Global garden products 72 Instruction manual

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7722 22
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7722 22 hh hhyy yydd ddrr rroo oo
Rel. 5.0 0010001➜
SERIAL NUMBER
The Manufacture reserves the right to make any improvements 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 features and various repair methods will remain the same.
WORKSHOP
MANUAL
by

CONTENTS
1. Rules and procedures of the service centre
This chapter deals with the main aspects in the relationship between the Manufacturer and the Service Centres.
Close co-operation between the Manufacturer and Service Centres is important for best resolving problems
and for maintaining an image of efficiency and reliability to present to the Customer.
Complying with these short and simple suggestions will help us in this task, avoiding for both you and us all
those possible misunderstandings which result in a mutual waste of time.
2. General regulations
This chapter deals with general aspects of working and the main rules for ensuring that the work is done prop-
erly and maintains the machine’s safety.
3. Maintenance
This chapter deals with the criteria for routine maintenance.
4. Adjustments and tuning
This chapter deals with the adjustments to be made to remedy the more frequent performance failures 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 unit con-
cerned 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 discretion of the mechanic’s experience.
6. Repairs
This chapter deals with all the more complex work connected with the replacement or repair of malfunctioning
or worn parts.
The descriptions must follow a logical sequenceand can include operations not specifically connected to a par-
ticular type of repair.
In this case, careful reading of the entire procedure can help you omit all those operations not connected with
the case in hand without, however, overlooking anything that may be necessary.
7. Electrical system
This chapter deals with the problems and checks connected with the electrical system.
All work can be done using a tester without having to use special equipment.
The electrical diagrams can be useful to you for understanding how the system functions and to facilitate the
pinpointing of any problems.
8. Technical specifications
This chapter summarises all the main information regarding the machine.
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GENERAL INDEX
1.1 0 Identification
1.2 0 Guarantee validity
1.3 0 Service repairs after guarantee period
1.4 0 Fault notification
1.5 0 Spare parts request
1.6 0 Safety regulations
2.1 0 Level of staff training
2.2 0 Precautions while working
2.3 1 Tools
2.4 0 Slings
2.5 0 Lifting
2.6 0 Placing the machine on its side
2.7 0 Opening the wheel cover
2.8 0 Practical hints
3.1 0 Criteria for maintenance
3.2 0 Occasional tuning
3.3 0 Regular maintenance
4.1 0-1 Blade engagement adjustment
4.2 1 Blade brake adjustment
4.3 0 Brake adjustment
4.4 0-1 Drive belt adjustment (➤mechanical drive models)
4.5 0 Drive lever adjustment (➤hydrostatic drive models)
4.6 0 Aligning the cutting deck
4.7 0 Steering allowance adjustment
4.8 0 Steering geometry adjustment
4.9 0 Check on blade alignment
4.10 1 Sharpening and balancing of the blade
4.11 0 Adjustment of the collector channel guide
5.1 0 Removal of the steering column protection cover
5.2 0 Removal of the footboard
5.3 0-1 Removal of wheels covers
5.4 0 Removal of the rear plate
5.5 0 Removal of the collector channel
5.6 0 Removal of the engine
5.7 0-1 Removal of the rear axle
5.8 0-1 Removal of the cutting deck
6.1 0 Replacement of tyres and wheels
6.2 0 Replacement of front wheel bearings
6.3 0 Replacement of steering components
6.4 0 Replacement of drive belt
6.5 0-1 Replacement of the blade belt
6.6 0 Replacement of the support and shaft of the blade
6.7 0 Replacement of the accelerator
6.8 0 Replacement of the brake pads and disc
6.9 0 Replacement of the drive lever unit (➤ hydrostatic drive models)
6.10 0 Replacement of the lever return cable (➤ hydrostatic drive models)
6.11 0 Replacement of the friction discs in the clutch device (➤ hydrostatic drive models)
6.12 0-1 Replacement of the drive release cable (➤ hydrostatic drive models)
7.1 0 Guide to the identification of problems in the electrical system
7.2 0 Summary table for the cutting in of the safety devices
7.3 0 Safety microswitches operation check
7.4 0 Terminal board supply check
7.5 0 Starter relay operation check
7.6 0 Electronics card operation check
7.7 0 Recharge circuit check
7.8 0 Care and maintenance of the sealed battery
7.9 0-1 Fitting safety microswitches
7.10 0-1 Electrical diagrams
8.1 0 Summary of tightening torques
8.2 0-1 Summary of main assembly amounts and checks
8.3 0 Special tools
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INTRODUCTION
This manual has been compiled to help Service Centres with the maintenance, dismantling and repair of the fol-
lowing versions of “Rider” 72 riding mower:
– mechanical drive with gear box;
– hydrostatic drive (hydro).
NOTE
➤ This symbol highlights all those operations that require differing working methods depending on the type of
machine, on subsequent modifications, or on the accessories fitted.
This symbol indicates an operation to be carried out with special carso as not to impair the
machine’s performance and safety.
This symbol indicates an operation to be carried out with special attention to ensure the physical
safety of the person executing the work.
This symbol indicates that a special tool should be used [see 2.3].
Descriptions of the more simple operations, which are easily carried out by a good mechanic, have 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 this manual so that you may acquire a basic understanding of the machine, which
is necessary for working rationally, without making errors or wasting time.
Remember that problems connected with usage are fully covered in the User’s instruction handbook which, being
frequently updated, more closely coincides with the product. Finally, exploded drawings of the spare parts, which
are also periodically updated, complete the technical literature in your hands and can be of use to you for recon-
structing the entire assembly sequence.
NOTE
Each page of the manual has these indications:
– years of production of the machine concerned;
– page number and total number of pages necessary for the description of the
operation;
– indication of additional pages.
@
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1.1 IDENTIFICATION
a) Machine
Each machine has a label attached (1) under the dri-
ver’s seat which shows the technical specifications,
the model and the serial number.
The model and serial number must be shown on
each repair sheet when requests are made
under guarantee, and are indispensable for
spare part orders.
b) Transmission (Rear axle)
The transmission unit (both mechanical and hydrosta-
tic) is made up of an engine block including the rear
axle. This unit is made by another manufacturer to our
precise technical specifications which differentiate it
from similar items by this same Manufacturer.
The serial number on the label (2) clearly identi-
fies the product and its specifications. This num-
ber must always be quoted when requesting
spare parts or any information from the Manu-
facturer.
c) Engine
The engine is made to precise technical specifications
which differentiate it from similar items by this same
Manufacturer.
The serial number on the label clearly identifies
the product and its specifications. This number
must always be quoted when requesting spare
parts or any information from the Manufacturer.
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1.2 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 are concerned, the conditions given by their respective manufacturers apply.
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1.3 SERVICE REPAIRS AFTER GUARANTEE PERIOD
The Service Centre has to make out a report containing the machine’s serial number, a summary of 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 in case of
any subsequent disputes with Customers.
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1.4 FAULT NOTIFICATION
The Manufacturer welcomes and finds useful the notifying of faults that recur with particular frequency. It gives the
opportunity for a careful inspection of the problem with the implementation of corrective action at production level.
Similarly, the Manufacturer will notify of any faults discovered on the machines produced, with recommendations
for the most suitable procedures for their remedy.
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1.5 SPARE PARTS REQUEST
When requesting spare parts, the code number must be given, referring to the exploded drawings for the year of
manufacture, shown on the identification label.
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1.6 SAFETY REGULATIONS
All the machines are manufactured in accordance with the strict European safety regulations in force.
To maintain these levels of safety in the longer term it would be helpful if the Service Centre works to this end by
making appropriate checks every time there is the chance to do so.
Particularly, every time there is work done on the machine the Service Centre should:
a) check:
– that safety microswitches are working correctly [see 7.3];
– that the casings and protection covers have not been removed;
– that the labels with instructions or provisions have not been removed or become illegible
(these form an integral part of the safety system).
b) they should also:
– restore to proper working order any safety devices which have been manipulated or removed;
– reattach inefficient, damaged or missing casings and protection covers;
– replace 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
case differently from that for which it was designed and approved;
– warn the Customer that the failure to comply with the above points results in the automatic
annulment of the Guarantee and the Manufacturer declining any responsibility, as also shown
in chapter 1 of the Instruction Handbook.
WARNING!
Repair or maintenance work which is well carried out well is a fundamental requisite for keeping the
same level of safety envisaged at the design stage and built in during production.
In this handbook some of the paragraphs are preceded by symbols, which indicate:
OPERATION TO BE CARRIED OUT VERY CAREFULLY SO AS NOT TO IMPAIR THE MACHINE’S PER-
FORMANCE AND SAFETY.
OPERATION TO BE CARRIED OUT WITH PARTICULAR REGARD FOR THE PHYSICAL SAFETY OF THE
PERSON EXECUTING THE WORK.
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2.1 LEVEL OF STAFF TRAINING
All maintenance, dismantling and repair 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
manual.
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2.2 PRECAUTIONS WHILE WORKING
Work carried out on the machine is not, as a rule, any more dangerous than any other normal mechanical work and
accidents are preventable by taking the normal care and attention for this type of work.
As well as the usual safety regulations applying to all workshops, we recommend:
– Taking out the ignition key before beginning any repair work.
– Protecting hands with suitable work gloves, especially when working on the blade or handling the
parts in steel plate.
– Ensuring that the work being done does not result in accidental loss or leakage of fuel.
– Not smoking near the engine or the fuel tank.
– Ensuring that other persons cannot accidentally carry out actions that may physically endanger
whoever is working on the machine.
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2.3 TOOLS
All work can be carried out using the tools normally
available in a good workshop. However, it is advisable
to have a kit of special 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 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. Pulley extractor
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2.4 SLINGS
The machine must never be lifted using a hoist or other lifting equipment which uses cables.
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2.5 LIFTING
A) Front
ONCE THE PARKING BRAKE HAS BEEN ENGAGED,
the machine 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 free movement of the front
spring equaliser has not been obstructed.
B) Rear
Place a suitably sized block (2) beneath the lower
edge of the plate.
In any case, an appropriately sized wedge (3) should
be placed behind the opposite wheels to stop the
machine from accidentally moving away.
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2
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2.6 PLACING THE MACHINE ON ITS SIDE
WARNING! Two people will be needed for this
work.
When moving the machine onto its side it should
only be gripped at strong parts (steering wheel,
seat, frame, etc.) and NEVER by the plastic parts
of the body.
The fuel tank must be totally emptied before placing
the machine on its side.
Put the machine onto a flat and firm surface, remove
the grass-catcher, engage the parking brake and
raise the cutting deck to its maximum height.
The machine must only be laid on its right hand side,
resting the seat (1) and one of the corners of the
grass-catcher (2) as shown. When doing this, firmly
grip the steering wheel and the seat and tip the
machine over until it is resting on the grass-catcher,
taking care not to damage the body’s plastic parts.
WARNING! Before carrying out any type of work
make sure that the machine is completely sta-
ble, and avoid operations that could cause it to
fall over.
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2.7 OPENING THE WHEEL COVER
The engine and the mechanical units can be reached
by turning back the wheel cover (1).
There are specific indications for opening the cover
which are shown below and also in the instruction
handbook.
Remove the grass-catcher or stoneguard and move
the machine to a flat floor. Raise the cutting deck to its
maximum height and place blocks (2) of about 65 –
70 mm beneath its edge in order to support the deck
during subsequent operations.
➤ Mechanical drive models: engage the parking
brake;
➤ Hydrostatic drive models: put the drive
release lever in the «ENGAGED» position. This is
because the parking brake needs to be disen-
gaged to ensure the necessary movement to the
speed lever.
Unscrew the knob on the lever (3) and ...
➤ In mechanical drive models: put it into neutral
«N»
➤ In hydrostatic drive models: put it into posi-
tion «R»
Open the access hatch (4) and unscrew the nut (5)
with a 13 mm spanner.
Release the lever (6) so that the deck rests on the
blocks, and keep it held to the side so that it does not
slip into any of the notches. Grip the base of the seat
(7) and turn back the cover.
When closing, make sure that the channel (8) is prop-
erly fitted onto the support (9) and resting on the
right-hand guide. Put the lever (3) into position «R»
and lower the cover (1) at the level of the levers (3)
and (6).
First put the lever (6) into its housing, and then lever
(3), lower the cover until it centres on the fixing screw.
If this has been done correctly and the guide (9) is
properly positioned, the opening of the channel will
easily slip into the hole in the plate (10) without any
need to guide it in manually.
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If it does not enter easily and correctly,
 Adjust the insertion [see 4.11].
Fully tighten the nut (5), put the lever (6) in position «7» engaging it in the stop notch,and remove the blocks (2).
Then refit the lever knob (3) and the hatch (4).
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2.8 PRACTICAL HINTS
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 be fac-
ing towards the element to be held (2), with the sharp
edges on the outside.
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 nut (4) with two anti-friction washers (5) in
between the pin (3) and the support element, and
between this and the nut (4).
Since these are joints, the nut must never be 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 becoming mis-
aligned and failing to work correctly.
C) Crown fasteners
Some pin ends (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
direction and push the fastener (7) onto the pin using
a pipe or socket spanner (8) with the right diameter,
so that it can be fitted without deforming the fastener
“crown”.
A deformed fastener should always be replaced.
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