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WORKSHOP
MANUAL
The Manufacturer reserves the right to make any necessary improvements to the product of a technical or
commercial nature. There may be, therefore, differences between the various series of machines and the infor-
mation given here, though the basic features and repair methods will remain the same.
© by GLOBAL GARDEN PRODUCTS - No use of the illustrations or duplication, reproduction or translation,
even partial, of the texts in this document may be made without explicit authorization.
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Rel. 5.0
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YEAR OF MANUFACTURE
2007
All brands, names, logos and
trademarks mentioned belong to
their respective owners.
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Table of Contents
Related Manuals for Global garden products 63
Summary of Contents for Global garden products 63
- Page 1 © by GLOBAL GARDEN PRODUCTS - No use of the illustrations or duplication, reproduction or translation, even partial, of the texts in this document may be made without explicit authorization.
- Page 2 GENERAL INDEX Identification and procedures Safety regulations Tools Lifting Positioning the machine vertically Practical hints Criteria for maintenance Engagement and blade brake adjustment Brake adjustment Drive engagement adjustment Cutting deck alignment © by GLOBAL GARDEN PRODUCTS 4/2007...
- Page 3 ➤ Only in electric start models) Care and maintenance of the sealed battery ( Fitting safety microswitches 7.10 3 Electrical diagrams Tightening torques and adjustments summary 8.2 Summary of main assembly amounts and checks © by GLOBAL GARDEN PRODUCTS 4/2007...
- Page 4 INTRODUCTION This manual has been compiled to help Service The manual refers to the following symbols: Centres with the maintenance, dismantling and repair of the following versions of “Rider” 63 riding mower: – Warns of operations that should be carried electric start models;...
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Page 5: Identification And Procedures
[u point A]. production level. © by GLOBAL GARDEN PRODUCTS 4/2005... -
Page 6: Safety Regulations
The operations described in this manual do not “WARNING” stresses the risk of injury to oneself entail particularly hazardous situations besides the and others if instructions and regulations are not normal hazard related to mechanical operations observed. © by GLOBAL GARDEN PRODUCTS 4/2005... - Page 7 1. Blocks H = 26 mm for adjusting the cutting deck 2. Blocks H = 32 mm for adjusting the cutting deck 3. Stopper for assembly of front wheel bushes 4. Wrench for dismantling the clutchs © by GLOBAL GARDEN PRODUCTS 4/2007...
- Page 8 Place a suitable 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. © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 9 WARNING! Be just as careful when putting the machine back on a flat surface; two people are needed for this operation. © by GLOBAL GARDEN PRODUCTS 4/2005...
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Page 10: Practical Hints
(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. © by GLOBAL GARDEN PRODUCTS 4/2005... -
Page 11: Criteria For Maintenance
– Clean away grass cuttings and wash the exterior – Clean and wash the inside of the cutting deck and collector channel – Clean and wash the grass-catcher – Touch up any damaged paint © by GLOBAL GARDEN PRODUCTS 4/2005... - Page 12 [see 6.4]. u Refit the blade [see 4.7] by tightening the nuts to the prescribed values. © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 13 Check that the two clevis pins (12) and (13) permit the regular and complete stroke of the lever (14) and pedal (15). u Refit the wheel cover [see 5.1]. u Check correct blade engagement and brake [see 4.1.A]. © by GLOBAL GARDEN PRODUCTS 4/2005...
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Page 14: Brake Adjustment
When the adjustments have been made, the park- ing brake should prevent the machine from moving on a slope of 30% (16°) with the driver in position. u Remove the collector channel [see 5.2]. © by GLOBAL GARDEN PRODUCTS 3/2003... - Page 15 (4) is not too taut or too loose and allows enough play. Otherwise, turn the adjusting nut (5) until you obtain the right conditions previously described. Finally, check the length of the spring (3) again. u Remove the collector channel [see 5.2]. © by GLOBAL GARDEN PRODUCTS 3/2002...
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Page 16: Cutting Deck Alignment
Remember to tighten all the nuts and locknuts once Check the front, and if necessary, adjust the nut (7) these adjustments have been made, allowing the pins to rotate freely [see 2.5.B]. and fully tighten nut (8) on the pin (9). © by GLOBAL GARDEN PRODUCTS 3/2002... -
Page 17: Steering Geometry Adjustment
(5) on the rod (6) until the steering wheel is aligned. When the adjustment is completed, fully tighten the nut (3) and locknut (4). Tightening torques 3 Joint nut .......... 45 ÷ 50 Nm 4 Joint locknut ........25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 18 If it is intact, check and if necessary replace the bracket mounted on the clutch [see 6.4]. IMPORTANT! Always replace a damaged blade and do not attempt to repair or straighten it. Always use the manufacturer’s genuine spare parts! © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 19 Using the right tool, check the balance to make sure that there is a maximum difference of 2 grams between one side and the other. Tightening torques Blade nuts ........60 ÷ 65 Nm © by GLOBAL GARDEN PRODUCTS 4/2007...
- Page 20 Unscrew the lever handles (15) of the gear change and the lifting lever (16) of the cutting deck. Remove the box (17) protecting the card, which is secured by two screws (18), leaving all the connec- tors attached. © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 21 Reattach the accelerator cable (20) and … u Adjust the «STARTER» position [see 6.6]. Tightening torques 31-32 Cover screws ........6,5 Nm 33 Cover screws ........6,5 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
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Page 22: Removal Of The Collector Channel
(2) that hold the pin (3). The first part of the channel protects the blade. When refitting the channel, always fit the two split pins first and replace any that look deformed or unusable with the same type. © by GLOBAL GARDEN PRODUCTS 3/2002... -
Page 23: Removal Of The Cutting Deck
Pull the cable (9) out of the two drive pulleys (10) and (11 - ➤ only with a B&S engine). u Position the machine vertically [see 2.4]. u Remove the blade [see 4.7]. © by GLOBAL GARDEN PRODUCTS 4/2005... - Page 24 With the cutting deck completely lowered, remove the front right split pin (24) and unscrew the two nuts (25) and (26) fastened to the front left rods. Then shift the cutting deck slightly to the left so that © by GLOBAL GARDEN PRODUCTS 4/2005...
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Page 25: Workshop Manual
(1) and check for any leaks. Finally, if necessary, … u Adjust the blade engagement [see 4.1]. u Adjust the drive engagement [see 4.3]. u Check that the cutting deck is aligned [see 4.4]. © by GLOBAL GARDEN PRODUCTS 4/2005... -
Page 26: Removal Of The Engine
(1) and (2) are positioned correctly and tighten the screws to the amount shown. u Refit the cutting deck [see 5.3]. u Refit the clutch [see 6.4]. Tightening torque – Engine screws ......... 25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 27 Loosen the two upper nuts (14) fixing the brackets (15) and unscrew the two nuts (16) fastening the gear change to the brackets. NOTE Loosen the brackets (15) to reposition the transmis- sion unit more easily during assembly. © by GLOBAL GARDEN PRODUCTS 3/2003...
- Page 28 13 Tie-rod nuts ........25 ÷ 30 Nm 14 Bracket screws ......25 ÷ 30 Nm 16 Gear change nuts ......25 ÷ 30 Nm 18 Nuts for fixing supports to frame .. 10 ÷ 15 Nm © by GLOBAL GARDEN PRODUCTS 3/2003...
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Page 29: Replacement Of Tyres And Wheels
(2) and the snap ring (1) with the rounded edge facing inwards. Tyre pressure Front ............1.8 Bar Rear ............1.3 Bar © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 30 Insert the new bush using a plastic mallet or a bronze pad (3) that works evenly on the surface, taking care to position the two pins (4) correctly between the ribs of the rim. © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 31 (8). u Remount the wheel cover [see 5.1]. When assembly is complete, ... u Check the steering geometry [see 4.5.B]. Tightening torque 8 Locknut for fixing ring gear shaft ..25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2003...
- Page 32 Check that the friction surface (9b) of the outer ele- ment (9a) is in good condition, not worn and with a minimum thickness of 1.8 mm; otherwise it must be replaced. © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 33 Refit the blade [see 4.7] by tightening the nuts to the amount shown. u Adjust the blade engagement [see 4.1]. Tightening torques 7 Screws for blade bracket ....25 ÷ 30 Nm 8 Clutch screw ........55 ÷ 65 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
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Page 34: Replacement Of The Drive Belt
When assembly is complete, ... u Remount the blade engagement clutch [see 6.4]. u Adjust the drive engagement [see 4.3]. Tightening torque 7 Nut for stretcher idle pulley ....25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 35 «STARTER» position. This position depends on the type of engine and is shown in the instruction hand- book. ➤ In manual start models: ensure that the engine switches off and stops correctly when the accelerator is set to «STOP». © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 36 Next, … u Refit the blade [see 4.7] by tightening the nuts to the amount shown. u Reassemble the wheel cover [see 5.1]. u Adjust the blade engagement [see 4.1]. © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 37 (11) and the rear lifting axle (12) of the cutting deck. Next, … u Remount the wheel cover [see 5.1]. u Check the brake adjustment [see 4.2]. u Remount the collector channel [see 5.2]. © by GLOBAL GARDEN PRODUCTS 3/2003...
- Page 38 (8) connecting the stub axles underneath the lifting axle (9) of the cutting deck. Next, … u Remount the wheel cover [see 5.1]. u Regulate the drive engagement [see 4.3]. u Remount the collector channel [see 5.2]. © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 39 Undo the two nuts (12) to reach the pads (13). If there is oil on the pads, clean with solvent and go over them with fine-grade abrasive paper. Check that the four-threaded screw (13) of the lever © by GLOBAL GARDEN PRODUCTS 3/2003...
- Page 40 When assembly is complete, … u Remount the rear left wheel [see 6.1]. u Adjust the brake [see 4.2]. Tightening torques Lever pin fastening nut ....10-15 Nm 13 Brake caliper nuts ........ 6,5 Nm © by GLOBAL GARDEN PRODUCTS 3/2003...
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Page 41: Dismantling And Replacement
C) Dismantling and replacing the brake disc u Remove the brake caliper [see 6.10]. Remove the chain tightener (21) secured by two screws (22). Unscrew the four nuts (23) securing the supports © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 42 Tightening torques 4 Gear change nuts ........8 Nm 13 Support nuts ..........8 Nm 26 Brake disc nuts ........10 Nm 27 Differential and ring gear nuts ....10 Nm © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 43 (4) and (5 - ➤ only with a B&S engine), so that it is secured by the respective con- tainment pegs. Fit the end of the cable (3) in the handle (2) and knot it so that the handle cannot slip out. © by GLOBAL GARDEN PRODUCTS 4/2005...
- Page 44 Starter works erratically for mechani- Check the starter motor stop when the key is cal or electrical reasons, taking exces- removed sive current and causing binding of relay contacts © by GLOBAL GARDEN PRODUCTS 3/2006...
- Page 45 Accidental disconnection of an Check all wiring electrical wire Starting of engine not permitted [see After checking that the conditions are met, summary logic table 7.2] check all the microswitches [see 7.3] and the relative wiring. © by GLOBAL GARDEN PRODUCTS 3/2006...
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Page 46: Summary Table For The Cutting In Of The Safety Devices
Does NOT start B) WHILE CUTTING OPERATOR GRASS-CATCHER BLADE TRANSMISSION PARKING ENGINE Absent –/– –/– Engaged –/– Stops Absent –/– Engaged –/– –/– Stops –/– Missing Engaged –/– –/– Stops –/– –/– Engaged –/– Engaged Stops © by GLOBAL GARDEN PRODUCTS 3/2006... - Page 47 1 - 3 (CN1) (without g.catcher (with g.catcher) 1 - 4 (CN1) O (neutral) SEAT MICROSWITCH PARKING MICROSWITCH ∞ (absent) ∞ (engaged) 1 - 5 (CN1) O (seated) 1 (CN1) - 2 (CN2) O (out) © by GLOBAL GARDEN PRODUCTS 3/2006...
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Page 48: Terminal Board Supply Check
DC 0 - 20), with the red ferrule on terminal 10 and the black one on terminal 6 of the wiring connector (2). The reading shows the battery voltage, which should never go below 11 Volts. CN 1 12 11 10 © by GLOBAL GARDEN PRODUCTS 3/2006... -
Page 49: Starter Relay Operation Check
(2) with a large section cable (5 mm between the power contacts of the relay. If the starter motor comes into operation, look for the fault in the relay or replace it. © by GLOBAL GARDEN PRODUCTS 3/2006... -
Page 50: Electronic Card Operation Check
4 - 5 - 7 - 8 of the wiring connector (1). In every case, the tester should indicate the battery’s voltage. This value should never go under 11 Volts. © by GLOBAL GARDEN PRODUCTS 3/2006... -
Page 51: Recharge Circuit Check
With the voltmeter tester, measure the voltage at the battery terminals. If the value does not rise but tends to fall, even slowly, it means that the regulator is not charging sufficiently and must be replaced. If the voltmeter shows no value it means that the fuse is blown. © by GLOBAL GARDEN PRODUCTS 3/2006... -
Page 52: Care And Maintenance Of The Sealed Battery
Battery voltage Operation to be carried Battery state with open circuit > 12.6 Volt Fully charged None < 12.4 Volt Flat Recharge Check the battery voltage at least 12-24 hours after recharging. © by GLOBAL GARDEN PRODUCTS 4/2005... -
Page 53: Fitting Safety Microswitches
B = seat with the driver in position: the lateral edge of the cam (2) should press the push-button, leav- ing at least 2-3 mm more travel. © by GLOBAL GARDEN PRODUCTS 3/2003... -
Page 54: Electrical Diagrams
Starter motor Motor stop Battery Starter relay Key ignition switch Blade microswitch Grass-catcher microswitch Seat microswitch Neutral microswitch Recharger connector Brake microswitch Fuse (10 A) CABLE COLOURS Black Blue Brown Grey Violet White Yellow © by GLOBAL GARDEN PRODUCTS 4/2007... - Page 55 NC - 3 NO - 2 NC - 3 NO - 2 Electronic card Engine Motor stop Blade microswitch Grass-catcher microswitch Seat microswitch Neutral microswitch Brake microswitch CABLE COLOURS Black Blue Brown Grey Violet Yellow © by GLOBAL GARDEN PRODUCTS 4/2007...
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Page 56: Tightening Torques And Adjustments Summary
Every section in this manual gives values for all the components involved in each operation. B) Adjustments Position Operation Position Adjustment of controls a) Drive engagement adjustment [see 4.3] 174 - 176 b) Engagement and blade brake adjustment [see 4.1] 140,5 - 141,5 © by GLOBAL GARDEN PRODUCTS 4/2007... -
Page 57: Summary Of Main Assembly Amounts And Checks
1 / 3 page 8.2 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS Frame Cutting deck Steering geometry Assembly of steering tie-rods Tie-rod connecting steering steering stub axles Drive belt development Assembly of gear lever rod © by GLOBAL GARDEN PRODUCTS 3/2002... - Page 58 WORKSHOP MANUAL <= ...BACK... <= 2002 •••• 8.2. from SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 2 / 3 page © by GLOBAL GARDEN PRODUCTS 3/2002...
- Page 59 WORKSHOP MANUAL <= ...BACK... <= 2002 •••• 8.2. from SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS 3 / 3 page © by GLOBAL GARDEN PRODUCTS 3/2002...