Stiga ZT 3107 T Workshop Manual
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Stiga ZT 3107 T Workshop Manual

2017-2019
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WORKSHOP MANUAL
ZT 3107 T
2017-2019

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  • Page 1 WORKSHOP MANUAL ZT 3107 T 2017-2019...
  • Page 2 All brands, names, logos and trademarks mentioned belong to their respective owners. © 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 authorisation.

  • Page 3: Table Of Contents

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 1 - INTRODUCTION 2017 1 - INTRODUCTION Summary CONSULTATION GUIDE ..............3 1.1.1 Limitation of Responsibility ............3 1.1.2 Structure of the Manual ..............3 1.1.3 Symbols and Definitions used ............4 WORK SAFETY INSTRUCTIONS ............5 1.2.1...

  • Page 4: Symbols And Definitions Used

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 1 - INTRODUCTION 2017 1.1.3 Symbols and Definitions used a) Symbols They are used to draw the attention of the operator, reminding him to perform the interventions with the necessary attention and caution.

  • Page 5: Work Safety Instructions

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 1 - INTRODUCTION 2017 1.2 WORK SAFETY INSTRUCTIONS 1.2.1 Qualification of operators All maintenance, disassembly and repairs must be carried out by expert mechanics who are fa- miliar with all the accident prevention and safety regulations after reading through the procedures in this manual.

  • Page 6: Safety Measures To Be Adopted

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 1 - INTRODUCTION 2017 1.2.4 Safety measures to be adopted All the machines are manufactured in accordance with the strict European safety regulations in force. To maintain these levels of safety in the longer term, the Service Centres should work to this end by making appropriate checks every time there is the chance to do so.

  • Page 7: Service Repairs Outside Warranty

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 1 - INTRODUCTION 2017 • Furthermore, this warranty does not apply to: - Components subject to wear such as blades, belts, wheels, batteries and cables. - Normal wear and tear due to use.

  • Page 8: Identification Of The Machine And Components

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 2 - SERVICING RECOMMENDATIONS 2017 2 - SERVICING RECOMMENDATIONS Summary IDENTIFICATION OF THE MACHINE AND COMPONENTS .....8 2.1.1 Machine identification ..............8 2.1.2 Engine identification ..............8 2.1.3 Transmission Unit identification ............9 EQUIPMENT REQUIRED ..............9 2.2.1...

  • Page 9: Servicing Recommendations

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 2 - SERVICING RECOMMENDATIONS 2017 2.1.3 Transmission Unit identification The machine is equipped with two transmission hydro- static units. These units are made by another manufacturer according to precise technical specifications which dif- ferentiate them from similar items by this same Manu- facturer.

  • Page 10: Transportation And Handling

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 2 - SERVICING RECOMMENDATIONS 2017 10 / Hexagonal head screws and nuts UNC Thread Ø 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 7/16" 1/2" 9/16" 5/8" 3/4" Torque (grade 2) Torque (grade 8) Hexagonal Allen grub screws UNC Thread Ø...

  • Page 11: Maintenance

    Every 25 hours dirt and debris). Do not use high pressure washers, sol- Cleaning the machine vents, aggressive detergents or abrasive cleaners. Re- seasonally store damaged paint using STIGA paint. Check the tyres See the technical specifications 3.1] Check and sharpen the Check that the blades are not worn or damaged.

  • Page 12: Control Of Safety Devices

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 2 - SERVICING RECOMMENDATIONS 2017 12 / 2.4.3 Control of safety devices It is of utmost importance that all the safety systems present upon delivery of the machine are kept in efficient working order over time, conducting appropriate checks every time there is the chance to do so.
  • Page 13 Summary TECHNICAL SPECIFICATIONS ............13 OVERALL DIMENSIONS ..............14 3.1 TECHNICAL SPECIFICATIONS Machine Model Stiga ZT 3107 T Dimensions (Length x Width x Height) (mm) 1651 x 1372 x 102 = 1020 General Information Machine weight (Kg) B&S Intek Series 7200 Engine Brand and Model...
  • Page 14 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 3- TECHNICAL DATA 2017 14 / 3.2 OVERALL DIMENSIONS 1041 1740 1356...
  • Page 15 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 4 - ENGINE AND FUEL TANK 2017 15 / 4 - ENGINE AND FUEL TANK Summary ENGINE ....................15 4.1.1 Engine tuning and maintenance ...........15 4.1.2 Removal of the engine ..............15 TANK ....................17 4.2.1...
  • Page 16 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 4 - ENGINE AND FUEL TANK 2017 16 / Disconnect the fuel delivery pipe, taking care not to spill fuel. 5. Remove all engine connections: • the accelerator cable; • the choke cable;...
  • Page 17 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 4 - ENGINE AND FUEL TANK 2017 17 / • tighten the clutch fastening screws to a torque of 43-64 Nm; • carefully reinstate all electric connections; • reconnect the fuel pipe, making sure there are no leaks;...
  • Page 18 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 4 - ENGINE AND FUEL TANK 2017 18 / 4. Disconnect the battery (8). FIRST disconnect the black ground cable from the battery, and THEN the red cable, to prevent possible short circuits and dangerous situations.
  • Page 19 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 4 - ENGINE AND FUEL TANK 2017 19 / 9. Rotate the left side (18) so it faces the rear section of the machine. 10. Grasp the tank nozzle (19) and extract it from its seat, twisting it back and forth to make ex- traction easier.

  • Page 20: Steering System (Direction Of Travel)

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 20 / 5 - STEERING SYSTEM - TRANSMISSION - WHEELS Summary STEERING SYSTEM (DIRECTION OF TRAVEL) .......20 5.1.1 General information ..............20 5.1.2 Ergonomic adjustment of the levers ..........20 5.1.3...

  • Page 21: Adjusting The Direction Of Travel

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 21 / 2. Before tightening the screws, move the lever (2) forwards or backwards, until the desired distance is reached in relation to the seat.

  • Page 22: Transmission

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 22 / To allow the machine to travel in a straight line in a forward direction, it is necessary to decelerate the faster wheel or accelerate the slower one.
  • Page 23 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 23 / B) Adjusting the “neutral” position 1. Remove the guard (1) fixed by the screws (2) and (3). 2. Release the split pin (4) and washer (5) and disconnect the parking brake rod (6).
  • Page 24 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 24 / b) Adjusting the parking brake WARNING! - When the adjustments have been made, the parking brake should pre- vent the machine from moving on a slope of 30% (16°) with the driver in position.

  • Page 25: Adjusting Maximum Operating Speed

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 25 / 5.2.2 Adjusting maximum operating speed NOTE The hydrostatic transmission units have a predetermined range of use, given by the sum of the maximum speeds in forward and reverse gear.

  • Page 26: Replacing The Transmission Belt

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 26 / b) Right shock absorber 1. Remove the fuel tank 4.2.2] 2. Identify the release tab on the lower head of the shock absorber and release it from the pin.

  • Page 27: Removing The Transmission Units

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 27 / 7. Free the belt (9) from transmission unit pulleys (10). 8. Fit the new belt following the indications illus- trated in the diagram.
  • Page 28 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 28 / 3. Undo the two screws (5) fastening the connec- tion rods (6) from the side of the transmission to be removed.

  • Page 29: Wheels And Tyres

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 29 / 7. Each transmission unit is supported by a holder (17) fixed by a screw with nut (18) and is fixed to the chassis by two screws with relative nuts (20). Undo the nut (18) and then carefully undo the two lower nuts (20), holding up the unit so that it does not fall.

  • Page 30: Replacing The Front Wheels

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 30 / 5.3.2 Replacing the front wheels • Lift the front part of the machine 2.3.2]. Undo the screw (1) and remove the wheel (2) from the support fork (3).

  • Page 31: Replacement And Repair Of Tyres

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 5 - STEERING SYSTEM - TRANSMISSION - WHEELS 2017 31 / 5.3.4 Replacement and repair of tyres The tyres used on this machine are of the «Tubeless» type and so every repair of a hole in the tyre must be done by a tyre specialist according to the methods used for this type of tyre.

  • Page 32: Adjusting The Cutting Deck

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 32 / 6 - CUTTING DECK Summary ADJUSTING THE CUTTING DECK ............32 6.1.1 General information ..............32 6.1.2 Adjusting the blade height ............32 BLADE MAINTENANCE ..............34 6.2.1 Access to the lower section of the cutting deck ......34 6.2.2...

  • Page 33: Cutting Deck

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 33 / 3. Manually rotate the two outer blades (3) and (4) so the tips are facing in the longitudinal direction 120 mm (direction of travel) WARNING!

  • Page 34: Blade Maintenance

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 34 / 6.2 BLADE MAINTENANCE 6.2.1 Access to the lower section of the cutting deck NOTE All operations described in this section can be performed without having to remove the cutting deck from the machine.

  • Page 35: Removing And Reassembling The Blades

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 35 / 6.2.4 Removing and reassembling the blades WARNING! - Always wear protective gloves when handling the blades. WARNING! -The three blades are con- nected to each other; the rotation of each blade engages the rotation of the other two.

  • Page 36: Replacement Procedures

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 36 / 6.3 REPLACEMENT PROCEDURES 6.3.1 Blade control belt replacement 1. Remove the right rear casing (1) fixed by two rear screws (2), two front screws (3) and a single nut (4), situated on the left side.

  • Page 37: Replacement Of The Blade Flanged Supports

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 37 / 5. Free the belt (7) from the clutch pulley (10). 6. Loosen the nuts (11) and (12) on the take-up pulley (13) and the guide pulley (14), enough to free the belt from the belt guides.

  • Page 38: Removal Of The Cutting Deck

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 38 / NOTE - The entire support element (3), including shafts and bearings, is a spare part available as single assembly unit, including the pulley. Reassemble all removed parts following the...
  • Page 39 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 6 - CUTTING DECK 2017 39 / 3. Remove the two front split pins (5) and the two rear split pins (6) from the lifting rods. 4. Remove the cutting deck. Reassemble all removed parts, following the above instructions in the reverse order.

  • Page 40: Troubleshooting

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 40 / 7 - ELECTRICAL SYSTEM Summary TROUBLESHOOTING .................40 7.1.1 Electrical system problem table ............40 7.1.2 Safety device intervention table ............41 7.1.3 Equipment ..................41 7.1.4 Electrical measure gauges ............42 7.1.5...

  • Page 41: Safety Device Intervention Table

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 41 / 7.1.2 Safety device intervention table The safety devices intervene on the engine, preventing ignition or stopping it in the event where the required machine operating conditions are no longer met.

  • Page 42: Electrical Measure Gauges

    STIGA does not recommend attempting to repair electrical components. Most do not lend themselves to repair and you would have more money invested in “time of repair” than the part would cost and the results may not be as good.

  • Page 43: Electrical Measurements

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 43 / It is best to learn proper procedures, even though some meters may be more forgiving of mistakes. Where differences in use may occur, they will be covered in the explanation.

  • Page 44: Battery

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 44 / 7.2.2 Battery NOTE - The machine comes equipped with a maintenance-free battery that requires no regular maintenance except the cleaning of the terminals. DANGER! - Battery poles, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and damage to the reproductive appara- tus.
  • Page 45 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 45 / Voltage (OCV) Charge % Charging time 12.60 100% 12.40 3 hours 12.20 7 hours 12.00 10 hours 11.80 12 hours • If you use a 12 volt automatic battery charger, select a good quality charger with minimum 5-10 Ampere output at 15 VDC and charge for 3-12 hours depending on the battery charge status (see table).

  • Page 46: Switches

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 46 / 5. Make the final jumper cable connection to the engine block or the furthest ground point away from the discharged battery. WARNING! - Make sure the cables are clear of any moving engine parts before start- ing the engine.
  • Page 47 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 47 / b) Normally Closed Switch (NC) To test a normally closed switch connect the ohmmeter between the switch terminals. • The meter should indicate a closed circuit (zero resistance «0»).

  • Page 48: Ignition Switch

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 48 / 7.2.4 Ignition switch NOTE - Refer to the wiring diagram of the machine (continuity diagram) to determine switch func- tions and test using the methods described.

  • Page 49: Fuses

    There are also a number of mechanical issues that may cause the problem. The starter solenoid used on STIGA machines is a sealed unit used to actuate the starter motor on the engines. These solenoids may have three or four connections. The two major connections carry high current to operate the starter motor.

  • Page 50: Diodes And Rectifiers

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 50 / 7.2.7 Diodes and Rectifiers Diodes are solid state, semiconductor devices. They contain no moving parts and conduct current better in one direction than the other.

  • Page 51: Functional Checks

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 51 / This results in a current flowing through the coil, magnetizing the coil pulling the armature onto the rotor with sufficient force to hold the two pieces together, connecting the output and the input shafts firmly together.
  • Page 52 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 52 / Manual activation of Normally Open Switches The contact resistance is 0.1-0.3 ohms when functioning correctly. Ignition switch test. Check the battery voltage in the «OFF» position, test for voltage at terminal "B".

  • Page 53: Electrical Wiring Diagrams

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 53 / 7.4 ELECTRICAL WIRING DIAGRAMS 7.4.1 General wiring diagram YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH WH/BK BR/YE WH/BK WH/BK GR/WH BR/WH YE/RE YE-RE BK-WH...

  • Page 54: Operating Layouts In User Modes

    WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 54 / 7.4.2 Operating layouts in user modes a) Ignition key in the «OFF» position YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH WH/BK BR/YE WH/BK WH/BK...
  • Page 55 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 55 / b) Ignition key in the «RUN» position YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH WH/BK BR/YE WH/BK WH/BK GR/WH BR/WH YE/RE YE-RE BK-WH Components...
  • Page 56 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 56 / c) Ignition key in the «START» position YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH WH/BK BR/YE WH/BK WH/BK GR/WH BR/WH YE/RE YE-RE BK-WH Components...
  • Page 57 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 57 / d) Ignition key in the «RUN» position Operator present / Parking brake disengaged YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH WH/BK BR/YE WH/BK WH/BK...
  • Page 58 WORKSHOP MANUAL Chapter EDITION PAGE ZT 3107 T 7 - ELECTRICAL SYSTEM 2017 58 / e) Ignition key in the «RUN» position Operator present / Parking brake disengaged / PTO blade engaged YE/RE BR/YE RE/GR BR/WH YE/RE YE/RE RE/GR GR/WH...
  • Page 59 STIGA S.p.A - Via del Lavoro, 6 - 31033 Castelfranco Veneto (TV) - Italy www.stiga.com...

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