Global garden products 98 Hydro Instruction manual

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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.
Rel. 2.0
WORKSHOP
MANUAL
by

3/2002
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 hood and 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 sequence and 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, inserted in the spare parts pamphlet, 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 law tractor.
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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 Practical hints
3.1 0 Criteria for maintenance
3.2 0 Occasional tuning
3.3 0 Regular maintenance
4.1 0 Blade engagement adjustment
4.2 0 Blades brake adjustment
4.3 0 Brake adjustment
4.4 0 Drive belt adjustment
4.5 0 Drive pedal 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 Checking blades alignment
4.10 0 Sharpening and balancing of the blades
5.1 0 Removal of front hood
5.2 0 Removal of the wheel cover
5.3 0 Removal of the fuel tank
5.4 0 Removal of the engine
5.5 0 Removal of the rear axle
5.6 0 Removal of the cutting deck
6.1 0 Replacement of tyres and wheels
6.2 0 Replacement of front wheel bearings
6.3 0 Dismantling 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 Replacement of the blades belt
6.7 0 Replacement of the lifting cable
6.8 0 Replacement of the blades engagement cable
6.9 0 Replacement of the supports and shafts of the blades
6.10 0 Replacement of the accelerator
6.11 0 Replacement of the brake pads and disc
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 Lights operation check
7.6 0 Starter relay operation check
7.7 0 Electronic card operation check
7.8 0 Recharge circuit check
7.9 0 Care and maintenance of the sealed battery
7.10 1 Fitting safety microswitches
7.11 0 Electrical diagrams
8.1 1 Summary of tightening torques
8.2 0 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 the J98 lawn-tractor:
– mechanical drive with gear box;
– hydrostatic drive (hydro).
NOTE
➤ This symbol highlights all those operations that require different 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 careso as not to 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 lawn-tractor has a label attached (1) in the bat-
tery area 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 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 Manu-
facturer.
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 force. 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.
At the same time the Manufacturer will notify of any faults met on the lawn-tractors produced, with recommenda-
tions 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 charts for the year of
manufacture, shown on the identification label.
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1.6 SAFETY REGULATIONS
All lawn-tractors 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 Centres work 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 lawn-tractor the Service Centre should:
a) check:
– that the safety microswitch is 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 have become illegi-
ble (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 lawn-tractor 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 Booklet.
WARNING!
Repair or maintenance work which is 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 the following signs, which indicate:
OPERATION TO BE CARRIED OUT VERY CAREFULLY SO AS NOT TO IMPAIR THE LAWN-TRACTOR’S
PERFORMANCE 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 lawn-tractor 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.
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2.2 PRECAUTIONS WHILE WORKING
Work carried out on the lawn-tractor is not as a rule any more dangerous than any other normal mechanical work
and accidents are preventable with the normal care and attention taken for this type of work.
As well as the usual safety regulations connected with typical workshop conditions, we recommend:
– 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 the work being done does not result in accidental loss or leakages 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 lawn-tractor.
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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 blades bearings
4. Stopper for assembly of wheel bearings
5. Pulley extractor
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2.4 SLINGS
The lawn-tractor must never be lifted using a hoist or other lifting equipment which uses ropes.
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2.5 LIFTING
A) Front
Once the parking brake has been engaged, 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 free movement of the front
spring equaliser has not been obstructed.
WARNING! - This machine IS NOT
DESIGNED to be positioned vertically with it
resting on the rear plate.
If you need to have easier access to the lower part of
the machine, you can lift the front.
Place the machine on firm and flat ground.
At least two competent people should be
involved in this operation to assure necessary
safety.
Position a support block (2) in wood (or other materi-
al) that can bear the weight of the machine; it should
be 30-35 cm high with a base of at least 100 x 25 cm.
To prevent the machine from moving accidentally,
engage the parking brake and put the gear lever in 1st
gear (➤in mechanical transmission models), or check
that the transmission release lever is engaged (➤ in
hydrostatic trasmission models).
Position a wedge (3) behind each of the two rear
wheels and raise the front of the machine by holding
parts with a secure grip. Then push the support block
(1) underneath the front wheels and lower the
machine until the wheels rest on the block.
B) Rear
Position a support (4) in wood (or other material) that
can bear the weight of the machine; it should be 28
cm high on the left, 26 cm high on the right and 45 cm
wide. Place it under the lower edge of the plate.
Position an appropriately sized wedge (5) in front of
the front wheels to stop the machine from accidental-
ly moving forwards.
Before carrying out any type of work, make
sure that the machine is completely stable and
avoid operations that could cause it to fall over.
5
4
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4
26 cm
28 cm
45 cm
2
30-35
cm
3
1
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2.6 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.
3
45
3
5 5
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6
7
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3.1 CRITERIA FOR MAINTENANCE
The Instruction Handbook has a number of operations to be carried out by the Customer for a minimum of basic
maintenance, and other operations which are not always within his capacity.
For 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 regular maintenance programme 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) [see 3.3].
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3.2 OCCASIONAL TUNING
– Check working order of safety 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 condition of the hubs
– Check for wear in the belts
– Check the blade brake engagement
– Grease front wheels lever joint pins and bushes
– Grease the bush of the drive pedal (
➤ hydrostatic drive models)
– Check tightness of engine screws
– Check all those items indicated in the engine manual
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3.3 REGULAR MAINTENANCE
– All work carried out in section 3.2, plus:
– Check battery charge
– Check tension of belts
– Adjust drive engagement (
➤ mechanical drive models)
– Adjust brake
– Adjust blade engagement
– Adjust blades brake
– Check steering allowance
– Check front bearings
– Check cutting deck lifting cables
– General lubrication
– Clean away grass cuttings and wash exterior
– Clean and wash inside cutting deck
– ETouching up of any damaged paint
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