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MAP

2 / 2

6.10.

REPLACEMENT

OF THE BRAKE PADS AND DISC

General informations:

---

Related topics:

Brake adjustment

[

4.2]

Replacement of wheels

[

6.1]

On reassembly, carefully reposition all the compo-

nents and refit the complete support. When connect-

ing the rod (1) be sure to use the upper hole in the

lever (2).

NOTE

During all these operations it is better to not unscrew

or loosen the central screw (9) to avoid altering the

calibration of the cam driving the pistons.

If it has been moved, the lever’s free movement will

have to be checked.

When fully reassembled ...
• Check the brake adjustment.

MODEL YEAR 2016

N…102 Hy

N…102

WORKSHOP MANUAL

BACK

Summary of Contents for N 102 Hy Series

Page 1: ...ication 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 own...

Page 2: ...and are usually resolved by quick checks and tunings 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...

Page 3: ...E Tuff Torq K46S 5 6a 0 Rimozione dell asse posteriore Hydro Gear T2 ADBF 2X3C 17X1 5 7 0 Removal of the cutting deck 6 Repairs 6 1 0 Replacement of tyres and wheels 6 2 0 Replacement of front wheel b...

Page 4: ...s described here refer to those shared or similar in all types of engine Related topics Drive belt adjustment 4 3 Removal of front hood 5 1 Adjusting the MINIMUM position 6 9 Tightening torques 5 Scre...

Page 5: ...WORKSHOP MANUAL WORKSHOP MANUAL N 102 N 102 Hydro iii 0 MAP OF INTERVENTIONS ENGINE FUEL TANK TRANSMISSION BRAKE WHEELS CUTTING DECK STEERING BODY ELECTRICAL BACK...

Page 6: ...102 WORKSHOP MANUAL WORKSHOP MANUAL INDEX OF RELATED TOPICS Removal of external parts and main assemblies Removal of front hood 5 1 Removing the tank and replacing the fuel pipe 5 4 Removal of the en...

Page 7: ...moval of the rear axle Peerless MST 205 535 E Tuff Torq K46S 5 6 Removal of the rear axle Hydro Gear T2 ADBF 2X3C 17X1 5 6a Repairs Replacement of tyres and wheels 6 1 Replacement of front wheel beari...

Page 8: ...nment 4 7 Removing sharpening and balancing the blades 4 8 Removal of external parts and main assemblies Removing the ejection conveyor 5 3 Removal of the cutting deck 5 7 Repairs Replacement of the b...

Page 9: ...iv 1 STEERING MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL INDEX OF RELATED TOPICS Adjustments and tuning Steering geometry adjustment 4 6 Repairs Dismantling steering components 6...

Page 10: ...6 iv 1 BODY MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL INDEX OF RELATED TOPICS Removal of external parts and main assemblies Removal of front hood 5 1 Removal of the wheel cover 5...

Page 11: ...tem 7 1 Summary table for the cutting in of the safety devices 7 2 Safety microswitches operation check 7 3 Terminal board supply check 7 4 Starter relay operation check 7 5 Starter relay operation ch...

Page 12: ...antee and 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 mad...

Page 13: ...the problem the repairs carried out and any spare parts used for each repair done on the machine A copy of this report must be retained to be made a vailable to the Manufacturer together with the part...

Page 14: ...e or use that is incorrect or different from the purpose for which it was de signed and approved warn the Customer that the failure to comply MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MA...

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

Page 16: ...ly available from a good workshop However it is advi sable to have a set of special tools 1 7 These tools 1 7 are to be used whenever is given in this text 1 Blocks H 26 mm for adjusting the cutting d...

Page 17: ...AS BEEN ENGAG 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 to see that the f...

Page 18: ...ore 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 150 mm under the lower edge of the plate and taking care...

Page 19: ...side 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 vari ous directions A typical situation has the pin 3 fixed by a self lock ing...

Page 20: ...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 di rection...

Page 21: ...devices and renew 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 blades and check the conditi...

Page 22: ...7 3 7 5 2 97 99 mm 1 2 3 3a A Adjusting blade engagement NOTE When adjusting the engagement it could be necessary to remove the belt guards in this case the guards must always be replaced after adjus...

Page 23: ...screwing the nut down on the rod and thus shortening the length of the spring Loosen the nut 4 which retains the bracket 5 and then turn the nut 6 so that the length A of the spring 2 is mechanical d...

Page 24: ...ext to the pin rod before beginning the braking action If this is not the case the free movement can be adjusted with the screw 8 unless the brake pads or discs are so worn that they need replacing Wh...

Page 25: ...in jerky movements or tipping up when engaging the drive In these cases the stretcher will need to be adjust ed Related topics Replacement of the drive belt 6 4 1 119 121 mm 2 The tension regulator ca...

Page 26: ...al posi tion This position N is easily recognised since it is held fast by a check ball The pedal 2 is in its best position when with the hydrostatic group lever 1 in neutral the lower edge of the fro...

Page 27: ...ch 5 of the cam 6 which is reached by the inspection hatch beneath the seat After having ensured that adjustment A has been made correctly with the pedal released and thus in neutral position N slacke...

Page 28: ...tyre pressures If one or more tyres have been replaced or you find differences in diameter do not attempt to compensate these differences by giving different tyre pressures but make the ad justments a...

Page 29: ...secure it in place Screw down the rear left screw 4 until the rear edge of the cutting deck begins to rise Screw down the front nuts 6 8 until the front edge of the cutting deck begins to rise evenly...

Page 30: ...any other action check that the joint fasten ings have not become loose A Toe in adjustment The exact toe in is obtained with a track of 483 485 mm measured between the centres of the pins 1 of the w...

Page 31: ...es To check the alignment of the blades one of them must first be removed and refitted after having remo ved the shaft key 2 to permit independent blade rotation NOTE Take note of the unscrewing and s...

Page 32: ...g the blades 4 8 Replacement of the supports and shafts of the blades 6 8 Tightening torques Screw for left blade 45 50 Nm Screw for right blade 45 50 Nm 2 IMPORTANT Always replace damaged blades and...

Page 33: ...moving a blade it must be firmly held and the central screw 1 undone bearing in mind that the screw on the left blade 1a is unscrewed anti clockwise the screw on the right blade 1b is unscrewed clockw...

Page 34: ...opics Tightening torques 1a Screw for left blade 45 50 Nm 1b Screw for right blade 45 50 Nm 2 be done from the rounded side removing as little material as possible The blade is to be replaced when the...

Page 35: ...Related topics 1 2 3 4 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL MAP 1 1 models with lights Disconnect the connector 1 The hood can be secured in two ways A Fixing with springs Un...

Page 36: ...ted topics 1 3 3 2 2 6 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL MAP 4 5 Remove the inspection hatch 1 Remove the spring covering plugs 2 and dismantle the two pins 3 to remove th...

Page 37: ...e for fixing on the rear plate The cover can be removed after the cutting height adjustment lever has been set to position 7 For reassembly follow the procedure described abo ve in reverse being caref...

Page 38: ...r Removing the collector channel is necessary to dis mantle the cutting deck and if the rear plate is removed Related topics 1 2 3 The conveyor 1 is connected to the rear plate 2 by two plastic clamps...

Page 39: ...not to leak it in the work area Remove the clip 4 and unthread the pipe 2 from the tank outlet union 5 with a 4 5 litre tank Loosen the fixing screw 6 and remove the tank 5 with a 5 5 litre tank Loos...

Page 40: ...ackening off the tension regulator FIRST disconnect the black earth cable from the bat tery and THEN the red cable to prevent possible short circuits and dangerous situations Free the blade belt 1 fro...

Page 41: ...rea Identify and undo all the screws that fasten the engine to the chassis then carefully lift and remove the engine using equipment suitable for the weight of the engine about 35 45 kg and the design...

Page 42: ...MINIMUM position 6 9 Tightening torques 5 Screw for pulley 45 50 Nm Screws for engine fastening 25 30 Nm 7 2 4 2 7 12 Carefully restore all electric and earth contacts and always refit the exhaust gu...

Page 43: ...30 Nm 2 2 3 4 7 8 6 5 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL Lift the rear part of the machine Remove the collector channel Remove the rear wheels For greater operating conven...

Page 44: ...30 Nm 11 9 3 12 10 13 20 16 15 19 18 20 17 14 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL The unit is supported by two brackets 9 with their screws 10 and 11 and is attached to the...

Page 45: ...ing screws 25 30 Nm 12 20 Screws for rear axle fastening 25 30 Nm 19 Rear axle locknut 25 30 Nm 21 22 23 24 25 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL mechanical drive models hy...

Page 46: ...Nm Lift the rear part of the machine Remove the collector channel Remove the rear wheels Engage the parking brake to slacken off the belt and obtain greater operating convenience Bring the cutting de...

Page 47: ...Rear axle fastening nut 25 30 Nm Carefully unscrew the four frame fastener nuts 11 adequately supporting the unit so it does not fall To reassemble reverse the order of the previous op erations When...

Page 48: ...justment lever to position 1 Unscrew the nut 3 and disconnect the steering rod 4 to allow the passage of the belt Unscrew the two nuts 5 fastening the two arms 5a to the frame Release the three flexib...

Page 49: ...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 use a releasing spray d...

Page 50: ...re 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 internal circumf...

Page 51: ...3 and lift the steering column 4 by enough to be able to remove the pinion 5 A Dismantling the steering crown wheel and pinion Working from the bottom of the machine unscrew the nut 3 being careful to...

Page 52: ...tention capacity B Lower bush replacement Use a universal socket wrench to unscrew the two screws 14 that fix the plate 15 and remove the spherical lower bush 16 On reassembly ensure that the bush 16...

Page 53: ...2 WORKSHOP MANUAL WORKSHOP MANUAL MAP 9 7 10 8 Remove the collector channel Dismantle the engine pulley and the clutch To allow removal of the belt and subsequent passage of the new belt also requires...

Page 54: ...Nm 5 Nuts for small wheels 25 30 Nm 9 10 Nuts for pulleys 25 30 Nm 12 13 When reassembling make sure that the belt 12 is correctly positioned in the pulleys inside the rims tak ing particular notice o...

Page 55: ...ical transmission models engaging the parking brake hydrostatic drive models grasping the two branches of the belt 2 pulling it just enough to free it from the pulley throat 3 overcoming the resistanc...

Page 56: ...ree the blade belt 1 from the clutch pulley 2 Unscrew the nut 3 and disconnect the steering rod 4 to allow passage of the belt Set the cutting deck to the lowest position to obtain greater access then...

Page 57: ...hey must all be removed after having identified all the fixing points Set the cutting deck in the lowest position to obtain greater accessibility then loosen and uncouple the adjuster 1 to release the...

Page 58: ...e at 90 from each other To reassemble perform the operations described above in reverse before locking the pin 11 and the pulleys 13 and 14 restore the previously detected adjuster length and check th...

Page 59: ...deck supports without removing the deck Remove the blade control belt Remove the blade connection belt Remove the blades and take off the hubs Pull out the two cogged pulleys 1 from the blade shafts u...

Page 60: ...cond bearing still in place must be removed by hitting it from the inside of the flange using a 12 15 mm diameter round bar 13 On assembling first put the shaft into the hole of the lower bearing and...

Page 61: ...neral informations Related topics 1 2 4 3 6 5 5 Remove the steering wheel unthreading the pin 1 Remove the small knob 2 Disconnect the end of the cable 3 from the engine connection terminal 4 The dash...

Page 62: ...he two fixing screws 7 and unthread the accelerator 8 together with the cable On assembling put the accelerator lever in the MI NIMUM position connect the end of the wire 3 to the terminal 3 on the en...

Page 63: ...Disconnect the control rod 1 from the lever 2 and undo the two screws 3 which hold on the support 4 The support 4 contains a pad 5a separated from the control pistons 6 by a plate 7 The other pad 5b...

Page 64: ...port When connect ing the rod 1 be sure to use the upper hole in the lever 2 NOTE During all these operations it is better to not unscrew or loosen the central screw 9 to avoid altering the calibratio...

Page 65: ...poor starting Battery terminal crossed Short circuit to earth Check the battery connections Check the connectors and wiring of the microswitches Sulphated battery it no longer accepts recharging Repl...

Page 66: ...ey is in the ON position and can be turned off only by removing the key pilot lamp on 8 The pilot lamp led 1 or dashboard led 6 become weak after several hours work and the engine goes off No fuel flo...

Page 67: ...ANUAL WORKSHOP MANUAL PROBLEM CAUSE REMEDY 10 The 10 A fuse blows 11 The 25 A fuse blows Short circuit or overload on the power side of the electronic card start up unit starter relay lights and recha...

Page 68: ...R GRASS CATCHER BLADE DRIVE CONSENT BUTTON PARKING ENGINE PILOT LAMP Absent Engaged Stops ON Absent Engaged Stops ON Missing Engaged Stops ON Engaged Engaged Stops ON Absent Stops ON Seated Fitted Eng...

Page 69: ...g 1 and should give this result ENGINE STOP This operation must be done by keeping the connec tor 1 attached and should give this result N Contacts Tester reading and condition GRASS CATCHER ATTACHED...

Page 70: ...5 15 6 16 7 17 8 18 9 19 10 20 18 17 16 15 14 13 12 11 20 19 9 8 7 6 5 4 3 2 1 10 1 This check is done with the tester in Voltmeter func tion Volt DC 0 20 with the black ferrule on termi nal 1 and the...

Page 71: ...2 11 20 19 9 8 7 6 5 4 3 2 1 10 WARNING This check must be made with the engine off Disconnect connector and bridge terminals 2 and 11 of cabling connector 1 With the key set to ON when the switch is...

Page 72: ...ried out To do this requires engaging the parking brake disengaging the blade the key in the ON position Disconnect the connector 1 In making a bridge between the terminals 11 and 4 of the wiring conn...

Page 73: ...service supply check This check is done with the tester in Voltmeter func tion Volt DC 0 20 with the black ferrule to earth and the red ferrule on terminal 10 of the wiring con nector 1 C Checking th...

Page 74: ...ds this threshold A faulty regulator may recharge the battery insuffi ciently therefore needing frequent recharging or otherwise may supply overloading that causes the self resetting protection to cut...

Page 75: ...rs could da mage the battery MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL C Rules for recharging the battery Recharging is a particularly important operation for the life of the batt...

Page 76: ...ICROSWITCHES General informations Related topics A min 1 mm B 15 mm 2 6 mm A B IMPORTANT If the microswitches are to function correctly it is important to follow the exact assembly posi tions by refer...

Page 77: ...9 8 7 6 5 4 3 2 1 NC 3 NO 2 C a b c d AVV Bt Mot Avv GND GND OR BK 1 6 12 WH WH 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 3 Battery 4 Starter relay 5 Key i...

Page 78: ...R 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL 1 Electronic card 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d Carburattor 2e Starter relay 3 Battery 4 Starter relay 5 Key ignition s...

Page 79: ...engine 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 val...

Page 80: ...Replacement of blade control belt 6 6 Replacement of blade connection belt 6 7 MODEL YEAR 2016 N 102 Hy N 102 WORKSHOP MANUAL WORKSHOP MANUAL 1 Drive belt development 2 Blade control belt development...

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