Stiga TRE 0702 Instruction manual

WORKSHOP MANUAL
WORKSHOP MANUAL
The manufacturer reserves the right to make all the necessary technical or commercial improvements to
its products, so there may be some differences between the series of engines and the contents of this
manual. However the basic specifications and different operating procedures will remain the same.
by STIGA - No use of the illustrations or duplication, reproduction or translation, even partial, of the texts
in this document may be made without explicit authorization.
IMPORTANT NOTICE : The information contained herein is intended for Service Operations and professionals
only, able to competently perform the operations described herein, using the appropriate equipment in
order to safeguard se-curity and performance of the machine. The manufacturer is not liable for damages
or injuries arising from operations performed by individuals or inadequate facilities.
PRODUCTION YEAR
Rel. 0.0 2018-->....
TRE 0701 - TRE 0702
TRE 0801
TRE 0701 - TRE 0702
TRE 0801

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pag. 3
Service manual
INTRODUCTION..................................................................................................... 5
1. RULES AND PROCEDURES FOR SERVICE CENTRES .......................................... 6
1.1. Guarantee validity ...................................................................................................................................6
1.2. Service repairs after guarantee period..................................................................................................6
1.3. Faultnotication.......................................................................................................................................6
1.4. Spare parts request..................................................................................................................................6
2. GENERAL AND SAFETY REGULATIONS............................................................. 7
2.1. Qualicationofoperators .......................................................................................................................7
2.2. Safety measures.......................................................................................................................................7
2.3. Precautions during servicing...................................................................................................................7
2.4. Etichette di sicurezza ...............................................................................................................................8
2.5. Necessary equipment .............................................................................................................................8
2.6. Symbols and terms used for safety purposes........................................................................................8
3. TECHNICAL DATA AND SPECIFICATIONS........................................................ 9
3.1. Identication.............................................................................................................................................9
3.2. Technical data .........................................................................................................................................9
3.3. Adjustments ..............................................................................................................................................9
3.4. Expendable materials..............................................................................................................................9
3.5. Use limits....................................................................................................................................................9
3.6. Tightening torques..................................................................................................................................10
3.7. Table of Tightening torques ...................................................................................................................11
3.8. Identicationofengineunits.................................................................................................................12
4. ENGINE TUNING AND TESTING ...................................................................... 13
4.1. Operating guidelines .............................................................................................................................13
4.2. Engine tuning program..........................................................................................................................13
4.3. Functional test ........................................................................................................................................14
5. PETROL SUPPLY AND AIR INTAKE ................................................................... 15
5.1. Maintenanceoflteringelement .........................................................................................................16
6. STARTING SYSTEM........................................................................................... 18
6.1. Replacement of brushes .......................................................................................................................18
6.2. Replacement of starting motor.............................................................................................................20
7. CARBURATION................................................................................................ 21
7.1. Removing and cleaning the carburettor .............................................................................................21
7.2. Replacing the carburettor.....................................................................................................................23
7.3. Adjusting minimum speed ....................................................................................................................24
7.4. Adjusting maximum speed...................................................................................................................24
7.5. Adjusting the carburation......................................................................................................................24
CONTENTS
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8. GOVERNOR SYSTEM OF THE CARBURETTOR ................................................. 25
8.1. Adjusting of accelerator cable ............................................................................................................25
8.2. Verify petrol pump (if present)..............................................................................................................26
8.3. Pump replacement (if present).............................................................................................................26
8.4. Adjusting maximum speed...................................................................................................................26
8.5. Replacing the lever support..................................................................................................................28
9. IGNITION......................................................................................................... 30
9.1. Checkingtheefciencyoftheignitionsystem ..................................................................................30
9.2. Adjusting the air gap and checking the coil ......................................................................................31
9.3. Replacing the coil..................................................................................................................................32
10. ENGINE BLOCK - External repairs............................................................... 33
10.1. Checking the compression...................................................................................................................33
10.2. Adjusting the valve clearance .............................................................................................................34
10.3. Dismantling and cleaning the cylinder head .....................................................................................35
10.4 Overhauling the cylinder head and valves ........................................................................................36
10.5.Dismantlingandreplacingthemagnetoywheel .............................................................................39
10.6. Checking the oil breather .....................................................................................................................40
10.7.Replacingtheuppercompressionringoftheengineshaft(ywheelside) ....................................41
10.8. Verify alternator charge ........................................................................................................................41
10.9.Replacingthelowercompressionringoftheengineshaft(sumpside)..........................................42
11. ENGINE BLOCK - Overhauling internal parts............................................. 43
11.1. Remove the engine from the machine................................................................................................43
11.2. Carter opening .......................................................................................................................................43
11.3.Dismantlingandcheckingthecamshaftandcounterweightgovernor..........................................44
11.4. Dismantling and checking the piston, piston rings, connecting rod and engine shaft ..................47
12. TURNING OFF AND STOPPING ENGINE ....................................................... 53
13. EXHAUST SYSTEM .......................................................................................... 53
14. TROUBLESHOOTING...................................................................................... 54
CONTENTS
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Service manual
The purpose of this manual is to provide to Service
Centres the information necessary for a correct
maintenance, dismantling and repair procedure
for engines TRE 0701, TRE 0702 and TRE 0801.
Interventions on the engine must be performed
in accordance with instructions in the following
pages and with safety regulations in force in the
country in which the engine is operated, and only
by authorised and appropriately trained personnel.
In every manual page the following informations
are described:
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Service manual
General information
The
located between the carburettor and the cylinder head, which carries the air/petrol mix towards the intake
valve.
See the relevant section [ 14] for advice on resolving problems due to the malfunctioning of the air
intake system.
cylinder.
other parts.
5. PETROL SUPPLY AND AIR INTAKE
3
3
4
5.1.
WARNING: Never run the engine without air
-
ged.
1).
2 - Unscrew the two screws (1) and remove the
knobs (2).
3) and remove the
4) from the cartridge.
22
1
A: Motor typ for which the page is valid.
B: Reference to the chapter and the argument
with the relative numbering.
C: Presence of previous or following chapters from
the present chapter.
D: Issue date or possible audit.
E: Audit number.
F: Page progressive numbering.
INTRODUCTION
A
B
CC
DEF
Certain symbols are used in the manual, highlighting
particularly important information, risks, warnings
and prescriptions:
Warns of operations that should be carried
out with utmost care to avoid impairing the
functionality and safety of the lawnmower.
Warns of operations that should be carried
out with utmost care to avoid injury to the
operator
 NOTE:Referstospecicadvicebythema-
nufacturer.
Reference to another procedure or part of
the manual.
Recommends that washers and O-rings are
checked and replaced if necessary.
Refers to use of special tools.
Shows all the operations requiring different
intervention methods depending on the en-
gine version.
NOTE: During the description of procedures,
the indications “right”, “left”, “front”, “rear”,
“upper” and “lower” refer to the engine
mounted on the machine seen from the
user’s perspective.
Please read all the contents of this manual to be-
come familiar with the basics of the engine, which
is fundamental for operating in a logical manner
without making errors or wasting time.
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1. RULES AND PROCEDURES FOR SERVICE CENTRES
1.1. Guarantee validity
The warranty is supplied under the terms, procedu-
res and limits stated in the contract.
1.2. Service repairs after guarantee period
The Service Centre must write a report for each
intervention containing the serial number of the
engine [ 3.1], and summary information about
the problems complained of, the intervention made
and possible spare parts used..
A copy of these reports must be kept and made
available to the manufacturer together with the
replaced parts, in case clients should make further
complaints.
1.3. Faultnotication
The manufacturer should be informed of all faults
that recur frequently; this allows it to carefully exa-
mine the problem and make corrections on the
production line.
Similarly, the manufacturer shall report any faults
traced on its engines, indicating the best trouble-
shooting procedure.
1.4. Spare parts request
When asking for spare parts, you must quote
their code by referring to the exploded views
corresponding to the year of manufacture reported
on the nameplate [ 3.1].
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Service manual
2. GENERAL AND SAFETY REGULATIONS
IMPORTANT: Before commencing with any
intervention, carefully read the information
provided in the present manual, in particular
the following safety regulations.
2.1. Qualicationofoperators
All maintenance, disassembly and repairs must be
carried out by expert mechanics who are familiar
with all the accident prevention and safety regu-
lations after reading through the procedures in this
manual.
2.2. Safety measures
All the engines are built in conformity with the Eu-
ropean safety regulations in force.
To maintain initial safety levels in the long term, the
Service Centre should take proactive measures by
making checks whenever possible.
Every time you are asked to service the engine
(or the lawnmower on which it is installed), you
should:
• check:
- that the safety devices function correctly;
- that the casings and protection covers have not
been removed;
- thatthenameplatesorspecicationlabelshave
not been removed or made illegible, (as they
form an integral part of the safety devices).
• also:
- restoretoproperworkingorderanysafetyde-
viceswhichhavebeenmanipulatedorremo-
ved;
- replace ineffective, damaged or missing guards
and covers;
- replace illegible labels;
- donotcarryoutoperationsormodicationson
thelawnmowerorontheenginethatcouldaf-
fect their performance or lead to an improper or
differentusefromtheoneforwhichithasbeen
designed and approved;
- warn the customer that the failure to comply
withtheabovepointsautomaticallyvoidsthe
warrantyandtheresponsibilityofthemanufac-
turer.
2.3. Precautions during servicing
As well as following the usual accident prevention
regulations that apply to most repair shops, we
recommend you:
- disconnect the spark plug cap before servicing;
- protect hands with suitable working gloves,
especiallywhenworkingnearthecuttingunit;
- check that you do not cause accidental petrol
leaks or other losses;
- donotsmokewhenworkingonthetankorwhen
handling petrol;
- do not inhale oil or petrol fumes;
- clean up all traces of spilt petrol immediately;
- testtheengineinawell-ventilatedenvironment
orwherethereareadequateexhaustfumeex-
traction systems;
- donotpollutetheenvironmentwithoil,petrolor
otherwasteanddisposeofallwasteinaccor-
dancewiththelawsinforce;
Exhaust gas contains carbon monoxide,
which is highly toxic, odourless and co-
lourless. Avoid inhaling.
- Perform tests on the engine in a well-ven-
tilated environment or in the presence of
adequate exhaust gas extraction systems.
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Service manual
2.4. Etichette di sicurezza
On the cowl motor, in a immediately identication
position, are some indication or prescription plates
for the safety operator.
The plates are as follows:
• ••• ••••
TREXXXX XXX
1 - Fire hazard due to:
- Petrol or oil
Prevent by following the precautions below:
- Do not smoke or ignite a ame in the vicinity of
the petrol or oil;
- Turn engine off before adding petrol;
- Do not spill petrol on overheated or electric parts
of the engine;
- Handle or store petrol or oil in well-ventilated
areas;
- Use non-ammable oil for cleaning engine parts.
-Accumulationofammablematerial
Prevent by following the precautions below:
- Remove dry leaves, chips, pieces of paper, dust
or other ammable material which has accumu-
lated in or is attached to the engine.
- Electrical cabling
Short circuits can cause res. Prevent by following
the precautions below:
- Always keep the electrical connections of the
machine clean and tightly sealed;
- Tighten any loose connectors or cabling clamps.
Replace those that are damaged.
2 - Observe the instructions and warnings contained
in the present manual and on the safety plates on
the engine.
Inappropriate functioning and maintenance can
result in serious injury or even death.
2. GENERAL AND SAFETY REGULATIONS
1 2 3
4
3 - Ventilation of closed areas:
In the event that it is necessary to start the engine
in a closed environment or if petrol or cleaning oil
is being used, open doors and windows to ensu-
readequate ventilation and, therefore, avoid gas
poisoning.
4 - Motor label (see [ 3.1])
2.5. Necessary equipment
All the operations can be carried out with the tools
normally used in a good garage.
The , symbol used for certain interventions
indicates that special tools or equipment are re-
commended.
2.6. Symbols and terms used for safety purposes
Some paragraphs in this manual are preceded by
symbols which indicate the following:
Operations that should be carried out with ut-
most care to avoid impairing the functionality
and safety of the engine and/or lawnmower
on which it is installed.
Operations that should be carried out with
utmost care to avoid injury to operators.
“WARNING” stresses the risk of injury to oneself
and others if instructions and regulations are not
observed.
INDEX
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Service manual
3.1. Identication
Every motor is marked with a serial number on the
base and applied on the cowl; this serial number
can identify:
• ••• ••••
TREXXXX
XXX
The serial number must be reported on every ope-
ratingsheetinthewarrantyapplicationandisfun-
damental for identifying and ordering spare parts.
3.2. Technical data
TRE 0701 TRE 0702 TRE 0801
Displacement 432 cc 414 cc 452 cc
Bore 90 mm 88 mm 92 mm
Stroke 68 mm
Minimum speed (SLOW) 1850 (±150) r.p.m.
Maximum speed (FAST) 2950 (±250) r.p.m.
Oil sump capacity 1.20 litres
Weight 32 kg
3.3. Adjustments
Distancebetweensparkplug
electrodes 0,6 - 0,8 mm
Coil air gap 0,25 - 0,40 mm
Inlet valve clearance 0,10 - 0,15 mm
Exhaust valve clearance 0,15 - 0,20 mm
Generator charge 3,0 ÷ 4,0 Ω(Ohm)
Daily progressive
number
3. TECHNICAL DATA AND SPECIFICATIONS
3.4. Expendable materials
Petrol Unleaded (green)
minimum 90N.O.
Engine oil - from 5 to 35 °C
- from -15 to +35 °C SAE 30 - 10W30
Spark plug RN12YC (Champion)
or equivalent
3.5. Use limits
The following table gives the use limits of certain
components subject to wear, after which the com-
ponent must be replaced.
TRE 0701
TRE 0702 TRE 0801
Brushes lenght starter push bot-
ton 8.5 ÷ 12 mm
Compression 4.2 bar
Minimum inlet valve stem diameter 6.425 mm
Minimum exhaust valve stem
diameter 6.375 mm
Minimum inlet valve head rim
thickness 0.5 mm 0.8 mm
Minimum exhaust valve head rim
thickness 1.0 mm
Valveseatwidth 1.5 mm
Minimum valve spring length 37.5 mm
Maximumgapbetweenendsof
cylinder rings 0.8 mm
Max. axial gap for compression
rings 0.15 mm
Minimum gudgeon pin diameter 19.95 mm
Max. gudgeon pin-piston seat
diameter 20.04 mm
Max. connec-
ting rod dia-
meter
gudgeon pin
side 20.07 mm
crank side 36.07 mm
Diameter connecting rod’s pin on
engine shaft 35.93 mm
Verify the engine shaft extremes 0.10 mm
Diameter Pump seat on camshaft 15.916 mm
Diameter aspiration cam 32.15 mm
Diameter discharge cam 32.35 mm
Diameter oil pump seat 29.21 mm
Height pump cylinder 9.95 mm
Cylinder/seat clearance on the
pump 0.26 mm
Year of
manufacture
Date
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3. TECHNICAL DATA AND SPECIFICATIONS
3.6. Tightening torques
8-12 Nm
18-22 Nm
8-12 Nm
110-120 Nm
8-10 Nm
8-12 Nm
8-12 Nm
8-12 Nm
24-27 Nm
16-18 Nm
50-55 Nm
8-12 Nm 8-12 Nm
8-12 Nm
22-30 Nm
8-12 Nm
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3. TECHNICAL DATA AND SPECIFICATIONS
3.7. Table of Tightening torques
Chapter Ref. Descriptionofscrew Tightening torques
6 - 10 Attachment bolt ywheel 110 - 120 Nm
6 - 9 Coil xing screws 8 - 12 Nm
6 Fixing screw starting motor 22 - 30 Nm
6 Starting motor screw 8 - 12 Nm
7Fixing nuts carburettor and lter 8 - 12 Nm
8 Support screws petrol pump 8 - 12 Nm
8 Support return air screw 8 - 12 Nm
8 Support screws 8 - 12 Nm
9 - 10 Spark plug tightening torque 18 - 22 Nm
10 Screws valve cover 8 - 12 Nm
10 Fixing head screws 50 - 55 Nm
10 Screws small plate drop wire 8 - 12 Nm
10 Fixing screws generator 8 - 12 Nm
11 Screws cover oil pump 8 - 12 Nm
11 Union screws under carter and sump 24 - 27 Nm
11 Fixing screws lower connecting rod cap 16 - 18 Nm
P.S.Forthecouplingtourqueofallstandardscrewsrefertothesingletable.
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3.8. Identicationofengineunits
For ease of reference, this manual has subdivided maintenance operations into different sections, each of
which refers to an engine component unit as indicated in the diagrams below.
3. TECHNICAL DATA AND SPECIFICATIONS
Air intake
Carburettor
Ignition
Carburation control
Engine block
Turning off and stopping engine
Starting system
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Service manual
4. ENGINE TUNING AND TESTING
4.1. Operating guidelines
The engine requires a series of interventions (shown in the table below) in order to ensure minimum basic
maintenance.
Operation First 5 hours Every 5 hours
or daily
Every 25
hours or
every season
Every 50
hours or
every season
Every 100
hours
Check oil level -■---
Change oil *(1) ■---■
Check and oil pre-lter *(2) -■---
Blow lter *(2) - - ■- -
Check spark plug ---■-
Replace spark plug ----■
*(1) Replace the oil every 25 hours if the engine is working at full load or at high temperatures.
*(2) Clean the air lter more often if the machine is working in dusty areas.
For the operations that are not difcult for the nal
user the assistance centre must maintain the mo-
tor in perfect efciency, in accordance with two
intervention lines:
- Tuning the engine whenever possible.
- Recommending the client a routine maintenan-
ce program at set intervals (e.g. at the end of
the season or before a long period of inactivity).
4.2. Engine tuning program
As part of general engine tuning or any intervention
on the machine, it is recommended that the Service
Centre performs a series of operations aimed at
maintaining the engine’s efciency.
Tuning should involve:
- external blowing and cleaning the cylinder
head, cylinder and mufer by removing any
remains of grass and mud;
- checking the oil level, topping up or replacing
parts if necessary;
- cleaning the air lter [ 5.1];
- adjusting minimum and maximum speeds [
7.3 and 8.4];
- inspecting the condition of the spark plug; che-
cking the distance between the electrodes [
9.1];
- tightening the screws [ 11.2];
- functional test [ 4.3].
Should the checks and adjustments fail to achieve
a satisfactory result, refer to chapter [ 14] for
troubleshooting.
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4.3. Functional test
A functional test needs to be carried out at the
end of each servicing operation, to check that the
operations made are effective. The test must be
performed in accordance with safety regulations
provided for the use of the machine on which the
engine is mounted.
The functional test is carried out as follows:
a. Refuelling and checking the supply system
When you have refuelled the tank with new petrol,
check the seal of the tank, the cap and the car-
burettor pipe.
b. Cold starting test
With the throttle control in “CHOKE”, start the engine
a few times to check it runs normally.
c. Check the engine rpm
When the engine is hot enough, check the engine
speed with the throttle control set to “SLO” and
“FAST”; the readings should be equal to the speci-
cations [ 3.2].
d. Hot start test
With the engine hot and the throttle control set to
“SLOW”, start the engine a few times to check it
runs normally.
If all of these operations have a positive result, the
engine can be considered fully serviceable and be
returned to the client.
4. ENGINE TUNING AND TESTING
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Service manual
IMPORTANT: Carefully read the information below before commencing any intervention.
General information
The petrol supply occurs via a tank mounted on the machine and connected to the carburettor by a pipe.
A lter, positioned between the tank and the petrol pump, stops deposits and impurities from reaching the
carburettor.
Supply to the oat chamber of the carburettor occurs via the petrol pump and the volume of petrol taken
from the tank during operation is compensated by a breather tted in the cap.
See the relevant section [ 14] for advice on resolving problems due to the malfunctioning of the petrol
supply system.
WARNING: All interventions on the supply system must be performed in safe conditions, therefore:
- do not smoke;
- workinaventilatedenvironmentawayfromnakedamesorunprotectedsourcesofheat;
- Collect any remaining petrol by positioning a suitable container under the engine, avoiding soiling the
workbench;
- remove all traces of spilt petrol immediately.
5. PETROL SUPPLY AND AIR INTAKE
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General information
The lteringsystem consists of an air lter directly connected to the carburettor and an internal manifold,
located between the carburettor and the cylinder head, which carries the air/petrol mix towards the intake
valve.
See the relevant section [ 14] for advice on resolving problems due to the malfunctioning of the air
intake system.
Aninefcientltercanletdustordebrisenterthecylinder,causingprematureweartothepistonringsand
cylinder.
The air lter is found on the left hand side of the engine and can be inspected without having to remove
other parts.
5. PETROL SUPPLY AND AIR INTAKE
3
3
4
5.1. Maintenanceoflteringelement
WARNING: Never run the engine without air
lter.Theenginewouldcertainlybedama-
ged.
1 - Clean around the lter cover (1).
2 - Unscrew the two screws (1) and remove the
knobs (2).
3 - Remove the lter element (3) and remove the
prelter (4) from the cartridge.
22
1
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Service manual
H2O
H2O
4 - Touch the cartridge on a solid surface and blow
with compressed air from the interior side to remove
dust and product residues.
IMPORTANT : For the cartridge cleaning don’t
use water, petrol, detergtent.
5 - Wash the prelter with water and detergent and
let it air dry.
 IMPORTANT:thepreleterMUSTNOTbeoiled.
6 - Ret the prelter (4) on the cartridge.
7 - With a jet of compressed air, clean inside the
seat (5) of the lter by removing dust and remains
of grass, making sure that the intake pipe hole (6)
is closed so that nothing gets inside the pipe.
8 - Install the foam element (3) in its housing and
ret the cover (1), tightening the knobs.
5. PETROL SUPPLY AND AIR INTAKE
H2O
H2O
5
6
3
1
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Release 00 - 03/2018
pag. 18
Engine TRE 0701-TRE 0702-TRE 0801
Service manual
General information
The starting system consists of the starting motor mounted on the engine casing which transmits movement
to the ywheel and therefore, to the enging shaft.
See the relevant section [ 14] for advice on resolving problems due to the malfunctioning of the star-
ting system.
The starting motor is located on the right-hand side of the engine. For maintenance operations, it is neces-
sary to dismantle the motor from the machine, observing the instructions provided in section [ 11.1].
Then proceed with the operations described below.
6. STARTING SYSTEM
1
2
2
3
5
4
6
7
6.1. Replacement of brushes
1 - Remove the cowl (1) of the engine by removing
the three screwsi (2).
2 - By means of a pneumatic wrench, loosen the nut
(3) and remove the fan (4), retaining the ywheel
lock (5).
3 - Remove the electronic coil (6) by removing the
screws (7).
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Release 00 - 03/2018
Engine TRE 0701-TRE 0702-TRE 0801
pag. 19
Service manual
6. STARTING SYSTEM
4 - Using a suitable extracting tool, remove the
ywheel (8) as indicated in the diagram.
Ensure that the engine shaft key is retained.
5 - Remove the screws (9) and lift out the starting
motor (10).
6 - Loosen the screws (11) and remove the lower
part of the starting motor.
7 - Unscrew the two screws (12) which secure the
brushes (13) inside the lower cover of the starting
motor. Remove the springs (14).
9
9
10
11
11
13
13
12
12
8
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Release 00 - 03/2018
pag. 20
Engine TRE 0701-TRE 0702-TRE 0801
Service manual
8 - Verify the condition of the brushes and,
using a gauge, measure (15) the length which
should be between 8.5 and 12 mm. If the length is
shorter, the brushes must be replaced as indicated
below.
9 - Insert new brushes in the appropriate seats and
secure with the screws (12).
Pay particular attention to the correct positioning
of the brushes and springs.
10 - Re-assemble the starter motor, securing the
screws (11) to the indicated couple.
11 - Fix the starter button with the screws (9) to the
indicated couple and ret the ywheel (8).
12 - Ret the tape reel and x the screws to the indi-
cated couple [ 9.3] execute the regolation in
accordance with the regolation air gap [ 9.2].
13 - Ret the fan and x the nut (3) to the indicated
couple, and the cowl.
6.2. Replacement of starting motor
Perform operations indicated in [ 6.1].
Tightening torques
3Flywheel xing nut 110-120 Nm
7Coil xing screw 8-12 Nm
9Fixing screw starting motor 22-30 Nm
11 Starting motor screw 8-12 Nm
Technical information
Brushes length 8,5÷12 mm
Air gap tape reel/ywheel 0,25-0,40 mm
Special equipment
15 Gauge
6. STARTING SYSTEM
14
14
15
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