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72FL hydro

8.1

- TIGHTENING TORQUES

AND ADJUSTMENTS SUMMARY

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WORKSHOP MANUAL

pag.

MODEL YEAR 2016

8.1 TIGHTENING TORQUES AND ADJUSTMENTS

SUMMARY

A) Tightening torques

Below are the specified tightening torques for the fix ing
bolts on the main parts.

Screws for engine fastening ............ 25 ÷ 30 Nm

Screw for engine pulley ................... 45 ÷ 50 Nm

Screws for rear axle brackets .......... 25 ÷ 30 Nm

Blade pulley screw .......................... 25 ÷ 30 Nm

Nuts for flanged supports ................ 25 ÷ 30 Nm

Screw for blade ............................... 45 ÷ 50 Nm

Every section in this manual gives values for all the components involved in each operation.

B) Adjustments

3/2015

Operation

Position

Adjustment

of controls

45 - 47

Tuff Torq K46T

77 - 79

34 - 36

Hydro Gear T2-BDBE-2X1A-16X1

Tuff Torq K46T

Hydro Gear T2-BDBE-2X1A-16X1

a) Brake adjustment

[see 4.3]

b) Blade engagement

adjustment

[see 4.1]

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Summary of Contents for 72FL Hydro

Page 1: ...e illustrations or duplication reproduction or translation even partial of the texts in this document may be made without explicit authorization All brands names logos and trademarks mentioned belong...

Page 2: ...bs greater accessibility may be required This can be done by taking the unit concerned off and working at the bench or by removing the cover or other external parts Whether or not this will be useful...

Page 3: ...1 Replacement of the drive belt 6 5 1 Replacement of the blade belt 6 6 0 Replacement of the support and shaft of the blade 6 7 0 Replacement of the accelerator 6 8 0 Replacement of the drive lever u...

Page 4: ...e concentrating more on specific aspects and the best servicing procedures You are asked to read through this manual to acquire a basic understanding of the machine which is nec essary for working rat...

Page 5: ...cations This number must always be quoted when requesting spare parts or any information from the Manufacturer B Guarantee validity The guarantee is supplied under the terms and the limits of the cont...

Page 6: ...lity as also shown in chapter 1 of the Instruction Booklet C Precautions during servicing The operations described in this manual do not entail particularly hazardous situations besides the normal haz...

Page 7: ...vailable from a good workshop However it is advi sable to have a set of special tools 1 5 These tools 1 5 are to be used whenever is given in this text 1 Blocks H 26 mm for adjusting the cutting deck...

Page 8: ...hine can be lifted using a jack which pushes on the underside of the frame Place a wooden block 1 between the base of the jack and the frame and check that the free movement of the front spring equali...

Page 9: ...ce remove the grass catcher engage the parking brake and raise the cutting deck to its maximum height The machine must only be laid on its right hand side resting the seat 1 and one of the corners of...

Page 10: ...access hatch 4 and unscrew the nut 5 with a 13 mm spanner Release the lever 6 so that the deck rests on the blocks and keep it held to the side so that it does not slip into any of the notches Grip t...

Page 11: ...rt element and bet ween this and the nut 4 Since these are joints the nut must never be tighte ned completely but only so much that it can ensure the free rotational movement of the pin on its axis wi...

Page 12: ...safety devices and renew illegible or missing labels Check tyre pressures Clean air filter Check engine oil level Check for fuel leaks Align cutting deck Sharpen and balance the blade and check the co...

Page 13: ...ade continuing to run belt shortened In both cases the stretcher needs to be adjusted The length of the spring 1 must be adjusted with the blade engaged and the cutting deck in position 1 because in o...

Page 14: ...e 4 is not deformed Remove the steering column cover see 5 1 Disengage the blade and check that the lever 2 and guide shoe 3 have a clearance of at least 7 8 mm If this is not so adjust the nuts 5 on...

Page 15: ...shers Never go under these amounts to avoid overloading the brake unit NOTE No further adjustments to the braking system are required for Hydro Gear T2 BDBE 2X1A 16X1 drive models Loosen the nut 21 an...

Page 16: ...the connection rod is incor rectly adjusted A Adjusting the neutral position Remove the right hand rear wheel see 6 1 Remove the collector channel see 5 5 The pedal position is to be adjusted startin...

Page 17: ...hen in motion the lever is held in the selected po sition by a clutch device which is made up of a sliding sector 12 between two friction discs 13 pressed to gether by a spring 14 The spring tension 1...

Page 18: ...inal 20 will need to be adjusted compared to the levers 21 and 22 This must be a position which prevents the terminal 20 from interfering with the swinging movement of the lever 21 and blocking the le...

Page 19: ...erent tyre pressures but make the adjustments as in points A and B A The combined adjustment to the parallel and the minimum height front and back Put the machine onto a flat and stable surface such a...

Page 20: ...lone Any difference in height from the ground between the left and right sides of the deck can be compensated by turning the nut 7 and the locknut 8 at the front left coupling point NOTE Remember to t...

Page 21: ...hub so that the ring gear is raised higher than the pinion Line up the front wheels and refit the ring gear 6 with the arrow pointing forwards then fully tighten the screw 5 Turn the steering column s...

Page 22: ...he front and rear protection covers for the steering column and the footboard see 5 1 Tightening torque 5 Ring gear fixing screw 25 30 Nm 3 2015 72FL hydro 4 6 0 STEERING ALLOWANCE ADJUSTMENT 2 2 WORK...

Page 23: ...wo tie rods 1 2 is 200 5 201 5 mm If the amount is different to this check if the error is due to one or both of the tie rods Dismantle the part concerned loosen the locknut 3 and screw the joint up o...

Page 24: ...lace a straight metal rod 1 on a point around the edge of the deck 2 turn the blade by hand and check the distance between the rod and the two ends A and B The distance should be the same and any diff...

Page 25: ...fit the flexible disc 4 so that the concave part is pressing against the knife tighten the screw 1 with a torque wrench set to 45 50 Nm B Sharpening and balancing Always sharpen both cutting edges of...

Page 26: ...wheels cover see 2 5 from closing properly which could let grass cuttings get into the engine housing causing damage Fit the channel see 5 5 Take the cutting deck to position 1 In this condition the...

Page 27: ...ews 2 and disassemble the guard 3 B Removal of front guard Remove the rear guard as shown in point A Using a screwdriver unhook the two central hooks and the two right and left hooks 11 holding the st...

Page 28: ...under the dashboard base When mounting reverse the operations described above making sure you restore connections to elec tric connectors removed during disassembly 3 2015 72FL hydro 5 1 0 REMOVAL OF...

Page 29: ...wheels cover 5 The footboard 6 is held to the frame by four internal screws 7 and four longer external screws 8 with washers 9 for resting on the tubular support ele ment On refitting reverse the orde...

Page 30: ...e 8 Undo the two self threading screws 9 and loosen the two screws 10 with nuts that hold the cover on to the rear plate Lift the wheels cover see 2 5 Undo the six screws which attach the tubular ele...

Page 31: ...microswitch 3 and release the stop cable 4 The plate is hinged at the base of the machine s frame by two small plates 5 each of which is fixed by four screws 6 and is attached to the frame of the whe...

Page 32: ...wo hinges be low and then attach the upper part of the frame of the wheels cover Reattach all the electrical connections and make sure that the microswitch is working Reassemble the wheels cover see 5...

Page 33: ...YEAR 2016 3 2015 5 5 REMOVAL OF THE COLLECTOR CHANNEL Removing the channel is necessary for draining oil from the engine accessing the right hand side of the engine Turn back the wheels cover see 2 5...

Page 34: ...e threaded hole of the shaft Remove the protection from the exhaust 5 differing according to the types of engine and disconnect the accelerator cable control and all the electrical wires Close the fue...

Page 35: ...and earth contacts and refit the protection covers 5 Refit the spring 1 of the stretcher Reattach the accelerator cable and Adjust the MINIMUM position see 6 7 Close up the wheels cover see 2 5 Tighte...

Page 36: ...e two ends of the rear plate Remove the rear wheels see 6 1 Disconnect the drive control rod 21 by removing the split pin 22 remove the pin 23 from the brake rod 24 unscrewing nut 25 move the tensione...

Page 37: ...35 36 37 are correctly fit ted to the shafts in the sequence given Reattach all the connections and then Check the brake see 4 3 Refit the engine pulley see 5 5 to release the belt Refit the rear whee...

Page 38: ...release the belt Place two spacers 1 of approximately 150 mm un der the two ends of the rear plate Remove the rear wheels see 6 1 Remove the split pin and remove the front pin 1 from the brake rod Un...

Page 39: ...roximately 15 22 kg To reassemble reverse the order of the previous op erations Check that the spacers 17 18 are correctly fitted to the shafts Reattach all the connections and then Check the brake se...

Page 40: ...pec tion hole in front of the seat and remove the pin 2 from the inside in order to disconnect the collector channel 3 Bring the cutting deck to position 1 and put a 40 mm block underneath the rear ri...

Page 41: ...in to the front right lever 17 Take care not to touch the nuts and lock nuts so that they remain aligned for assembly After checking that there is nothing in the way the deck can be removed first by r...

Page 42: ...Wheels The wheels are held by a snap ring 1 which can be removed with the help of a screwdriver NOTE If a wheel is jammed onto the shaft use a releasing spray directed around the splining hole On ass...

Page 43: ...1 The front wheel bearings 1 are force splined into the front wheel hub To be able to remove a bearing a 10 12 mm round bar 2 is needed Insert this from the opposite side and hammer it on various poin...

Page 44: ...haft After having dismantled the pinion and the ring gear as described at point A take out the snap ring 1 from its seat in the shaft 2 and extract the shaft from the bushings 3 pulling it downwards A...

Page 45: ...he stretcher 2 held by the nut 3 The belt 6 can now be removed from the pulley 5 On reassembling make sure that the belt 6 is cor rectly positioned in the pulleys inside the rims When assembly is comp...

Page 46: ...4a without loosening the nuts to free the brake 4 Loosen the screw 5 in order to move the stretcher pulley 6 until the belt 2 is released without un screwing it completely Dismantle the pulley 7 of t...

Page 47: ...re part available as single assembly unit If you should want to just replace the shaft or bear ings remove the key 6 and hit the shaft with a plas tic mallet on the pulley side in order to remove the...

Page 48: ...016 3 2015 Fit on the upper bearing and using the special bush 13 which works on the inner ring hit it squarely with a mallet until the bearing is fully driven home Fit the flange support onto the dec...

Page 49: ...reassembling put the accelerator lever in the MINIMUM position shown on the label connect the end of the wire 2 to the terminal 3 on the engine after having moved the cursor 6 in the same MIN IMUM po...

Page 50: ...using the two screws 11 Hook the barrel 5 of the cable 6 and refit the pins 2 and 4 without fully tightening their nuts and af ter having loosened the adjuster nuts of the rods 1 and 3 Check that the...

Page 51: ...4 4 B Adjust the lever s return cable see 4 4 D and lastly Refit the collector channel see 5 5 Close up the wheels cover see 2 5 Tightening torques 11 Drive lever support screws 25 30 Nm 3 2015 72FL h...

Page 52: ...With the pedal released unhook the barrel 1 from the lever 2 take it off the lever 3 loosen the nut 4 of the adjuster release the spring 5 and remove the cable 6 Start fitting the spring 5 using the...

Page 53: ...steel discs 10 When reassembling carry out the operations de scribed above in reverse order making sure that the two tabs of the steel discs are correctly positioned in the recesses made in the lever...

Page 54: ...ct the ca ble 2 terminal 8 At this point the cable 2 can be removed extracting it from below When mounting reverse the operations described above taking care to always replace the crown fastener 7 pas...

Page 55: ...longer accepts recharging Replace the battery Faulty or wet electronic card Check and dry with low pressure tepid air hair dryer Disconnected or missing battery Reconnect the battery which must always...

Page 56: ...er works erratically for mechanical or electrical reasons taking excessive current and causing binding of relay contacts Check the starter motor 7 The starter motor operates as soon as the key is in t...

Page 57: ...hat is known to work If the problem stops replace the faulty card 11 The 25 A fuse blows Faults in the battery charging circuit Replace fuse 25 A and check the recharge circuit see 7 7 12 No audible s...

Page 58: ...intervene Uninfluential OPERATOR GRASS CATCHER BLADE DRIVE PARKING ENGINE PILOT LAMP Engaged DOES NOT start Flashing Engaged DOES NOT start Flashing Absent DOES NOT start Flashing A STARTING START po...

Page 59: ...ached and should give this result N Contacts Tester reading and condition GRASS CATCHER ATTACHED MICROSWITCH 10 6 without g catc O with g catcher SEAT MICROSWITCH 10 14 absent O seated PARKING MICROSW...

Page 60: ...one with the tester in Voltmeter func tion Volt DC 0 20 with the black ferrule on termi nal 1 and the red ferrule on terminal 11 of the wiring connector 1 The key in the ON position The reading shows...

Page 61: ...of the relay bobbin should be heard and the starter motor should come into action only with B S engines If the relay clicks but the starter motor does not go make a bridge 2 with a large section cable...

Page 62: ...k ferrule to earth and the red ferrule on terminal 10 of the wiring con nector 2 C Checking the operation of the self setting protection For this test put everything in the same situation as in point...

Page 63: ...er measure the voltage at the battery terminals If the value does not rise but tends to fall even slowly it means that the regulator is not charging sufficiently and must be replaced If the voltmeter...

Page 64: ...life of the battery and must be carried out according to these instructions do not recharge the battery when its case is broken or damaged carefully read the instructions for using the battery charger...

Page 65: ...DEL YEAR 2016 3 2015 7 9 FITTING SAFETY MICROSWITCHES IMPORTANT If the microswitches are to function correctly it is important to follow the exact assembly positions by referring to the drawings that...

Page 66: ...ARDEN PRODUCTS 72FL hydro 7 10 2 ELECTRICAL DIAGRAMS 1 2 WORKSHOP MANUAL pag MODEL YEAR 2016 3 2016 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 3 Battery 4 S...

Page 67: ...ELECTRICAL DIAGRAMS 2 2 WORKSHOP MANUAL pag MODEL YEAR 2016 by GLOBAL GARDEN PRODUCTS 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 2e Starter relay 3 Battery...

Page 68: ...for engine pulley 45 50 Nm 3 Screws for rear axle brackets 25 30 Nm 4 Blade pulley screw 25 30 Nm 5 Nuts for flanged supports 25 30 Nm 6 Screw for blade 45 50 Nm Every section in this manual gives va...

Page 69: ...by GLOBAL GARDEN PRODUCTS 72FL hydro 8 2 1 BELTS ASSEMBLY 1 1 WORKSHOP MANUAL pag MODEL YEAR 2016 3 2015 8 2 BELTS ASSEMBLY 1 Blades belt development 2 Drive belt development 1 2 BACK...

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