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WORKSHOP MANUAL

CHAPTER

REVISION

FROM ...

PAGE

ii

0

2018

1 of 6

TC 108 SD  -  TC 118 SD

RELATED TOPICS:

Adjustments and tuning

  ---

Removal of external parts and main assemblies               

TC 108 SD - TC 118 SD

  Removal of front hood   ............................................................    

[  5.1]

  Removal of the engine   ......................................................  

[  5.4]  [  5.4a] 

  Removal the rear tank (if present)   ...........................................    

[  5.7]

Repairs

  Replacement of the accelerator and adjustment of the carburettor     

[  6.7]

INDEX OF FUNCTIONAL UNITS

Engine - Fuel Tank

General informations

Different  fittings  are  foreseen  for  this  machine 

which can imply the use of different engines with­

in the same.

This  manual  only  describes  the  operations  re­

lating to the application of the machine engine; 

reference to the engine’s Manufacturer’s Manual 

is recommended for information regarding serv­

icing,  disassembly  and  replacement  of  compo­

nents.

Related topics

[  1.1] 

 

Identification of components

Содержание TC 108 SD

Страница 1: ...formed by individuals or inadequate facilities The Manufacture reserves the right to make any im provements to the product of a technical or commercial nature that may be necessary There maybe therefo...

Страница 2: ...aining an image of efficiency and reliability Compliance with these brief and simple guide lines will facilitate this task and prevent general mi sunderstandings and time wasting for both the manufact...

Страница 3: ...essary to avoid damage to the machine or equip ment WARNING Non observance will result in the risk of injury to oneself or others DANGER Non observance will result in the risk of serious injury or dea...

Страница 4: ...celerator and adjustment of the carburettor 6 7 INDEX OF FUNCTIONAL UNITS Engine Fuel Tank General informations Different fittings are foreseen for this machine which can imply the use of different en...

Страница 5: ...s Manufacturer s Manual is recommended for information regarding servic ing disassembly and replacement of compo nents Related topics 1 1 Identification of components RELATED TOPICS Adjustments and tu...

Страница 6: ...the blades 4 9 Removal of external parts and main assemblies Removal of the cutting deck 5 6 Repairs Replacement of the blades control belt 6 5 6 5a Replacement of the supports and shafts of the blad...

Страница 7: ...eering allowance adjustment 4 6 Steering geometry adjustment 4 7 Removal of external parts and main assemblies Repairs Dismantling of the steering components 6 3 General informations Related topics IN...

Страница 8: ...ns except for instructions provided for each specific outfitting recognisable accord ing to the type of dashboard installed on the ma chine Related topics RELATED TOPICS Adjustments and tuning Removal...

Страница 9: ...Troubleshooting of the electrical system 7 1 Cutting in of the safety devices 7 2 Safety microswitches operation check 7 3 Terminal board supply check 7 4 Carburettor solenoid valve operation check 7...

Страница 10: ...and serial number must be shown on each repair sheet when requests are made un der guarantee and are indispensable for spare part orders 2 Transmission The transmission hydrostatic unit is made up of...

Страница 11: ...the parts in ca se of any subsequent disputes with Customers D Fault notification The Manufacturer welcomes any notifications of faults that recur with particular frequency It gives the oppor tunity f...

Страница 12: ...action systems do not pollute the environment with oil petrol or other waste and dispose of all waste in ac cor dance with the laws in force A Qualification of operators All maintenance disassembly an...

Страница 13: ...t actions that may physically endanger those working on the machine D Necessary equipment All the operations can be carried out with the tools nor mally used in a good garage Some operations require s...

Страница 14: ...the 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 blades bearings 4 Stopper for assembly of wheel bearings 5 Pulley extra...

Страница 15: ...r be lift ed using a hoist or other lifting equipment which uses cables A Front Once the parking brake has been en ga ged the ma chine can be lifted using a jack which pushes on the underside of the f...

Страница 16: ...d becoming mi saligned and failing to work correctly A Fitting snap rings One side of the Benzing snap rings 1 has a round ed edge and the other a sharp edge For maximum grip the rounded part needs to...

Страница 17: ...hold so they should never be reused On assembly make sure it is inserted in the right di rection and push the fastener 7 onto the pin using a pipe or socket spanner 8 with the right diameter so that...

Страница 18: ...oposing a regular maintenance pro gramme to the Customer to be carried out at prearranged intervals for example at the end of the summer or prior to a long period of inactivity A Occasional tuning Che...

Страница 19: ...tank Top up Dirty or old fuel Empty the fuel tank and add fresh fuel Clogged carburettor filter Check and clean Black exhaust fumes Excessively oily carburetion Check the starter and command cable En...

Страница 20: ...brake is not adjusted correctly Check and adjust 4 2 Hydrostatic unit failure Check the Manufacturer s Instruction Manual The machine will not move in either direction Pulley splines broken Replace H...

Страница 21: ...e opti mised for the application for which they are intended In short this means that the blades are suitable for the shape of the casing and to the number of revolutions to provide the best possible...

Страница 22: ...op within 5 sec onds from disengagement appropriate checks must be made to the electrical system and the clutch must be re plac ed if no result is achieved General informations The blades are driven b...

Страница 23: ...s 45 47 mm measured from the inside of the washers When the adjustment has been made tighten the nut 1 NOTE Never go under these amounts to avoid over loading the brake unit WARNING When the adjustmen...

Страница 24: ...General informations If it seems that the forward drive is not working pro perly after a long period of use or after repla cing the belt this may be caused by a change in the length of the belt A loo...

Страница 25: ...ving the pedal to the forward gear and neutral position you should hear the click of the button at each gear change before the wheels start moving A Adjusting the pedal in the neutral position Adjustm...

Страница 26: ...e front 26 mm 1 at the rear 32 mm 2 Set the lifting lever to position 1 and slacken off the nuts 3 screws 5 and locknuts 4 6 on both the right and left hand sides so that the deck rests firmly on the...

Страница 27: ...e to guarantee even lifting of the cutting deck Turn both the rear screws 5 until the rear of the deck begins to rise both at the right and the left and then tigh ten the relevant locknuts 6 Push the...

Страница 28: ...e front 26 mm 1 at the rear 32 mm 2 Set the lifting lever to position 1 and slacken off the nuts 3 screws 5 and locknuts 4 6 on both the right and left hand sides so that the deck rests firmly on the...

Страница 29: ...ee even lifting of the cutting deck Turn both the rear screws 5 until the rear of the deck begins to rise both at the right and the left and then tigh ten the relevant locknuts 6 Push the two connecti...

Страница 30: ...t lining up the two reference points punched on them Tighten the grub screw 3a then reassemble the steering column 2 using the relative spring 1 Check that the movement is not caused by loose linka ge...

Страница 31: ...lated joints 1 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...

Страница 32: ...is not the case check the sup ports or the shafts for the blades re placing if neces sary and check the condition of the point where the flanges rest on the cutting deck IMPORTANT Always replace dama...

Страница 33: ...he rotation of each blade engages the rotation of the other A Removing and reassembling For removing a blade it must be firmly held and the cen tral screw 1 undone Always check that the fins are intac...

Страница 34: ...e from the rounded side removing as lit tle material as possible The blade is to be replaced when the cutting edge has worn down to 10 mm Using the appropriate equipment check the ba lance to make sur...

Страница 35: ...tener springs 2 and pull out the pins 3 B Fixing with a cotter pin Take out the cotter pin 4 from the right hand side and remove the hood by moving it to the right REMOVAL OF FRONT HOOD CHAPTER REVISI...

Страница 36: ...of the wheel cover only Loosen the two screws 1 and disassemble the two side sections 2 unhooking the 7 fastener tabs 3 positioned inside each of them Remove the rear cover 4 fixed with four screws 5...

Страница 37: ...o cated under the side footboards and two rear screws 21 On reassembly ensure that the two side tabs 22 of the cover are correctly inserted into the housings in the footboards Complete the assembly pr...

Страница 38: ...ectric cables to pre vent reassembly errors Models with cruise control Loosen the screw 7 and remove the control knob 8 General informations Removing the dashboard gives better access to the accelerat...

Страница 39: ...ectrical con nections and the starter cable where present The dashboard 13 can be removed at this point it is fix ed to the chassis by two upper screws 14 co vered by plastic caps and three lower scre...

Страница 40: ...ier access Loosen and release the screw adjuster 3 to loosen the blade control belt 4 and free it from the pulley 5 Disconnect the connector 6 unhook the check spring 7 from the clutch side and undo t...

Страница 41: ...bly On reassembly fully tighten the screws for the en gi ne and the pulley to the amounts shown Reassemble the spacer 11 with the countersink facing the engine En su re that the pin 13 is inserted int...

Страница 42: ...ier access Loosen and release the screw adjuster 3 to loosen the blade control belt 4 and free it from the pulley 5 Disconnect the connector 6 unhook the check spring 7 from the clutch side and undo t...

Страница 43: ...ly On reassembly fully tighten the screws for the en gi ne and the pulley to the amounts shown Reassemble the spacer 11 with the countersink facing the engine En su re that the pin 13 is inserted into...

Страница 44: ...dler pulley spring Remove the drive control rod 3 by unscrewing the relative pin nut 4 and the brake rod 5 by un screwing the nut 6 under the lever General informations The rear axle Transaxle is made...

Страница 45: ...ce given Reattach all the connections and then Check the brake Refit the rear wheels Refit the rear tank if installed Refit the rear part of the wheel cover If the the drive control rod has been repla...

Страница 46: ...some practice and experience it is possible to do this work with the deck still in position Related topics 4 5 Aligning the cutting deck TC 108 SD 4 5a Aligning the cutting deck TC 118 SD REMOVAL OF T...

Страница 47: ...emove the two split pins 10 of the rear pins and then having checked that there are no obstructions the deck can be removed by extracting it in such a way that all the pins leave their housings Repeat...

Страница 48: ...MOVING THE REAR TANK if present Remove the tank cap 6 and protect the nozzle to prevent foreign bodies from falling into the tank Remove the rear part of the wheel cover Disconnect the level indicator...

Страница 49: ...f present During reassembly make sure the protuberance 10 of the tank is correctly positioned in its seat 11 on the chassis Complete the assembly process follow the steps de scribed above in the rever...

Страница 50: ...necessary to check the pressure and to check the alignment of the cutting deck ATTENZIONE Replace distorted wheel rims as they could impair the tyre s hold B Wheels The wheels are held by a snap ring...

Страница 51: ...rom the opposite side and struck with a hammer around various points of the in ner circumference of the bearing The new bearing must be fitted with the help of a pla stic mallet or of a bronze pad 3 t...

Страница 52: ...e the spring 1 Loosen the grub screw 3a and lift the steering col umn 2 just enough to be able to extract the pinion 3 A Dismantling the steering pinion and ring gear Remove the tie rod 6 unscrew the...

Страница 53: ...the correct a lign ment and regular ro tation of the steering wheel column When reassembled Check the steering geometry During assembly please note that to replace both the ring gear teeth and pinion...

Страница 54: ...over Remove the rear tank if present Working from the rear section grasp the two branch es of the belt 1 pulling it just enough to free it from the pulley throat 2 overcoming the resistance of the idl...

Страница 55: ...guard Remove the left 3 and right 4 internal safety guards Pull one branch of the belt 5 to release it from the clutch pulley 6 General informations Related topics 4 1 Adjusting the engagement and che...

Страница 56: ...completely free and can be extracted During reassembly operations make sure the belt is positioned accurately in relation to the containment pins On completing the reassembly it is necessary to Adjus...

Страница 57: ...uard Remove the left 3 and right 4 internal safety guards Pull one branch of the belt 5 to release it from the clutch pulley 6 General informations Related topics 4 1 Adjusting the engagement and chec...

Страница 58: ...lt 5 is completely free and can be extracted During reassembly operations make sure the belt is positioned accurately in relation to the containment pins and its passage through the fork 12 On complet...

Страница 59: ...ible to dismantle the deck supports without removing the cutting deck Remove the blade control belt Remove the blades and take off the hubs Loosen and release the screw adjuster 1 Unscrew the nut 2 an...

Страница 60: ...es must meet perfectly in the centring step 32 cut into the up per part of each support Reassemble the blades Reassemble the blade control belt After having removed the key 25 the snap ring 26 and the...

Страница 61: ...ove the blades and take off the hubs Undo the central screw 1 and extract the left pulley 2 Unscrew the screw 3 and remove the drive pulley 4 and the connection plate 5 Undo the central screws 6 7 and...

Страница 62: ...opper 31 that acts on the inner ring hitting it squarely with a mallet until the bearing is fully driven home Refit the flanged supports onto the deck fully tighte ning the nuts 22 B Replacement of th...

Страница 63: ...ype of engine and shown in the in struc tion booklet When assembly is completed Refit the dashboard Remove the dashboard Take off the knob 1 and disconnect the cable 2 from the connection terminal 3 o...

Страница 64: ...t right 10 A fuse blown Replace fuse 10 A Battery terminal crossed Check connections 1 The cutting in of the self resetting protection of the electronic card is signalled by a beep except in cases whe...

Страница 65: ...p when the key is removed Mechanical difficulties with the contact breakers of the starter relay Replace the starter relay Starter works erratically for mechanical or electrical reasons taking excessi...

Страница 66: ...10 A fuse cuts in The safety devices have cut in or are faulty Check the operation of the microswitch operation and the rel evant wiring Accidental detaching of an electrical wire Check all wiring Sta...

Страница 67: ...B WHILE CUTTING The engine STOPS start when Operator Absent Absent Absent Seated Blades Engaged Engaged Engaged Engaged Drive Engaged Reverse Consent Button Released Parking Engaged Indication on the...

Страница 68: ...0 2018 1 of 1 SAFETY MICROSWITCHES OPERATION CHECK No of Contacts Tester reading and condition OPERATOR PRESENCE 1 14 absent O seated PARKING MICROSWITCH 1 17 O free engaged BLADES SWITCH 1 16 engaged...

Страница 69: ...one on terminal 11of the con nector 1 of the wiring The key in the ON position The reading shows the battery voltage which should never go below 11 Volts General informations Related topics TERMINAL...

Страница 70: ...make this check When the key is set to ON a click must be heard from the carburettor solenoid valve coil General informations Related topics CARBURETTOR SOLENOID VALVE OPERATION CHECK CHAPTER REVISION...

Страница 71: ...11 and 4 of connector CN1 of the wiring 1 the relay bobbin must be heard to click and the starter must start If the bobbin clicks but the starter does not start make a bridge 2 with a large section ca...

Страница 72: ...of the clutch due to excitation of the electric wiring If this is not so check the operation of the cabling and control switch The clutch must be replaced if engagement does not take place after thes...

Страница 73: ...ts it means that the regulator is charging too much and must be replaced The job of the voltage regulator is to supply a flow of current to the battery at a constant voltage of about 14 15 Volts cutti...

Страница 74: ...oltage at least 12 24 hours after recharging A General information In a sealed dual battery the electrolyte for each el ement is carefully measured out during manufacture and sea led at source in orde...

Страница 75: ...are to func tion correctly it is important to follow the exact assem bly positions by re ferring to the drawings that indicate the various usages of each type A Free B Activated General informations...

Страница 76: ...C 3 C BL BL BK BK OR BK BL BL AVV Bt Mot Avv GND BK YW YW BL BK BK BK BK BK BK BR BR Engines B S GGP Kawasaki Models with front tank 1 Circuit board 2 Engine 2a Generator 2b Starter motor 2c Engine st...

Страница 77: ...O 2 NC 3 C BL BL BK BK OR BK BL BK BL AVV Bt Mot Avv GND BL BK BK BK BK BK BR BR Engines B S GGP Kawasaki Models with rear tank 1 Circuit board 2 Engine 2a Generator 2b Starter motor 2c Engine stop 2d...

Страница 78: ...d support fixing nuts 25 30 Nm 6 Screw for blade 45 50 Nm Every section in this manual gives values for all the com ponents involved in each operation B Adjustments TIGHTENING TORQUES AND ADJUSTMENTS...

Страница 79: ...8 2 0 2018 1 of 1 BELTS ASSEMBLY General informations Related topics 6 4 Replacement of the drive belt 6 5 Replacement of the blades control belt TC 108 SD 6 5a Replacement of the blades control belt...

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