Global garden products 92 hydro Workshop Manual Download Page 64

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8.2

- SUMMARY OF MAIN ASSEMBLY AMOUNTS

AND CHECKS

1 / 4

WORKSHOP MANUAL

page

from

2003

••••

4/2005

8.2 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS

Frame

Cutting deck

Steering geometry

Drive belt development

Blades belt development

Fitting the gearchange control tie-rod (

➤

in mechanical drive models)

Fitting the drive control tie-rod (

➤

in mechanical drive models)

Fitting the pedal tie-rod (

➤

in hydrostatic drive models

)

Fitting the deck lifting tie-rod

Fitting the blades brake tie-rod

Summary of Contents for 92 hydro

Page 1: ...es and that described here though the basic features and various repair methods will remain the same by GLOBAL GARDEN PRODUCTS No use of the illustrations or duplication reproduction or translation ev...

Page 2: ...ing 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 is at the discre tion of the mechanic s experience 6 Repairs Thi...

Page 3: ...6 1 Replacement of the blade belt 6 7 0 Replacement of the lifting cable 6 8 0 Replacement of the blade engagement cable 6 9 0 Replacement of the supports and shafts of the blades 6 10 0 Replacement o...

Page 4: ...nd the best servicing procedures You are asked to read through this manual to acquire a basic understanding of the machine which is necessary for working rationally without making errors or wasting ti...

Page 5: ...Manufactur er A Guarantee validity B Guarantee validity The guarantee is supplied under the terms and the limits of the contractual relations in being As far as the engine and the transmission unit ar...

Page 6: ...erations described in this manual do not entail particularly hazardous situations besides the normal hazard related to mechanical operations and that can be avoided by taking the necessary care and at...

Page 7: ...cial tools 1 5 which are already part of a set Code no 82180040 2 or which can be made following the instructions given in chapter 8 3 These tools 1 5 are to be used where there is the symbol in this...

Page 8: ...ock 1 between the base of the jack and the frame and checking to see that the free movement of the front spring equaliser has not been obstructed B Rear Place a suitable block 2 beneath the lower edge...

Page 9: ...position to make sure that there is no more than 2 litres of fuel inside To assure full stability the lawn tractor must only be rested on the points shown inserting a block 1 of about 120 mm under the...

Page 10: ...ht ened completely but only so much that it can ensure the free rotational movement of the pin on its axis without however creating excessive free play which could result in the parts concerned becomi...

Page 11: ...s Align cutting deck Sharpen and balance the blades and check the condition of the hubs Check for wear in the belts Check the blade brake engagement Grease front wheels lever joint pins and bushes Gre...

Page 12: ...which can result in mal functioning i e belt slipping belt or cable stretched difficulty in disengaging with a stiff lever and the blades continuing to run belt shortened In both cases the stretcher...

Page 13: ...loosening the two screws 3 Take off the left hand guard 4 held by two screws 5 Check that the two shoes 6 are not distorted and that the link rod 7 is not distorted so varying the centre distance Che...

Page 14: ...g 2 is 43 5 45 5 mm In mechanical drive models 45 47 mm In hydrostatic drive models measured from the inside of the washers When the adjustment has been made tighten the nut 4 Never go under these amo...

Page 15: ...If braking is still poor or unsteady even after making the adjustment you cannot make any further adjust ments from the outside Therefore you need to dismantle the whole rear axle of the machine see 5...

Page 16: ...mits forward movement power a belt which is too tight increases noise and results in jerky movements or tipping up when engaging the drive In these cases the stretcher will need to be adjust ed The st...

Page 17: ...ate using the nuts 4 of the control rod 5 until the pedal is positioned properly Take care not to accidently change the position of the lever 2 dur ing the adjustment B Adjusting the neutral position...

Page 18: ...and back Put the lawn tractor onto a flat and stable surface such as a work bench and put blocks beneath the cutting deck in line with the centre lines of the blades at the front 26 mm 1 code 6070000...

Page 19: ...ront part tends to rise faster or slower it can be adjusted by turning the nuts 10 on the link rod 11 Turning the nuts clockwise will lift the front part and make it rise faster and turning anti clock...

Page 20: ...nd take out the whole ring gear shaft 6 without dismantling the tie rod 7 Take away one or both of the blocks 8 under the ring gear depending on the amount of free play to be reduced Reassemble the pi...

Page 21: ...When assembly is completed Refit the fuel tank see 5 4 Tightening torque 5 Nut for ring gear 45 50 Nm 92 4 7 1 STEERING ALLOWANCE ADJUSTMENT 2 2 WORKSHOP MANUAL page from 1997 to by GLOBAL GARDEN PRO...

Page 22: ...1 of the wheel connection rod 2 If a different distance is found dismantle one or both the joints and screw the necessary amount down or up on the rod On assembly fully tighten the locknuts 3 and the...

Page 23: ...des With the blades disengaged firmly hold each blade and bring the cutting edges together in the various positions possible A B A B1 A1 B1 A1 B At each position they should be aligned to within 2 mm...

Page 24: ...from the rounded side removing as little as possible The blade is to be replaced when the cutting edge has worn down to 10 mm B Balancing Using the appropriate equipment check the bal ance to make sur...

Page 25: ...ity to the engine and its accessories the silencer and protection devices In models with lights Disconnect the connector 1 The hood can be secured in two ways A Fixing with springs Unhook the two fast...

Page 26: ...he knob from the blade engagement lever 3 and the knob from the gear lever 4 In hydrostatic drive models unscrew the knob from the blade engagement lever 3 and the drive pedal 5 Remove the caps 6 from...

Page 27: ...crews have a washer When the cutting height lever has been moved to position 7 and the engage lever to the blades engaged position it is possible to remove the cover 4 2005 10 13 13 13a 12 92 5 2 1 RE...

Page 28: ...rive belt the control rod for engaging drive and the micro switch to signal neutral in hydrostatic drive models Undo the two screws 1 the hold the support for the sack full signal microswitch undo the...

Page 29: ...try to the fuel filter 1 taking care not to spill fuel Remove the electronic card take off the lower part of the protective cover 2 Loosen the screw 3 holding the support 4 and lift the tank until the...

Page 30: ...e 4 Turn the belt shifter 5 forward until the belt 6 is released from the pulley 7 Undo the central screw 8 and take out the pulley 7 from the shaft If it is difficult to take out use the special extr...

Page 31: ...ontacts and refit the protection covers if fitted To reassemble reverse the order of the previous operations Reset the belt shifter 5 into position refit the fork 4 with the relative safety pin 3 and...

Page 32: ...should also be loosened This is done by In mechanical drive models engaging the parking brake In hydrostatic drive models loosening the nut 1 of the stretcher Disconnect the blade engagement cable 3...

Page 33: ...e unit is held up by a support 22 and fastened to it by a screw with a nut 23 and it is attached to the frame by four screws 24 Undo the nut 23 and then carefully undo the four lower screws 24 holding...

Page 34: ...loos ened without having touched the rear one the right tension will be achieved by just tighten ing up the nut 1 When assembly is completed Refit the collector channel see 5 3 Tightening torques 14 S...

Page 35: ...rods 10 to the frame and loosen the two nuts 11 fas tening the deck Release the three split pins 12 holding the pins onto the lifting lever being careful to not touch the nuts and locknuts so that on...

Page 36: ...y to check the pressure and to check the alignment of the cutting deck see 4 6 WARNING Replace distorted wheel rims as they could impair the tyre s hold B Wheels The wheels are held by a snap ring 1 w...

Page 37: ...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 points around the int...

Page 38: ...to draw out the pinion 4 A Dismantling steering pinion and ring gear Unscrew the nut 5 and take out the whole ring gear shaft 6 after dismantling the tie rod 7 To dismantle the ring gear 6 take out t...

Page 39: ...efore the pinion and fully tighten the nut 5 In hydrostatic drive models tighten the spring of the stretcher see 4 4 If only the front nut 1 has been loosened without having touched the rear one the r...

Page 40: ...lt detach the brake control rod 8 by dismantling the pin 9 from the lever 10 When reassembling make sure that the belt 11 is correctly positioned in the pulleys inside the rims see 8 2 4 taking partic...

Page 41: ...right hand wheel 2a 2c the short spacer 4b is to be fitted beneath the left hand wheel 2b 2d In mechanical drive models the left wheel 2b must be fitted to the front sup port of the frame see 8 2 4 In...

Page 42: ...etcher spring see 4 4 If only the front nut 1 has been loosened without having touched the rear one the right tension will be achieved by just tightening up the nut 1 Tightening torque 3 Nuts for smal...

Page 43: ...lease the right spring 14 loosen the nut 15 of the idle pulley and take off the guide pulley 16 after having released the spring 17 At this point the brake shoes can be manually moved away from the pu...

Page 44: ...the maximum height so that the toothed sector turns to the back Pass the cable along the groove and insert the end 5 in the hous ing Put the cable back in its path around the pulley hook on the adjust...

Page 45: ...lowest position and the lever in the disengaged position loosen the adjuster 1 remove it from its housing and unhook the spring 2 Take off the barrel 3 at the end of the fork 4 which is near the join...

Page 46: ...ws 3 Take off the left hand cover 4 held by two screws 5 Release the two springs 7 and 8 of the right and left brakes and take off the left guide pulley 6 At this point it is possible to undo the cent...

Page 47: ...put the shaft into the hole of the lower bearing and insert this into the support Fit on the upper bearing and using the special bush Cod 60800030 0 20 which works on the inner ring hit it squarely w...

Page 48: ...ndo the two screws 7 and take out the accelera tor together with the wire On reassembling put the accelerator lever in the MINIMUM position connect the end of the wire 5 to the terminal 6 on the engin...

Page 49: ...er of them is less than 5 mm Renew the disc if it is damaged distorted or less than 4 mm thick On reassembly carefully reposition all the compo nents and refit the complete support When con necting th...

Page 50: ...r contact Check and clean the connections c after several minutes use Poor or missing earth contact on the charge regulator Check the earth connections and the screws fastening the regulator 2 With th...

Page 51: ...e electronic circuit or in the signalling LED Replace the card NOTE You can finish the work in any case but you need to replace the card or signalling LED as soon as possi ble 9 The pilot lamp becomes...

Page 52: ...is known to work If the problem stops replace the faulty card PROBLEM CAUSE REMEDY 13 No audible signal for the grass catcher full con dition Malfunctioning or faulty blades microswitches and grass c...

Page 53: ...h the safety devices intervene Uninfluential A STARTING START position OPERATOR GRASS CATCHER BLADES DRIVE PARKING ENGINE PILOT LAMP Engaged DOES NOT start Flashing Engaged DOES NOT start Flashing Abs...

Page 54: ...3 CN2 1 CN5 O free engaged BLADE MICROSWITCH 3 4 CN2 engaged O disengaged IN NEUTRAL SIGNAL 3 1 CN2 drive O neutral GRASS CATCHER FULL MICROSWITCH 2 CN2 Massa O full empty STARTER UNIT Battery 2 CN3...

Page 55: ...done with the tester in voltmeter func tion Volt DC 0 20 with the black ferrule on termi nal 3 CN5 and the red ferrule on terminal 2 CN3 the wiring connectors 1 The key in the ON position The reading...

Page 56: ...position Disconnect the connector CN3 In making a bridge between the terminals 2 and 4 CN3 of the wiring connector 1 the click of the relay bobbin should be heard and the starter motor should come in...

Page 57: ...test put everything in the same situation as in point A By connecting terminal 3 of the CN2 connector of the electronic card 3 to the frame s earth the pilot lamp should go out due to the protection...

Page 58: ...h the voltmeter tester 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 replac...

Page 59: ...tion for the 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 ba...

Page 60: ...s usages of each type A Free B Activated 15 mm A B 2 6 mm min 1 mm A B 1 2 Adjust the seat safety microswitch 1 only by changing the position of the cam 2 after loosening the two fixing screws 3 This...

Page 61: ...1 a b c d 16a 16b 1 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 3 Battery 4 Starter relay 5 Key ignition switch 6 Blades microswitch 7 Brake microswitch 8 Gr...

Page 62: ...6a 2 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 2e Starter relay 3 Battery 5 Key ignition switch 6 Blades microswitch 7 Brake microswitch 8 Grasscatcher mic...

Page 63: ...ne pulley 45 50 Nm 3 Rear axle locknut 25 30 Nm 4 Screws for blades pulleys fastening 25 30 Nm 5 Nuts for flange support 25 30 Nm 6 Screw for blades 45 50 Nm Every section in this manual gives values...

Page 64: ...ND CHECKS 1 Frame 2 Cutting deck 3 Steering geometry 4 Drive belt development 5 Blades belt development 6 Fitting the gearchange control tie rod in mechanical drive models 7 Fitting the drive control...

Page 65: ...by GLOBAL GARDEN PRODUCTS 92 8 2 1 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 2 4 WORKSHOP MANUAL page from 2003 to 4 2005 2 3...

Page 66: ...SEMBLY AMOUNTS AND CHECKS 3 4 WORKSHOP MANUAL page from 2003 to 4 2005 2 5 2 5 2 5 1 9 2 1 10 12 1 3 5 1 3 5 5 6 4 2 4 2 5 3 5 3 5 5 3 5 4 5 2 7 5 2 7 5 2 4 3 5 4 5 DANA drive models PEERLESS drive mo...

Page 67: ...by GLOBAL GARDEN PRODUCTS 92 8 2 1 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 4 4 WORKSHOP MANUAL page from 2003 to 4 2005 9 10 8 7...

Page 68: ...UAL page from 1997 to 8 3 SPECIAL TOOLS 1 60700000 0 Steel 2 60700001 0 Steel 3 60800030 0 Bronze 4 60800031 0 Bronze 5 60253000 0 Steel 65 M8 110 152 10 40 20 50 30 58 M16 7 2 8 5 22 15 21 78 30 40 4...

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