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Global garden products MJ66, Workshop Manual

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TOOLS

General informations

This chapter covers the main aspects of a servicing 

procedure and the general rules for guaranteeing a 

successful service which respects the safety of the 

machine.

Related topics

­­­

All work can be carried out using the tools normally 

a vailable from a good workshop. However, it is ad vi -

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

2. 

Blocks H = 32 mm     for adjusting

the cutting deck

3. 

Bush for assembly of blade bearings

4. 

Stopper for assembly of wheel bearings

5. 

Blade pulley extractor 

MODEL YEAR 2015

MJ66-Hy

MJ66

WORKSHOP MANUAL

BACK

Summary of Contents for MJ66

Page 1: ...lication 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 to their respective ow...

Page 2: ...usually resolved by quick checks and tun ings 5 Removal of external parts and main assemblies For doing more difficult jobs greater accessibility may be required This can be done by taking the unit co...

Page 3: ...e blade engagement cable 6 12 2 Replacing and regulating the gear cable mechanical drive models 6 13 0 Replacement of the brake pads and disc 7 Electrical system 7 1 1 Troubleshooting of the electrica...

Page 4: ...Mechanical drive models MJ66 MJ 66 rear discharge and multi function Hydrostatic drive models MJ66 Hy MJ 66 Hydro rear discharge and multi function B Page number specifically the first two figures sep...

Page 5: ...MJ66 MJ66 SD MJ66 Hy MJ66 SD Hy WORKSHOP MANUAL iii 0 MAP OF INTERVENTIONS ENGINE FUEL TANK TRANSMISSION BRAKE WHEELS CUTTING DECK STEERING BODY ELECTRICAL SYSTEM MJ66 MJ66 Hy BACK...

Page 6: ...pics Removal of external parts and main assemblies Removal of the wheel cover 5 3 Removal of the tank 5 4 Removal of the engine 5 5 Repairs Replacing the accelerator and adjusting the carburettor 6 7...

Page 7: ...s 5 2 Removal of the wheel cover 5 3 Removal of the rear axle mechanical drive models 5 6 Removal of the rear axle hydrostatic drive models 5 6a Removing the lower part of the rear plate 5 9 Repairs R...

Page 8: ...ning and balancing the blade 4 8 Removal of external parts and main assemblies Removal of the side guards 5 2 Removal of the cutting deck 5 7 Removal of the discharge conveyor 5 8 Repairs Replacement...

Page 9: ...lated topics Adjustments and tuning Removal of external parts and main assemblies Removal of steering column covers 5 1 Repairs Disassemble the steering column and replace bushes 6 6 MODEL YEAR 2015 M...

Page 10: ...NDEX OF Related topics Removal of external parts and main assemblies Removal of steering column covers 5 1 Removal of the side guards 5 2 Removal of the wheel cover 5 3 MODEL YEAR 2015 MJ66 Hy MJ66 WO...

Page 11: ...safety devices 7 2 Safety microswitches operation check 7 3 Terminal board supply check 7 4 Starter relay operation check 7 5 Electronic card operation check 7 6 Recharge circuit check 7 7 Care and ma...

Page 12: ...are indispensable for spare part orders 2 Transmission Rear axle The transmission unit both mechanical and hydro static is made up of an engine block including the rear axle This unit is made by anot...

Page 13: ...a report contai ning the machine s serial number a summary of the problem the repairs carried out and any spare parts u sed for each repair done on the machine A copy of this report must be retained t...

Page 14: ...correct or dif ferent from the purpose for which it was de si gned and approved warn the Customer that the failure to comply with the above points results in the automatic annulment of the Guarantee a...

Page 15: ...bols and terms used for safety purposes Some paragraphs in this manual are preceded by sym bols which indicate the following Operations that should be carried out with ut most care to avoid impairing...

Page 16: ...ried out using the tools normally a vailable from a good workshop However it is ad vi 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...

Page 17: ...E PARKING BRAKE HAS BEEN ENGA G ED the lawn tractor can be lifted using a jack which pushes on the underside of the frame placing a wood block 1 between the base of the jack and the frame and checking...

Page 18: ...rtical position to make sure that there is no more than 1 litres of fuel inside hydrostatic drive models Move the drive disengage lever 4 to A block ed to reduce its protruding from the rear plate To...

Page 19: ...B Joint pivot pins There are a large number of pivot pins usually con nected to rods that need to be able to move in va rious directions A typical situation has the pin 3 fixed by a self lock ing nut...

Page 20: ...nds 6 are secured by crown fasteners 7 During dismantling these fasteners are always damaged and lose their hold so they should never be reused On assembly make sure it is inserted in the right direc...

Page 21: ...safety devices and re new illegible or missing labels Check type pressures Clean air filter Check engine oil level Check for fuel leaks Align cutting deck Sharpen and balance the blade and check the c...

Page 22: ...emoval of the side guards 6 4 Replacement of the drive belt 6 11 Replacing the blade engagement cable A Adjusting blade engagement Remove left guard With the cutting deck in its lowest position suitab...

Page 23: ...ve the steering column s rear guard Only make the adjustment when the parking brake is engaged mechanical drive models Remove the recall spring 3 to make the brake spring 4 accessible Adjust the regis...

Page 24: ...ion mechanical drive models If brake adjustments should still not be enough or be irregular disconnect the pin 6 from the lever 7 and check that the latter has a 20mm vacuum stroke measured vertically...

Page 25: ...r engagement cable 5 2 Removal of the side guards 6 3 Replacement of the drive belt 6 10 Replacing the drive engagement cable Remove the left guards You obtain correct spring 1 tension by moving the h...

Page 26: ...ent cable Mechanical drive models Remove the steering column s rear guard Remove the right hand guard Remove the conveyor Unhook the cotter pin 1 and disconnect the eyelet 2 of the lever cable 3 With...

Page 27: ...usting the pedal in the neutral position Regulating consists in adjusting the position of the pedal 4 with the hydrostatic group lever 3 which is brought to the forward maximum speed position by a spr...

Page 28: ...p of the cam so that it stays pressed down By moving the pedal to the forward gear neutral po si tion and reverse gear you should hear the click of the button at each gear change before the wheels sta...

Page 29: ...the spacers Adjust the register 3 till the control cable is tight and the cutting deck s rear right hand side starts to lift Screw the left nut 4 until the left side starts to lift then block the loc...

Page 30: ...de place 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...

Page 31: ...Nm Always wear protective gloves when handling the blade and protect eyes when sharpening A Removing and reassembling For removing a blade it must be firmly held and the central screw 1 undone On ass...

Page 32: ...Screw for blade 45 50 Nm B Sharpening and balancing Always sharpen both cutting edges of the blade 2 using a medium grade grinding wheel sharpening should only be performed on the side opposite to the...

Page 33: ...w the central screw 13 dismantle the steering wheel 14 and extract the steering column extension 15 Dismantle the upper part of the dashboard 16 un hooking the three hooks 17 General informations Gene...

Page 34: ...ve engagement cables the micro switches on blade engagement and parking brake from the front the steering column and bushes registers of brake cables and drive engagement mechanical drive models Relat...

Page 35: ...ame NOTE When mounting make sure the register 7 remains outside of the guard 5 B Removing the right hand guard The right hand guard 11 is fixed by the screw 12 and fastener tooth 13 inserted in a spec...

Page 36: ...wheel cover s rear part 3 is completed by 5 screws 6 on the rear plate NOTE Removing the rear part 3 is facilitated by widening the two side elements slightly and lifting the rear part just enough to...

Page 37: ...ight are each fixed by 1 screw on the rear part 12 1 screw on the front part 13 1 screw on the lower part 14 1 side fin 15 hooked to the central element and released using a screwdriver When mounting...

Page 38: ...l out the wire and connector 28 Disconnect ignition block wire connectors Remove the central cover 29 fixed with two screws 30 The wheel cover central element 31 is fixed by 2 screws on the front lowe...

Page 39: ...3 and empty the tank collecting all the fuel in a suitable container taking care not to cause any leakage Unscrew the two lower screws 4 and the upper screw 5 fixing the tank 6 and remove the tank thr...

Page 40: ...m Screws for engine fastening 50 55 Nm Remove the collector channel Remove the left and right side guards Remove all wheel cover parts Remove the drive belt Disconnect the accelerator cable Detach the...

Page 41: ...ws of differ ent length and in different positions so it is best to label them so that no errors are made on assembly If the pulley 7 has to be dismantled unscrew the central screw 8 and extract the p...

Page 42: ...orques 23 Nuts for bracket fastening 25 30 Nm 24 Self tapping screw 25 30 Nm 25 Rear axle fastening nuts 20 25 Nm 5 6 2 REMOVAL OF THE REAR AXLE mechanical drive models Mechanical drive models Remove...

Page 43: ...rt of the rear plate 6 1 Replacement of tyres and wheels Tightening torques 23 Nuts for bracket fastening 25 30 Nm 24 Self tapping screw 25 30 Nm 25 Rear axle fastening nuts 20 25 Nm Move the tightene...

Page 44: ...crew 25 30 Nm 25 Rear axle fastening nuts 20 25 Nm Loosen the two lower screws 24 to allow the brack ets 21 to sway a little and unscrew the nuts 23 then carefully unscrew the four nuts 25 supporting...

Page 45: ...cover 5 8 Removal of the discharge conveyor 5 9 Removing the lower part of the rear plate 6 1 Replacement of tyres and wheels Tightening torques 17 18 Nuts for bracket fastening 25 30 Nm 21 Rear axle...

Page 46: ...eel cover 5 8 Removal of the discharge conveyor 5 9 Removing the lower part of the rear plate 6 1 Replacement of tyres and wheels Tightening torques 17 18 Nuts for bracket fastening 25 30 Nm 21 Rear a...

Page 47: ...Tightening torques 17 18 Nuts for bracket fastening 25 30 Nm 21 Rear axle fastening nuts 20 25 Nm Loosen the upper nut 18 to give a minimum of move ment to the bracket 17 unscrew the nut 19 and slide...

Page 48: ...sup porting the deck from the right Unhook the cotter pin 11 unscrew the nut 11a and remove the tie rod 12 which supports the deck from the left side General informations By removing the cutting deck...

Page 49: ...eck still in position Related topics 4 6 Aligning the cutting deck 5 2 Removal of the side guards 5 8 Removal of the discharge conveyor 6 1 Replacement of tyres and wheels Check there are no blocks th...

Page 50: ...ove the engine tank rear axis and cutting deck Related topics 5 8 2 REMOVAL OF THE DISCHARGE CONVEYOR The conveyor 1 is connected to the rear plate 2 by two plastic clamps 3 removable with the help of...

Page 51: ...ns on the rear axis Related topics Tightening torques 2 Rear plate fixing screws 12 15 Nm The lower part of the rear plate 1 is fixed to the upper part with 7 screws 2 Hydrostatic drive models When mo...

Page 52: ...ace distorted wheel rims as they could impair the tyre s hold B 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...

Page 53: ...arings 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 intern...

Page 54: ...ey tightener fixing screws 25 30 Nm Mechanical drive models Remove the collector channel Remove the lower part of the rear plate Remove the left and right side guards Unhook the drive belt tightener s...

Page 55: ...13 on the tightener 14 just enough to free the drive belt 15 from its pin 16 Loosen the nuts 17 on the two belt guides 18 of the drive belt With the parking brake disengaged you can extract the drive...

Page 56: ...MJ66 MJ66 4 models Remove the collector channel Remove the lower part of the rear plate MJ66 SD models Remove the lower rear part of the wheel cover Remove the left and right side guards Unhook the d...

Page 57: ...e rear plate Hold the two parts of the belt 10 to release it from the pulley 11 and to extract it On assembly follow the procedures described above in reverse order When assembly is completed Reassemb...

Page 58: ...de 3 fixed by a cot ter pin 4 from the left side and by a nut 5 from the right and remove the blade belt from the engine pul ley Loosen the screw 6 on the tightener 7 just enough to free the belt 8 fr...

Page 59: ...ade and extract the hub Loosen the two lower nuts 1 holding the belt guide 2 just enough to free the belt 3 from the pulley 4 Unhook the spring 5 from the tooth 6 and move the lever 7 sideways with th...

Page 60: ...ent the point of the ex tractor from damaging the thread The second bearing still in place must be removed by hitting it from the inside of the flange using a 12 15 mm diameter round bar 24 On reassem...

Page 61: ...ting blade brake 12 T Side plate and hole for supporting tightener 13 On completion of assembly of the supports Reassemble the hubs and start sharpening balancing and assembling the blade Remove the c...

Page 62: ...termi nals of the steering 4 tie rods from the bushes 5 If the bushes 5 should need replacing due to exces sive play they can be extracted using pliers Extract the steering wheel pin 6 the upper pin...

Page 63: ...tightening the screws 13 reassemble the steering column 10 making sure to replace the shoulder washers 8 and 11 the three pins 6 7 9 so they remain centred with the steering column fully tighten the...

Page 64: ...the wire 7 terminal 6 from the lever 8 and remove the accelerator with the wire To assemble put the accelerator lever in MIN and connect the wire 7 terminal 6 to the lever 8 Move the lever 8 to the sp...

Page 65: ...er 3 Unhook the end 7 of the cable 6 from the control lever 8 and from the plate s lifting lever 9 to remove the cable When mounting reverse the operations described above paying attention to the corr...

Page 66: ...e the pin 5 connecting the brake cable 3 Remove the clamp 6 and extract the cable 3 When mounting restore the cable route 3 follow ing layout instructions making sure you replace the clamp 6 Reassembl...

Page 67: ...the two screws 11 and dismantle the brake cable 3 support 12 to be able to unhook the spring 13 from the lever 15 pin 14 Remove the cable 3 from the support 12 Remove the clamp 16 and extract the cabl...

Page 68: ...Reassemble the right hand guard Reassemble the steering column s rear guard Reassemble the collector channel Regulate the drive engagement cable Mechanical drive models Remove the collector channel R...

Page 69: ...ng column covers 5 2 Removal of the side guards Remove the steering column s rear guard Move the tightener 1 by hand just enough to unhook the spring 2 Using pliers disconnect the cable 3 from the sup...

Page 70: ...Removal of steering column covers 5 2 Removal of the side guards Remove the clamp 10 and extract the cable 3 When mounting restore the cable route 3 following layout instructions making sure you repl...

Page 71: ...side of the wheel cover Unscrew the screw 3 dismantle the speed gear con trol lever 4 and disconnect the two cable terminals 5 Unscrew the two screws 7 dismantle the supporting bracket 8 to facilitate...

Page 72: ...13 and on the support 8 and making sure you re place the clamp 12 Regulate the cables Move the left side of the lever 4 fully forward corre sponding to reverse gear R and then move it back a notch co...

Page 73: ...nd unscrew the two screws 4 holding the support 5 The support 5 contains a pad 5a separated from the control pistons 6 by a plate 7 The other pad 5b can be reached by taking off the disc 8 If there is...

Page 74: ...ort When connecting the pin 1 take care to use the le ver s 2 upper hole and to replace the spring 3 NOTE During all these operations it is better to not un screw or loosen the central screw 9 to avoi...

Page 75: ...rter relay activates Battery or card not earthed to frame Check and put right 10 A fuse blown Replace fuse 10 A Fault in the electronic card Try replacing the card with one that is known to work Check...

Page 76: ...key is in the ON position and can be turned off only by removing the key Fault in the card Replace the card Starter block operating faults Replace the block Insufficient charge Check that the chargin...

Page 77: ...RATOR GRASS CATCHER BLADE TRANSMISSION PARKING ENGINE Absent Does NOT start Engaged Does NOT start Engaged Does NOT start A STARTING START position OPERATOR GRASS CATCHER BLADE TRANSMISSION CONSENT PE...

Page 78: ...Earthing to frame O Always REVERSE CONSENT This check must be performed by enabling the reverse consent pedal micro switch and the reverse gear en gaged indicator micro switch at the same time The fol...

Page 79: ...ected cor rectly The key in the ON position This check is done with the Voltmeter tester Volt DC 0 20 with the red ferrule on terminal 10 and the black one on terminal 6 of the wiring connector 2 The...

Page 80: ...gaging the blade the key in the ON position Disconnect connector CN1 On making a bridge be tween terminals 10 and 9 of the wiring connector 1 you should hear the click of the relay bobbin and the star...

Page 81: ...wiring 2 and terminal 10 of the card 1 in order to supply power to the card The key in the ON position With the Voltmeter tester Volt DC 0 20 earth the black ferrule and the red one on terminals 4 5 7...

Page 82: ...make sure that the connections are correct the earth connections are firmly attached the battery is charged and not sulphated the fuse is not blown Checking the lower charging limit Start the engine...

Page 83: ...source in order to ensure maximum performance during the battery s entire life With a battery of this type it is not necessary to add water or acid and the cover must never be opened or re mo ved B R...

Page 84: ...rocedure inhibits all safety systems so it is best to disassemble the blade release the two belts from their respective pul leys Remove the brown engine STOP cable connected to the engine and try to s...

Page 85: ...tches are to function correctly it is im portant to follow the exact assembly positions by refer ring to the drawings that indicate the various usages of each type A Free B Activated 7 10 0 FITTING SA...

Page 86: ...Neutral microswitch hydrostatic drive models 10 Recharger connector 11 Brake microswitch 12 Fuse 10 A 13 Reverse consent pedal microswitch 14 Reverse gear microswitch mechanical drive models 14a Reve...

Page 87: ...stening 50 55 Nm 2 Screw for engine pulley 30 35 Nm 3 Screws for rear axle brackets 20 25 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...

Page 88: ...LTS ASSEMBLY General informations Related topics Drive belt development Drive belt development mechanical drive models Drive belt development hydrostatic drive models MODEL YEAR 2015 MJ66 Hy MJ66 WORK...

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