e-mail]
289 07 internet: http://www.vari.cz/
http://techweb.vari.cz

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8 List of components

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8.1 Machine casing

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Pos. Name Size Drawing-Standard Order. No. Pcs

1 Frame assembly 22 9 1536 050 196 001 1
2 Apron frame-front 22 9 1856 008 196 018 1
3 Apron frame-rear 22 9 1856 009 196 019 1
4
5 Upper housing 22 9 8545 029 196 020 1
6 Mud-guard flap holder 32 0 1530 129 196 012 1
7
8 Mud-guard flap 32 0 8530 036 189 115 1

9
10 Mud-guard flap support 32 0 9230 010 182 010 1
11
12 Pillar 632 0 1520 049 196 525 1
13 Rear pillar 632 0 1520 050 196 526 1
14 Apron 632 0 1840 073 196 514 1
15 Left mud guard 632 0 8545 045 196 506 1
16 Right mud guard 632 0 8545 046 196 505 1
17 Lower housing 632 0 8545 047 196 513 1
18
19 Bolt M6x16

ČSN 02 1103.25

189 552 10

20 Bolt M6x20

ČSN 02 1103.25

189 551 9

21 Bolt M8x16

ČSN 02 1103.25

106 547 2

22 Bolt M8x30

ČSN 02 1174.25

196 537 2

23 Nut M6

ČSN 02 1492.25

168 516 15

24 Nut M8

ČSN 02 1492.25

104 622 3

25 Washer 6,4

ČSN 02 1702.15

189 571 15

26 Washer 8,4

ČSN 02 1702.15

131 517 1

27 Washer 6,6

ČSN 02 1727.15

169 508 16
28
29
30 Washer 9

ČSN 02 1729.05

150 536 2
31 Washer 8,2

ČSN 02 1740.05

104 574 2
32
33 Nut cap 034-03-M6

SUNAP Neratovice

169 505 6
34 Nut cap 034-03-M8 (13)

SUNAP Neratovice

169 504 2
35
36

Machine casing

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8.2 Handlebars

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HANDLEBARS

Pos. Name Size Drawing-Standard Order. No. Pcs

1 Handlebars 22 9 8078 059 196 002 1
2 Control lever 32 0 8058 009 196 013 2
3
4 Clutch bowden cable 622 9 8074 044 196 515 1
5 Pulley bowden cable 622 9 8074 045 196 516 1
6 Brake Bowden cable 622 9 8074 046 196 517 1
7 Lever stop 632 0 8065 002 196 519 2
8 Lever pin 632 0 9311 157 196 520 2

9
10 Bolt M5x10 ÈSN 02 1103.25 195 525 2
11 Bolt M8x50 ÈSN 02 1319.25 189 593 2
12 Nut M6 ÈSN 02 1401.25 1800141 3
13 Nut M5 ÈSN 02 1492.25 105 518 2
14 Washer 8,4 ÈSN 02 1702.15 131 517 2
15 Yoke ring 4 ÈSN 02 2929.05 189 576 4
16 Washer 5,3 ÈSN 021702.15 189 581 2
17 Plastic rosebit M8-pr.50 "JJW" EUROPLAST 189 521 2
18 Washer 6,4 ÈSN 02 1702.15 189 571 4
19 Rubber grip ART 773 èerná

195 518 2

20 Gas lever AE 653 H START 182 532 1

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8.3 Mowing disk drive

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34

MOWING DISK DRIVE

Pos. Name Size Drawing-Standard Order. No. Pcs

1 Brake shoe 22 9 1664 024 189 014 2

2 Driven belt pulley 22 9 3325 012 189 004 1

3 Upper disk 22 9 5025 007 189 056 1

4 Brake cam 22 9 8032 048 196 003 1

5 Pulley arm 32 0 3330 034 196 010 1

6 Drive 32 0 3821 017 189 058 1

7 Drive Shaft 32 0 3822 022 196 005 1

8 Lower disk 32 0 5020 011 189 057 1

9 Knife 32 0 6030 009 189 060 3

10 Shim block 42/36/0,1 32 0 9220 024 110 012 3
12 Distance ring 32 0 9220 199 189 011 1
13 Housing 32 1 9220 126 127 014 1
14 Pulley 632 0 3325 040 189 586 1
15 Flange 632 0 3821 015 189 059 1
16 Washer 14 632 0 9220 205 189 061 3
17 Brake shoe pin 632 0 9311 152 196 524 1
18 Pulley bearing 632 0 9320 071 196 528 1
19 Brake shoe spring 632 0 9746 044 189 511 1
20 Spring TZ1,8x16,2x63x20 FEVOZ Slavièín 169 514 1
21 Spring TZ0,8x8,8x95,2x100 FEVOZ Slavièín 189 516 1
22 Bolt M6x14 ÈSN 02 1151.25 189 557 6
23 Bolt M6x45 ÈSN 02 1103.25 195 523 1
24 Bolt M6x55 ÈSN 02 1101.25 196 523 1
25 Bolt M10x30 ÈSN EN 24017 189 545 3
26 Nut M6 ÈSN 02 1401.25 1800141 6
27 Nut M6 ÈSN 02 1492.25 168 516 2
28 Nut M10 ÈSN 02 1401.55 189 561 3
29 Washer 6,4 ÈSN 02 1702.15 189 571 4
30 Washer 8,4 ÈSN 02 1702.15 131 517 1
31 Washer 10,5 ÈSN 02 1702.15 131 518 3
32 Washer 21 ÈSN 02 1702.15 124 530 1
33 Washer 6,1 ÈSN 02 1740.05 6510920 6
34 Pin 5x40 ÈSN 02 2156 196 502 1
35 Feather 5x5x25 ÈSN 02 2562 189 574 1
36 Feather 6x6x25 ÈSN 02 2562 169 503 1
37 Retaining ring 8 ÈSN 02 2930 195 534 2
38 Retaining ring 10 ÈSN 02 2930 6021519 1
39 Retaining ring 20 ÈSN 02 2930 110 515 2
40 Retaining ring 35 ÈSN 02 2931 126 503 1
41 Retaining ring 42 ÈSN 02 2930 136 506 2
42 Bearing 6300 2RS ÈSN 02 4630 189 585 1
43 Bearing 6004 2RS ÈSN 02 4630 9943158 4

Set of spare knives

129 8565 144 189 066

BDR-595 E EuroAdela

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36

8.4 Wheel driving gear

BDR-595 E EuroAdela

37

Pos. Name Size Drawing-Standard Order. No. Pcs

1 Gearbox BDR-595 22 9 3282 052 196 014 1
2 Driven belt pulley 22 9 3325 030 196 026 1
3 Driven clutch element 32 0 3625 029 196 025 1
4 Engine plate 22 9 8032 050 196 008 1
5 Feather 3/16" 32 0 3330 021 189 036 1
6 Screw W 3/8" 32 0 9016 057 105 011 1
7 Cuff 632 0 1642 008 189 507 2
8 Free wheel 632 0 8021 026 196 509 2

9 Spring 632 0 9746 046 189 512 2
10 Wheel clutch spring 632 0 9746 056 196 518 1
11 Bolt M5x12 ČSN 02 1143.50 189 580 6
12 Bolt M8x16 ČSN 02 1103.25 106 574 4
13 Bolt M8x40 ČSN 02 1103.25 196 503 4
14 Nut M8 ČSN 02 1492.25 104 622 3
15 Nut M16x1,5 ČSN 02 1412.25 189 560 2
16 Washer 5,1 ČSN 02 1740.05 127 512 6
17 Washer 5,3 ČSN 02 1702.15 189 581 6
18 Washer 8,2 ČSN 02 1740.05 104 574 8
19 Washer 8,4 ČSN 02 1702.15 131 517 7
20 Washer 10,2 ČSN 02 1740.05 106 530 1
21 Washer 17 ČSN 02 1702.25 189 566 2
22 Split pin 4x32 ČSN 02 1781.05 189 577 2
23 Feather 4x4x18 ČSN 02 2562 196 508 1
24 Left wheel 3.00-8 EP-007 ET-91590 189 505 1
25 Right wheel 3.00-8 EP-007 ET-91590 189 506 1
26 V-belt X13x1300 Ld 6T6K OPTIBELT 196 504 1
27 HONDA engine GCV 160 171 535 1
28 Ball pr. 7,144 189 575 4

Left wheel 22 1 1770 024 189 042 1
Right wheel 22 1 1770 025 189043 1

Wheel driving gear

NOTE : For easier replacement of wheels, the manufacturer supplies wheels with pressed-on balls ( pos. 28) under
designation :

BDR-595 E EuroAdela

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8.5 Gearbox

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39

GEARBOX

Pos. Name Size Drawing-Standard Order. No. Pcs

1 Fork weldment 22 1 3330 013A 189 078 1
2 Complete lever 22 9 3330 017 196 022 1
3 Complete carrier

plate

22 9 3616 006 189 029 1

4 Worm 2:54 32 0 3214 028 196 023 1
5 Worm wheel 32 0 3221 016 196 027 1
6 Shaft-Wheel axis 32 0 3814 008 189 028 1
7 Shim block 20/14,2/0,2 32 0 9220 115 127 027 1
8 Shim block 20/14,2/0,3 32 0 9220 114 127 026 1

9 Distance ring 32 0 9220 195 189 032 1
10 Dish 32 0 9220 197 196 032 1
11 Plug 32 1 9016 036 106 050 2
12 Pinion 19 teeth 632 0 3014 010 196 530 1
13 Gear 51 teeth 632 0 3021 028 196 529 1
14 Cover 632 0 3253 044 196 511 1
15 Box 632 0 3253 045 196 510 1
16 Felt 632 0 9520 045 189 528 1
17 Spring 632 0 9746 047 189 527 1
18 Pin M4x10 ÈSN 02 1143.50 196 521 4
19 Pin 5x12 ÈSN 02 2150 196 522 2
20 Pin 5x20 ÈSN 02 2150 189 566 2
21 Pin 10x45 ÈSN 02 2150 2010260 2
22 Retaining ring 12 ÈSN 02 2930 6021502 2
23 Retaining ring 14 ÈSN 02 2930 110 513 1
24 Retaining ring 17 ÈSN 02 2930 110 514 1
25 Retaining ring 28 ÈSN 02 2930 189 553 1
26 Retaining ring 47 ÈSN 02 2931 126 504 2
27 Baering 3203 ÈSN 02 4630 196 533 1
28 Bearing 6005 ÈSN 02 4630 129 535 2
29 Baering 6202 ÈSN 02 4630 9943131 1
30 Baering 6203 ÈSN 02 4630 106 507 1
31 Ring 18x14 ÈSN 02 9280.2 189 591 1
32 Ring 14x18 AL ÈSN 02 9310.3 106 539 2
33 Gufero 17x30x7 ÈSN 02 9401.0 9943223 1
34 Gufero 25x47x7 ÈSN 02 9401.0 124 505 2
35 Feather 6x6x20 ÈSN 022562 196 536 1