Stiga TRE 224 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
TRE 224
TRE 224
Rel. 0.0 2018!


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Workshop 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. Faultnotication.......................................................................................................................................6
1.4. Spare parts request..................................................................................................................................6
2. GENERAL AND SAFETY REGULATIONS............................................................. 7
2.1. Qualicationofoperators .......................................................................................................................7
2.2. Safety measures.......................................................................................................................................7
2.3. Precautions during servicing...................................................................................................................7
2.4. Warning labels..........................................................................................................................................8
2.5. Necessary equipment .............................................................................................................................8
2.6. Symbols and terms used for safety purposes........................................................................................8
3. TECHNICAL DATA AND SPECIFICATIONS........................................................ 9
3.1. Identication.............................................................................................................................................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. Identicationofengineunits.................................................................................................................12
4. ENGINE TUNING AND TESTING ...................................................................... 13
4.1. Operating guidelines .............................................................................................................................13
4.2. Engine tuning program..........................................................................................................................13
4.3. Functional test ........................................................................................................................................14
5. SUPPLY SYSTEM ............................................................................................... 15
6. STARTING SYSTEM........................................................................................... 16
6.1. Removing the starter motor...................................................................................................................16
6.2. Disassembly and cleaning the starter motor pinion...........................................................................17
7. INTAKE SYSTEM ............................................................................................... 18
7.1. Maintenanceoflteringelement .........................................................................................................18
8. CARBURATION................................................................................................ 21
8.1. Removing and cleaning the carburettor .............................................................................................21
8.2. Replacing the carburettor.....................................................................................................................24
8.3. Adjusting minimum speed ....................................................................................................................24
8.4. Adjusting maximum speed...................................................................................................................24
8.5. Adjusting the carburation......................................................................................................................24
CONTENTS
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9. GOVERNOR SYSTEM OF THE CARBURETTOR ................................................. 25
9.1. Adjusting of accelerator cable ............................................................................................................25
9.2. Adjusting maximum speed...................................................................................................................26
9.3. Replacing the lever support..................................................................................................................27
10. AUTO-CHOKE SYSTEM.................................................................................. 28
10.1. Replacing of the AUTO-CHOKE system................................................................................................28
11. IGNITION....................................................................................................... 29
11.1.Checkingtheefciencyoftheignitionsystem ..................................................................................29
11.2. Adjusting the air gap and checking the coil ......................................................................................30
11.3. Replacing the coil..................................................................................................................................31
12. TURNING OFF AND STOPPING THE ENGINE ................................................ 32
13. EXHAUST SYSTEM .......................................................................................... 33
13.1.Removingandreplacingthemufer ...................................................................................................33
14. ENGINE BLOCK - External operations ........................................................ 34
14.1. Checking the compression...................................................................................................................34
14.2. Adjusting the valve clearance .............................................................................................................35
14.3. Dismantling and cleaning the cylinder head .....................................................................................36
14.4 Overhauling the cylinder head and valves ........................................................................................37
14.5.Dismantlingandreplacingthemagnetoywheel .............................................................................39
14.6. Alternator removal and replacement..................................................................................................40
14.7. Checking the oil breather .....................................................................................................................40
14.8.Replacingtheuppercompressionringoftheengineshaft(ywheelside) ....................................41
14.9.Replacingthelowercompressionringoftheengineshaft(sumpside)..........................................41
15. ENGINE BLOCK - Overhauling internal parts............................................. 43
15.1. Carter opening .......................................................................................................................................43
15.2.Dismantlingandcheckingthecamshaftandcounterweightgovernor..........................................44
15.3. Dismantling and checking the piston, piston rings, connecting rod and engine shaft ..................46
16. TROUBLESHOOTING...................................................................................... 52
CONTENTS
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Workshop 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 224.
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 authori-
sed and appropriately trained personnel.
In every manual page the following informations
are described:
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Workshop Manual
General information
The starter system consists of a motor supplied by a 12 Volt battery (mounted on the machine). The battery
See the relevant section [ 16] for advice on resolving problems due to the malfunctioning of the star-
ting system.
6. STARTING SYSTEM
3
2
6.1. Removing the starter motor
1 - Remove the cover by unscrewing the three
nuts (1).
2 - Disconnect the connector (2) from the wiring.
3 - Disconnect the live cable (3) and the earth
cable (4).
4 - Remove the two screws (5) and remove the
motor.
5 - To assemble repeat the operation in reverse.
When attaching the connector (2) the three wires
must attached in the proper places.
6 - Assemble the cover.
4
5
5
1
1
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.
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:Referstospecicadvicebythema-
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.
INTRODUCTION
AB
CC
DEF
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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. Faultnotication
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 trou-
bleshooting 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].
1. RULES AND PROCEDURES FOR SERVICE CENTRES
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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. Qualicationofoperators
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;
- thatthenameplatesorspecicationlabelshave
not been removed or made illegible, (as they
formanintegralpartofthesafetydevices).
• also:
- restoretoproperworkingorderanysafetydevi-
ceswhichhavebeenmanipulatedorremoved;
- replace ineffective, damaged or missing guards
and covers;
- replace illegible labels;
- donotcarryoutoperationsormodicationson
thelawnmowerorontheenginethatcouldaf-
fect their performance or lead to an improper or
differentusefromtheoneforwhichithasbeen
designed and approved;
- warnthecustomerthatthefailuretocomplywith
theabovepointsautomaticallyvoidsthewar-
ranty and the responsibility of the manufacturer.
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,
especiallywhenworkingnearthecuttingunit;
- check that you do not cause accidental petrol
leaks or other losses;
- donotsmokewhenworkingonthetankorwhen
handling petrol;
- do not inhale oil or petrol fumes;
- clean up all traces of spilt petrol immediately;
- testtheengineinawell-ventilatedenvironment
orwherethereareadequateexhaustfumeex-
traction systems;
- donotpollutetheenvironmentwithoil,petrolor
otherwasteanddisposeofallwasteinaccor-
dancewiththelawsinforce;
Exhaust gas contains carbon monoxide,
which is highly toxic, odourless and co-
lourless. Avoid inhaling.
- performtestsontheengineinawell-ventilated
environment or in the presence of adequate
exhaust gas extraction systems.
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INDEX

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2. GENERAL AND SAFETY REGULATIONS
2.4. Warning labels
On the canopy motor, in a immediately identica-
tion position, are some indication or prescription
plates for the safety operator.
The plates are as follows:
•• ••• ••••
TRE224
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.
-Accumulationofammablematerial
Prevent by following the precautions below:
- Remove dry leaves, chips, pieces of paper, dust or
other ammable material which has accumulated
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.
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.
1 2 3
4
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Daily progressive
number
3.1. Identication
Every motor is marked with a serial number on the
base and applied on the canopy; this serial number
characters and can identify:
•• ••• ••••
TRE224
The serial number must be reported on every ope-
ratingsheetinthewarrantyapplicationandisfun-
damental for identifying and ordering spare parts.
3. TECHNICAL DATA AND SPECIFICATIONS
3.4. Expendable materials
TRE 224
Petrol Unleaded (green)
minimum 90N.O.
Engine oil - from 5 to 35 °C
- from -15 to + 35°C SAE 30 - 10W30
Spark plug
K7RTC
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 224
Compressionwithde-compressor
shut
0,8 Mpa (1300
r.p.m.)
Minimum inlet valve stem dia-
meter 5,32 mm
Minimum exhaust valve stem
diameter 5,27 mm
Minimum inlet valve head rim
thicknesse 0,5 mm
Minimum exhaust valve head
rim thickness 0,5 mm
Valve seat depth 2,0 mm
Minimum valve spring length 33,0 mm
Maximumgapbetweenendsof
cylinder rings 1,0 mm
Max. axial gap for compression
rings 0,15 mm
Minimum gudgeon pin diameter 17,95 mm
Max. gudgeon pin-piston seat
diameter 18,05 mm
Max. connecting
rod diameter
gudgeon pin
side 18,07 mm
crank side 30,07 mm
Diam. connecting rod’s pin on
engine shaft 29,92 mm
Diameter aspiration cam 27,30 mm
Diameter discharge cam 27,45 mm
Diameter seat of camshaft 13,92 mm
Verify the engine shaft extremes 0,10 mm
3.2. Technical data
TRE 224
Displacement 224 cc
Bore 75 mm
Stroke 51 mm
Compressionratiowhennew8,3:1 Minimum 4 bar
Minimumspeed(SLOW) 1800 (±150) r.p.m.
Maximumspeed(FAST) 2800 (±100) r.p.m.
Oil sump capacity 0,5 litres
Dryweight 13,8 kg
3.3. Adjustments
Distancebetweensparkplug
electrodes 0,6 - 0,8 mm
Coil air gap 0,35 - 0,45 mm
Inlet valve clearance 0,10 - 0,15 mm
Exhaust valve clearance 0,15 - 0,20 mm
Year of
manufacture
Date
TRE224
15 035 0164
TRE224150350164
11501091-1/6594018/440
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3. TECHNICAL DATA AND SPECIFICATIONS
3.6. Tightening torques
8-12 Nm
30-36 Nm
27-30 Nm
24-32 Nm
8-12 Nm
8-12 Nm
13-15 Nm 8-10 Nm
5-8 Nm
8-10 Nm
8-12 Nm
5-7 Nm
8-12 Nm
5-7 Nm
8-12 Nm
80-90 Nm
4-6 Nm
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3. TECHNICAL DATA AND SPECIFICATIONS
3.7. Table of Tightening torques
Chapter Ref. Descriptionofscrew Tightening torques
6Cover xing nuts 8 - 10 Nm
6Starter motor xing screws 8 - 12 Nm
6 Starter motor screws 5 - 8 Nm
8Carburettor and lter xing nuts 8 - 10 Nm
9 Throttle support screws 8 - 12 Nm
10 - 13 Fixing screw AUTO-CHOKE 5 - 7 Nm
11 - 14 Spark plug tightening torque 27 - 30 Nm
11 - 14 Coil xing screw 8 - 12 Nm
11 - 14 Coil xing stud 8 - 12 Nm
13 Mufer xing nuts 8 - 12 Nm
14 Valve cover xing screws 8 - 12 Nm
14 Fixing head screws 30 - 36 Nm
14 Attachment bolt ywheel 80 - 90 Nm
14 Fixing screws generator 8 - 12 Nm
14 Pad plate screw 4 - 6 Nm
15 Union screws under carter and sump 24 - 32 Nm
15 Counterweight governor xing screw 5 - 7 Nm
15 Fixing screws lower connecting rod cap 13 - 15 Nm
P.S.Forthecouplingtourqueofallstandardscrewsrefertothesingletable.
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3.8. Identicationofengineunits
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
Exhaust system
Engine block
Starting system
Carburettor
Carburation control
Air intake
Ignition
AUTO-CHOKE
Starting system
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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 50 hours
or every season
Every 100
hours
Check oil level -■- -
Change oil *(1) ■-■-
Clean mufer and engine -■- -
Check air cleaner *(2) -■- -
Replace air cleaner *(2) - - ■-
Check spark plug - - ■-
Replace spark plug ---■
Fuel lter control ---■
*(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 difcult for the nal
user the assistance centre must maintain the mo-
tor in perfect efciency, 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 efciency.
Tuning should involve:
- external blowing and cleaning the cylinder
head, cylinder and mufer by removing any
remains of grass and mud;
- checking the oil level, topping up or replacing
parts if necessary;
- cleaning the air lter [ 7.1];
- adjusting minimum and maximum speeds [
8.3 and 9.2];
-
inspecting the condition of the spark plug;
checking the distance between the electrodes
[ 11.1];
- tightening the screws;
- functional test [ 4.3].
Should the checks and adjustments fail to achieve
a satisfactory result, refer to chapter [ 16] 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 compliance with the safety regu-
lations regarding the use of the machine on which
the engine is installed.
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. Hot and cold starting test
The engine is equipped with intelligent starter sy-
stem (AUTO-CHOKE), with the throttle in the “SLOW”
position, perform some cold and hot starts to make
sure they happen regularly.
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].
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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5. SUPPLY SYSTEM
IMPORTANT: Carefully read the information below before commencing any intervention.
General Information
The fuel supply system is via a tank installed on the machine connected to the carburettor by a pipeline; a
lter between the tank and the fuel pump, prevents deposits and impurities from reaching the carburettor.
The supply to the carburettor oat chamber is caused by gravity and the volume of petrol taken from the
tank as the engine runs is compensated by a breather pipe in the cap.
See the relevant section [ 16] 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;
- workinaventilatedenvironmentawayfromnakedamesorunprotectedsourcesofheat;
- collect any remaining petrol by positioning a suitable container under the engine, avoiding soiling the
workbench;
- remove all traces of spilt petrol immediately;
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General information
The starter system consists of a motor supplied by a 12 Volt battery (mounted on the machine). The battery
is charged by a coil type alternator which receives impulses from the magneto ywheel.
See the relevant section [ 16] for advice on resolving problems due to the malfunctioning of the star-
ting system.
6. STARTING SYSTEM
3
2
6.1. Removing the starter motor
1 - Remove the cover by unscrewing the three
nuts (1).
2 - Disconnect the connector (2) from the wiring.
3 - Disconnect the live cable (3) and the earth
cable (4).
4 - Remove the two screws (5) and remove the
motor.
5 - To assemble repeat the operation in reverse.
When attaching the connector (2) the three wires
must attached in the proper places.
6 - Assemble the cover.
4
5
5
1
1
1
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6. STARTING SYSTEM
6.2. Disassembly and cleaning the starter motor
pinion
1 - Remove the cover.
2 - Use a screwdriver to rotate the pinion (6) to
check that it spins and moves co-axially and can
compress the spring (7).
3 - In case the full movement is impeded by dirt:
- remove the dirt by using compressed air;
- spray with lubricant and repeatedly move the
pinion;
- when the movement becomes smooth clean with
compressed air;
- spray again with lubricant.
Avoid using grease or oil as it causes dirt to accu-
mulate.
If the motor becomes noisy it should be replaced
[ 6.1].
4 - Remove the pinion assembly by undoing the
screws (8)and check the condition of the gears.
(Replace the pinion assembly if there is any da-
mage).
Tightening torques
1Cover xing nuts 8-10 Nm
5
Fixing screw starting motor
8-12 Nm
8Starting motor screw 5-8 Nm
7
6
8
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General information
The intake system uses an air lter directly connected to the carburettor by means of a manifold which
conveys the air/petrol mixture to the inlet valve.
See the relevant section [ 16] for advice on resolving problems due to the malfunctioning of the air
intake system.
Aninefcientltercanletdustordebrisenterthecylinder,causingprematureweartothepistonringsand
cylinder.
The air lter is found on the left hand side of the engine and can be inspected without having to remove
other parts.
The lter assembly is to be removed only to accede the carburettor.
7. INTAKE SYSTEM
7.1. Maintenanceoflteringelement
WARNING: Never run the engine without air
lter.Theenginewouldcertainlybedama-
ged.
1 - Clean the area around the lter cover (1) by
blowing it with compressed air.
2 - Remove the cover plate (1) by turning the dedi-
cated knob (2) and remove the lter element (3).
3 - Check carefully that the element has no holes
or tears, and replace it if it is damaged.
WARNING:Whenthelterelementisremo-
ved the intake duct should be covered to
avoid foreign bodies from entering. (see the
gure).
2
1
3
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7. INTAKE SYSTEM
H2O
H2O
H2O
H2O
4 - Remove the lter element (4) and remove the
prelter (5) from the cartridge.
5 - Beat 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.
6 - Wash the prelter with water and detergent and
let it air dry.
IMPORTANT:thepreleterMUSTNOTbeoi-
led.
7 - Ret the prelter (5) on the cartridge.
8 - With a jet of compressed air, clean inside the
seat (6) of the lter by removing dust and remains
of grass.
5
4
6
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7. INTAKE SYSTEM
9 - Reassemble in their seats the lter element (3)
and its cover plate (1) by turning the dedicated
knob (2).
3
2
1
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INDEX
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