Rally RE1138K - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document describes the Rally RE1138K ride-on mower, providing essential information for its safe operation, assembly, and maintenance.

Function Description

The Rally RE1138K is a ride-on mower designed for cutting grass. It features a functional control panel that allows the operator to manage various aspects of the machine's operation. Key controls include:

Throttle Control (2): Regulates engine revolutions per minute (RPM) and, consequently, the rotation speed of the blades. It has settings for full speed and idling speed.
Brake and Clutch Pedal (3): When pressed, this pedal engages the brake and disengages the engine, stopping the machine and interrupting power to the drive.
Gear Shift Lever (4): The gearbox offers forward, neutral, and reverse positions. Gear changes can be made from neutral to top gear without stopping in intermediate positions, but the motor must be disengaged. The machine should be stopped before shifting from reverse to forward or vice versa.
Cutting Unit Connection/Disconnection (5): Moving this lever forward connects the drive to the cutting unit, tensioning the drive belt and causing the blades to rotate. Moving it backward disconnects the drive, and brake shoes slow the blade rotation.
Quick Lifting/Lowering of the Cutting Unit (6): This lever allows for quick adjustment of the cutting unit's height. Pulling it backward lifts the unit for transport or to clear irregularities, while pushing it forward lowers it for cutting.
Ignition Lock (7): Features "OFF," "ON," and "START" positions to control the electrical current and start the engine. The key should always be removed when leaving the machine unattended.
Parking Brake (8): Engaged by pressing the brake pedal fully down and then pulling the parking brake lever upwards. It is released by simply pressing the brake pedal again.
Choke Control (9): Used for starting a cold engine. It should be pulled out before starting and pushed in once the engine is running smoothly.

The machine is equipped with a safety switch that immediately cuts power to the engine if the operator leaves the seat while the engine is running and the cutting unit is engaged.

Important Technical Specifications

The Rally RE1138K has the following technical specifications:

Engine Power: 11/8.2 hp/kW.
Speed: 0-6.7 km/h.
Cutting Width: 97 cm.
Cutting Height: 38-102 mm.
Weight: 180 kg.
Noise Emissions (ISO 3744, 98/37/EC): Sound pressure level (LpA) < 90 dBa.
Guaranteed Sound Power Level (ISO 11094, 2000/14/EC): LWA < 100 dBa.
Vibration Levels (m/s²):
- Vibration (EN 1033): 8 m/s².
- Vibration (EN 1032): 4 m/s².

Usage Features

Safety Rules:

Read and understand the manual before use.
Never allow children or untrained individuals to operate the mower.
Do not mow when people or pets are nearby.
The operator is responsible for accidents.
Professional instruction is recommended, emphasizing care, concentration, and understanding that braking will not regain control on a sliding slope.
Wear substantial footwear and long trousers; never operate barefoot or in open sandals.
Inspect the area for objects that could be thrown by the machine.
Refuel outdoors only, do not smoke, and never refuel a hot or running engine.
Do not operate in confined spaces due to carbon monoxide fumes.
Mow only in daylight or good artificial light.
Do not use on slopes greater than 10°. Exercise extreme caution on grass slopes to prevent overturning: avoid sudden stops/starts, engage the clutch slowly, keep machine in gear (especially downhill), maintain low speeds, and be aware of hidden hazards. Never mow across the face of a slope unless the mower is designed for it.
Use caution when pulling loads or heavy equipment, using only approved hitch points and limiting loads to what can be safely controlled. Avoid sharp turns and use counterweights if recommended.
Watch for traffic near roadways.
Stop blades before crossing non-grass surfaces.
Never direct discharge toward bystanders or allow anyone near the machine during operation.
Do not operate with defective guards or without safety devices.
Do not change engine governor settings or overspeed the engine.
Before leaving the operator's position: disengage power take-off, lower attachments, shift to neutral, set parking brake, stop engine, and remove the key.
Disconnect spark plug wire(s) before cleaning, inspecting, or working on the mower, after striking foreign objects, or if abnormal vibration occurs.
Disengage drive to attachments when transporting or not in use.
Stop the engine and disengage drive to attachment before refueling, removing the grass catcher, or adjusting height (unless adjustable from the operator's position).
Reduce throttle setting during engine run-out and turn off fuel if a shut-off valve is present.

Assembly:

Steering Wheel: Mount the extension shaft, main shaft cover, and steering wheel securely. Ensure front wheels are aligned.
Seat: Remove from packaging, place on seat pan, and engage the shoulder bolt in the slot. Adjust the seat position for comfort relative to the clutch and brake pedal, then tighten the adjustment bolt. Ensure the safety switch cable is correctly connected.
Battery: Install the battery, ensuring the positive terminal is connected first to prevent accidental grounding. Remove metal bracelets, wristwatches, and rings before handling the battery. If the battery is put into service after the indicated date on the label, charge it for at least one hour at 6-10 amps.

Driving:

Starting the Motor: Ensure the cutting unit is in the transport position (top) and the connection/disconnection lever is in the disconnected position. Press the clutch/brake pedal completely, hold it down, and set the gear lever to neutral. Pull out the choke control if the engine is cold. Turn the ignition key to "START" (do not run the start motor for more than 5 seconds; wait 10 seconds between attempts). Once the engine starts and runs smoothly, push in the choke and set the gas control to the desired speed (full gas for cutting).
Driving: Lower the cutting unit by moving the lever forward, connect the cutting unit, and choose a driving speed suitable for the terrain and desired cutting results. Release the brake/clutch pedal slowly.
Cutting: Use the left side of the machine to cut close to trees, bushes, and paths, as the blade cuts about 15 mm inside the edge of the cover.
Stopping the Engine: Move the gas control to idle, disconnect the cutting unit, lift the cutting unit, and turn the ignition key to "OFF." Allow the engine to idle for 1-2 minutes to cool down after hard work. Never leave the key in the ignition lock when leaving the machine unattended.

Maintenance Features

General Maintenance:

Perform periodic maintenance to keep the tractor in good running condition.
Always disconnect the spark plug wire before any repair, inspection, or maintenance.
Before each use, check oil level, lubricate pivot points, check brake operation, ensure all bolts, nuts, and cotter pins are secure, check battery terminals and vents, recharge battery if needed (slowly at 6 amps), clean air screen, and keep the tractor free of dirt and chaff.

Engine Maintenance:

Refer to the engine manual for specific service instructions.
Oil Drain Valve: Remove the cap, install the drain tube, open the valve by pushing in and turning counterclockwise, drain the oil, close the valve by pushing in and turning clockwise, remove the drain tube, and reinstall the cap.
Engine Oil: The oil level should be between the two markings on the oil stick. If more oil is needed, add SAE 30 oil to the "FULL" marking. For winter (below freezing point), use SAE 5W-30 oil.

Tire Air Pressure:

Regularly check tire pressure. Front tires should be 1 bar (14 PSI) and rear tires 0.8 bar (12 PSI).

Cutting Unit Maintenance:

Blades: For best cutting results, keep blades sharp. Replace worn or damaged blades. Sharpening can be done with a file or grinding disc. It is crucial to sharpen both sides of the blade uniformly to maintain balance.
Blade Removal: Raise the mower to its highest position. Remove the hex bolt, lock washer, and flat washer securing the blade.
Blade Installation: Install a new or sharpened blade with the trailing edge up toward the deck. Ensure the central hole of the blade aligns perfectly with the mandrel star. Reinstall the hex bolt, lock washer, and flat washer in the exact reverse order and tighten securely (27-35 Ft. Lbs. torque). The blade bolt is grade 8 heat treated.
Drive Belt Replacement: Dismantle the cutting unit. Engage the parking brake. Work off the belt from the pulleys (engine, clutch, rear axle). Install the new belt in reverse order, ensuring it lies inside all belt guides. Use only original belts.
Cutting Unit Adjustment: The front edge of the cutting unit (B) should be about 10 mm (0.375") lower than the back edge (A) for best cutting results. Adjust by loosening nut (1) on both left and right levers, then screwing nut (2) the same number of turns on both levers. Once the correct distance (A) is achieved, lock the setting with nut (1).

Storage:

At the end of the mowing season:
- Clean the entire machine, especially underneath the cutting unit cover.
- Touch up chipped paint surfaces to prevent corrosion.
- Change engine oil.
- Drain the fuel tank. Start the engine and let it run until it's out of fuel.
- Remove the spark plug, pour one tablespoon of engine oil into the cylinder, pull the engine over to distribute the oil, and reinstall the spark plug.
- Remove the battery, recharge it, and store it in a cool, dry place, protecting it from low temperatures.
- Store the machine indoors in a dry, dust-free place.
Never use gasoline for cleaning; use degreasing detergent and warm water instead.

Service:

When ordering spare parts, provide the purchase date, model, type, and serial number of the mower. Always use original spare parts. Contact your local dealer for warranty service and repairs.