Global garden products TH4X 102 Workshop Manual Download

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Summary of Contents for TH4X 102

Page 1: ......

Page 2: ...provements to the product of a technical or commercial nature that may be necessary There may be therefore differences between the various series of machines and that described here though the basic f...

Page 3: ...n assemblies For doing more difficult jobs greater accessibility may be required This can be done by taking the unit con cerned off and working at the bench or by removing the hood and external parts...

Page 4: ...ls 6 2 0 Replacement of front wheel bearings 6 3 0 Dismantling the steering pinion and ring gear 6 4 0 Replacement of the drive belt 6 5 0 Replacement of the small wheels for the drive belt 6 6 0 Repl...

Page 5: ...e been omitted with greater detail being given to the more specific aspects of the machine and suggestions on the most appro priate methods for achieving the best repairs You are asked to read through...

Page 6: ...ing the rear axle This unit is made by another manufacturer to our precise technical specifications which differentiate it from similar items by this Manufacturer The serial number on the label 2 clea...

Page 7: ...the terms and the limits of the contractual relations in force As far as the engine and the transmission unit are concerned the conditions given by their respective manufacturers apply 102 122 1 2 0...

Page 8: ...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 available to the Manufacturer together with the parts...

Page 9: ...portunity for a careful inspection of the problem with the implementation of corrective action at production level At the same time the Manufacturer will notify of any faults met on the machines produ...

Page 10: ...When requesting spare parts the code number must be given referring to the exploded charts for the year of manufacture shown on the identification label 102 122 1 5 0 SPARE PARTS REQUEST 1 1 from 200...

Page 11: ...ace illegible labels not endorse any repair or modification on the machine or the engine which results in a change in the performance and which leads to the machine being used incorrectly or in any ca...

Page 12: ...r work on the machine must be carried out by trained mechanics who know of all the safety and accident prevention regulations and after they have read the procedures described in this handbook 102 122...

Page 13: ...mend Taking out the ignition key before beginning any repair work Protecting hands with suitable work gloves especially when working on the blades or handling the parts in steel plate Ensuring that th...

Page 14: ...hich can be made following the instructions given in chapter 8 3 These tools 1 8 are to be used where there is the symbol in this text 1 Blocks H 26 mm for adjusting the cutting deck 2 Blocks H 32 mm...

Page 15: ...3 2002 2 4 SLINGS The machine must never be lifted using a hoist or other lifting equipment which uses ropes 102 122 2 4 0 SLINGS 1 1 from 2000 to WORKSHOP MANUAL page RET...

Page 16: ...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 of the plate In any case an appropria...

Page 17: ...fuel tank must be checked before putting the machine in a vertical position to make sure that there is no more than 2 litres of fuel inside To assure full stability the machine must only be rest ed on...

Page 18: ...tight 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 be...

Page 19: ...this reason the Service Centre should undertake to keep the machine in perfect working order in two ways a Tuning the machine whenever possible see 3 2 b Proposing a routine maintenance programme to...

Page 20: ...r fuel leaks Aligning the 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 p...

Page 21: ...Adjust brake Adjust blade engagement Adjust blades brake Check steering allowance Check front bearings General lubrication Clean away grass cuttings and wash exterior Clean and wash inside cutting de...

Page 22: ...ngaging with a stiff lever and the blades continuing to run belt shortened In both cases the stretcher needs to be adjusted With the cutting deck in the lowest position identify the adjuster 1 located...

Page 23: ...engagement or the slipping of the belt on the pul leys resulting in overheating and the typical smell of burnt rubber Check that the engagement spring is adjusted to the right length see 4 1 Correct...

Page 24: ...tighten the nut 1 Never go under these amounts to avoid overloading the brake unit When the adjustments have been made the parking brake should prevent the machine from moving on a slope of 30 16 with...

Page 25: ...making the adjustment you cannot make any further adjustments from the outside Therefore you need to dismantle the whole rear axle of the machine see 5 6 and contact one of the manufacturer s Service...

Page 26: ...wer 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 stretcher can be accessed...

Page 27: ...the required measurement is reached Take care not to accidentally modify the position of the lever 1 during the adjustment B Adjusting the neutral position of the micro switch IMPORTANT This is a ver...

Page 28: ...A Combined adjustment to the parallel and the minimum front and rear height Put the machine onto a flat and stable surface such as a work bench and put blocks beneath the cutting deck in line with the...

Page 29: ...bly positioning the engine side terminal 11a depending on whether the electromagnetic clutch is present or not Distance B is set by using the corresponding front right connecting rod nuts to obtain th...

Page 30: ...ar shaft 5 without dismantling the tie rod 6 Take away one or both of the blocks 7 under the ring gear depending on the amount of free play to be reduced Reassemble the pinion and the ring gear shaft...

Page 31: ...of the wheel connection rod 2 If a different distance is found dismantle one or both the joints and screw or unscrew them on the rod 6 as much as necessary On assembly fully tighten the locknuts 3 an...

Page 32: ...e central screw of each blade 1 see 4 10 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 t...

Page 33: ...one from the rounded side removing as little material 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 balance...

Page 34: ...and its accessories the silencer and protection devices To remove the hood disconnect the connector to the lights 1 The hood can be secured in two ways A Fixing with springs Unhook the two fastener sp...

Page 35: ...gs and undo the screws inside 6 Up to serial no 156930 disconnect the seat microswitch cables 7 marking them so that they can be replaced correctly during assembly From serial no 156931 disconnect the...

Page 36: ...electrical connections of the seat and check that the conditions provided by the safety systems allowing starting are met see 7 2 Tightening torques 11 Lower cover fixing screw 4 0 4 5 Nm 12 Upper co...

Page 37: ...of the collector channel is indispensable for dismantling the cutting deck and if the rear plate is to be removed Undo the rear plate inner fixing screws 1 and pull out the collector channel 2 On rea...

Page 38: ...5 mm diameter round bar to remove the pin 1 and take out the steering wheel 2 Disconnect the end of the accelerator cable from the engine and disconnect all electrical connections and the starter cab...

Page 39: ...2 and take out the pulley 3 from the shaft If it is difficult to take out use the special extractor code 60253000 0 inserted into the holes 4 of the pulley but do not completely undo the screw 2 so th...

Page 40: ...d remember to refit the spring 6 Remember to fit the clamps back on the fuel pipe and check that it does not leak Reattach all the electrical and earth contacts and refit the protection covers For hyd...

Page 41: ...dismantling procedure differs slightly depending on the various types of drives used In mechanical drive models Disconnect the gear lever rod 4 the brake control rod 5 with spring 6 and then disconnec...

Page 42: ...In hydrostatic drive models refit the blade engagement cable 22 in lever operated engagement models so that it is under the release lever 18 and do not fully tighten nut 16 so that correct movement of...

Page 43: ...belt 4 from the motor pulley 5 Unscrew the two nuts 6 of the two front connecting rod pins 7 without loosening or changing the posi tion of thenuts 8 and locknuts 9 Remove the two split pins 10 of the...

Page 44: ...e 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 which can be r...

Page 45: ...force splined into the front wheel hub A 10 12 mm diameter round bar 2 must be used to extract a bearing inserted from the opposite side and struck with a hammer around various points of the inner ci...

Page 46: ...e play but sufficiently freed from the ring gear Then fully tighten the locknut 8 From year 2002 Insert the split pin 8a Reassemble the pinion and ring gear axle matching the two reference points punc...

Page 47: ...ve models slacken off the fixing nuts 7 of both small wheels 8a and remove the pin 9 from the brake rod to allow passage of the belt On reassembly ensure the exact positioning of the belt 6 with respe...

Page 48: ...ling you should bear in mind that In mechanical drive models the tall spacer 3a must be fitted under the small right front wheel 1a and the low one 3b under the other three 1b In hydrostatic drive mod...

Page 49: ...without disman tling the jockey pulley 6 so that the belt can be removed For models with lever operated engage ment engage the blades to withdraw the brake pad 7 from the pulley 8 Keeping the blade l...

Page 50: ...m its slots Record the reading on the adjuster 10 this must be reset at reassembly to give a preliminary belt adjust ment and slacken it off completely Dismantle the pin 11 slacken off the fixing nuts...

Page 51: ...the casing stretcher and blades control belt taking care over their exact positioning with respect to the pins and containment guides see 8 2 6 When refitting the spring 2 make sure that it is con nec...

Page 52: ...ged position loosen the adjuster 1 remove it from its housing and unhook the spring 2 Take the end barrel 3 off the fork 4 which is near the joint for the lever and take out the whole cable 5 On reass...

Page 53: ...hit the shaft on the pulley side with a plastic mallet to extract the shaft together with the lower bearing 7 After having removed the key 8 the snap ring 9 and the dust cover 10 the bearing 11 spline...

Page 54: ...plate 3 the holes correspond ing to the support axes must meet perfectly in the centring step 15 cut into the upper part of each support Tightening torques 2 Plate fixing screws 30 35 Nm 5 Flanged su...

Page 55: ...the engine Undo the two fixing screws 4 and take out the accel erator together with the wire On reassembling put the accelerator lever in the MINIMUM position connect the end of the cable 2 to the ter...

Page 56: ...th of either 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 conn...

Page 57: ...ard not earthed to frame Check and put right 6 3 A fuse blown Replace fuse 6 3 A delayed Battery terminal crossed Check connections WARNING Immediately remove the key to avoid irreparably damaging the...

Page 58: ...n as possible 8 The battery warning light remains on Insufficient charge Check that the charging cable has not detached Check that there are no current leakages caused by cables with damaged insulatio...

Page 59: ...hing of an electrical wire Check all wiring Starting of engine not permitted see summary logic table 7 2 After checking that the conditions are met check all the microswitches see 7 3 and the relative...

Page 60: ...ged Uninfluential DOESN T start Absent Uninfluential Disengaged Neutral Disengaged DOESN T start Seated Uninfluential Disengaged Neutral Uninfluential Starts Absent Uninfluential Disengaged Neutral En...

Page 61: ...ICROSWITCH 6 2 O free engaged BLADES MICROSWITCH OR PUSH BUTTON 6 1 engaged O disengaged IN NEUTRAL SIGNAL 17 8 O drive neutral GRASS CATCHER FULL MICROSWITCH 17 9 empty O full FUEL WARNING LIGHT 6 4...

Page 62: ...he tester operating as a Volt meter Volts DC 0 20 with the black ferrule on ter minal 17 and the red one on terminal 12 of the female connector 1 of the wiring The reading shows the battery voltage wh...

Page 63: ...itted To make this test it is necessary to have The key in the ON position Connectors CN4 and CN3 disconnected When a bridge is made between contacts 14 and 13 of the wiring connector 1 the carburetto...

Page 64: ...he starter does not start make a bridge 2 with a large section cable 5 mm2 between the power contacts of the relay If the starter comes into operation look for the fault within the relay or replace it...

Page 65: ...d 12 of connector CN3 of the wiring 1 the moving part of the clutch must be heard to click due to excitation of the electric wind ing If this does not occur check the wiring and the opera tion of the...

Page 66: ...Making a bridge between the following terminals of connectors CN1 CN2 and CN4 of the card 3 should produce the following effects Gr catcher warning light Terminals 6 7 off Seat warning light Terminal...

Page 67: ...n reaches very high temperatures around 160 C which are to be con sidered normal Similarly there might be some smoke inside the transparent box which is due to the overheating of the powder inside WAR...

Page 68: ...10 A Checking the lower charging limit Start the engine and keep running at minimum with the headlights on With the tester in the voltmeter function measure the voltage at the battery terminals If the...

Page 69: ...nd no longer able to take the charge sulphated always recharge the battery before and after peri ods of prolonged inactivity or storage WARNING Only recharge with a constant voltage battery charger Us...

Page 70: ...ltage gives an indication of the operations to be carried out as per the following table Check the battery voltage at least 12 24 hours after recharging 102 122 7 10 0 CARE AND MAINTENANCE OF THE SEAL...

Page 71: ...3 2002 7 11 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 indicate the...

Page 72: ...f each type A Free B Activated min 1 mm A B 15 mm A B 2 6 mm Adjust the seat safety microswitch 1 only by chang ing the position of the cam 2 after loosening the two fixing screws 3 This adjustment is...

Page 73: ...BK BK NC NO C BK GY 10b 1 Models with lever operated engagement 1 Electronic card 2 Engine 2a Generator 2b Starter 2c Engine stop 2d Carburettor 2e Oil 3 Battery 4 Starter relay 5 Key ignition switch...

Page 74: ...W BK BK NC NO C BK GY 10b 1 Models with electromagnetic engagement 1 Electronic card 2 Engine 2a Generator 2b Starter 2c Engine stop 2d Carburettor 2e Oil 3 Battery 4 Starter relay 5 Key ignition swit...

Page 75: ...O C BK GY 10b 9 1 Models with lever operated engagement 1 Electronic card 2 Engine 2a Generator 2b Starter 2c Engine stop 2d Carburettor 2e Oil 3 Battery 4 Starter relay 5 Key ignition switch 6 Blades...

Page 76: ...NO C BK GY 10b 9 1 Models with electromagnetic engagement 1 Electronic card 2 Engine 2a Generator 2b Starter 2c Engine stop 2d Carburettor 2e Oil 3 Battery 4 Starter relay 5 Key ignition switch 7 Brak...

Page 77: ...rew for pulley 45 50 Nm 3 Screws for rear axle fastening 25 30 Nm 4 Blade pulley screws 25 30 Nm 5 Flanged support fixing nuts 25 30 Nm 6 Screw for blade 45 50 Nm Every section in this manual gives va...

Page 78: ...LY AMOUNTS AND CHECKS 1 Frame 2 Cutting deck 3 Steering geometry 4 Drive belt development 5 Blades control belt development 6 Blades connection belt development 7 Gearbox control rod assembly in mecha...

Page 79: ...102 122 8 2 0 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 2 5 from 2000 to WORKSHOP MANUAL page 3 2002 2 Square profile cutting deck Round profile cutting deck RET...

Page 80: ...102 122 8 2 0 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 3 5 from 2000 to WORKSHOP MANUAL page 3 2002 4 Hydrostatic drive models Mechanical drive models 3 RET...

Page 81: ...102 122 8 2 0 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 4 5 from 2000 to WORKSHOP MANUAL page 3 2002 6 5 Models 122 Models 102 Models with engagement by lever RET...

Page 82: ...3 2002 102 122 8 2 0 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 5 5 from 2000 to WORKSHOP MANUAL page 9 RET...

Page 83: ...3 from 2000 to WORKSHOP MANUAL page 8 3 SPECIAL TOOLS 1 60700000 0 Steel 2 60700001 0 Steel 3 60800030 0 Bronze 4 60800031 0 Bronze 5 60253000 0 Steel 6 60205000 0 Steel 7 60205001 0 Steel 60208000 0...

Page 84: ...102 122 8 3 0 SPECIAL TOOLS 2 3 from 2000 to WORKSHOP MANUAL page 3 2002 5 6 RET...

Page 85: ...SPECIAL TOOLS 3 3 from 2000 to WORKSHOP MANUAL page 3 2002 20 247 30 10 272 20 20 32 5 17 372 318 690 172 30 10 6 13 5 75 30 30 44 56 19 20 20 156 278 72 75 1 5 1 5 15 R 4 5 10 16 1 8 15 25 1 5 10 10...

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Global garden products TH4X 102, Workshop Manual

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