Global garden products 92 Workshop Manual

Hide thumbs

Table Of Contents

WORKSHOP

MANUAL

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.

even partial, of the texts in this document may be made without explicit authorization.

Rel. 7.0

YEAR OF MANUFACTURE

r r

2006

Table of Contents

Need help?

Do you have a question about the 92 and is the answer not in the manual?

Questions and answers

Summary of Contents for Global garden products 92

Page 1: Workshop Manual
© 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: Table Of Contents
This chapter summarises all the main information and tunings. regarding the machine. GENERAL INDEX Identification and procedures Safety regulations Tools Lifting Vertical position Practical hints Criteria for maintenance Blade engagement adjustment Blade brake adjustment Brake adjustment © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 3: Maintenance
Electronics card operation check Recharge circuit check Care and maintenance of the sealed battery 7.10 1 Fitting safety microswitches 7.11 3 Electrical diagrams Summary of tightening torques Summary of main assembly and checking values Special tools © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 4 Whenever a reference is made to a position on the machine “front”, “back”, “left” or “right” hand side, this is determined by facing the direction of forward travel. © by GLOBAL GARDEN PRODUCTS 4/2005 A) Machine or machine series to which the page applies.
Page 5: Identification And Procedures
[u The Service Centre has to make out a report con- point A]. taining the machine’s serial number, a summary of © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 6: Safety Regulations
C) Precautions during servicing “WARNING” stresses the risk of injury to oneself The operations described in this manual do not and others if instructions and regulations are not entail particularly hazardous situations besides the 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. Bush for assembly of blades bearings 4. Stopper for assembly of wheel bearings 5. Pulley extractor © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 8: Lifting
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 lawn-tractor from accidentally moving backwards. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 9: Vertical Position
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...
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
– Check cutting deck lifting cables – General lubrication – Clean away grass cuttings and wash exterior – Clean and wash inside cutting deck and collector channel – Clean and wash grass-catcher – Touching up of any damaged paint © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 12: Blade Engagement Adjustment
(1) which can be reached from the wheel arch of the right-hand rear wheel. Turn the nuts until the spring (2) reaches the length 97 ÷ 99 mm, measured from the outer edge of the eyelet with the blades engaged. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 14 20 mm (measured vertically next to the pin rod) before beginning the braking action. If this is not the case, the free movement can be adjusted with the screw (8), unless the © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 15 Therefore you need to dismantle the whole rear axle of the machine [see 5.5] and contact one of the manufacturer’s Service Centres. When assembly is completed … ➤ In mechanical drive models: u Refit the fuel tank [see 5.4]. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 16 – 119 ÷ 121 mm ➤ In mechanical drive models – 120 ÷ 122 mm ➤ In hydrostatic drive models measured from the outer ends of the springs with the drive commands disengaged. When the adjustment has been made, tighten the nuts (2). © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 17 «N» to the forward and reverse gear positions: you should hear the click of the button The neutral position «N» is signalled by the at each gear change before the wheels start moving. microswitch (6) of the cam (7). © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 18 Any difference in height from the ground between the left and right sides of the deck can be compen- sated by turning the two nuts (4 - 8) and locknuts (5 - 9) of just the back rods. © by GLOBAL GARDEN PRODUCTS 3/2003...
Page 19 The right distance between the two centres is 356 ÷ 357.5 mm, which will give an even rise and descent [see 8.2.9]. Remember to tighten all the nuts and locknuts once these adjustments have been made. © by GLOBAL GARDEN PRODUCTS 3/2003...
Page 20 [see 4.4]. If only the front nut (1) has been loosened without having touched the rear one, the right tension will be achieved by just tightening up the nut (1). © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 21 •••• 4.7. from STEERING ALLOWANCE ADJUSTMENT 2 / 2 page When assembly is completed … u Refit the fuel tank [ see 5.4]. Tightening torque Nut for ring gear ......45 ÷ 50 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 22 (9) angled in both directions. Tightening torques 3 - 7 Locknuts for articulated joints ..25 ÷ 30 Nm 4 - 8 Nuts for articulated joints .... 45 ÷ 50 Nm © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 23: Repairs
IMPORTANT! Always replace damaged blades and do not attempt to repair or straighten them. Always use manufacturer’s genuine spare parts! © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 24 (4) is pressing against the blade. Tightening torques Screw for left blade ...... 45 ÷ 50 Nm 1a - 1b Screw for right blade ....45 ÷ 50 Nm © by GLOBAL GARDEN PRODUCTS 3/2003...
Page 25 Unhook the two fastener springs (2) and pull out the pins (3). B) Fixing with a split pin Take out the split pin (4) from the right-hand side and remove the hood by moving it to the right. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 26 (7). Remove the seat after having taken out the two pins (9). The cover (10) is held by a screw at the front (11), four screws (12) at the bottom of the dashboard © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 27 The two back ones (13a) of these last screws have a washer. When the cutting height lever has been moved to position «7» and the engage lever to the «blades engaged» position, it is possible to remove the cover. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 28 (2) fixing onto the rear plate and take out the channel (3). When reassembling, fully tighten the screws (2) and make sure that the collector channel moves freely. Tightening torque Screws for collector channel ..25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 29 Loosen the screw (3) holding the support (4) and lift the tank until the two pegs (5) come out of the lower support. On reassembling, remember to fit the clamp back on the fuel pipe and check that it does not leak. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 30 Remove the protection from the exhaust (10) and disconnect the cable control from the accelerator and all the electrical wires. Detach the fuel line pipe, taking care not to spill fuel. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 31 Adjust the «MINIMUM» position [see 6.10]. u Refit the front hood [see 5.1]. Tightening torques 8 Screw for pulley ....... 45 ÷ 50 Nm – Screws for engine fastening ..... 25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 32 The dismantling procedure differs slightly depend- ing on the various types of drives used. ➤ In mechanical drive models: Dismantle the guide pulley (7) from the rear plate and detach the gear lever (8) by loosening the © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 33 When refitting the blade engagement cable, make sure that the washer (25) is correctly positioned between the bracket (26) and the cable sheath (3). Reattach all the connections, and then … u Check the brake [see 4.3] © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 34 14 Screws for brackets ....... 25 ÷ 30 Nm 15 Self-tapping screws ....... 25 ÷ 30 Nm 16-24 Screws for rear axle fastening .. 25 ÷ 30 Nm 23 Rear axle locknut ......25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 35 Reset the belt shifter (6) into position, refit the fork (5) with the relative safety pin (4) and fully tighten the screw (3). u Reattach the collector channel [see 5.3]. u Check the alignment of the cutting deck [see 4.6]. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 36 (2) and the snap ring (1) with the rounded edge facing inwards. Tyre pressures Front ............1.5 Bar Rear ............1.2 Bar © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 37 The new bearing must be inserted with the help of a plastic mallet or a bronze pad (3) # code 60800031/0 working only on the outer ring of the bearing. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 38 (8c), undo the upper nuts (8a) and (8b) and take out the various components. On reassembling be very careful to restore the exact sequence and to fully tighten the nut (9a) which holds the pin (10a). © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 39 Check the steering geometry [see 4.8]. u Refit the fuel tank [ see 5.4]. Tightening torques Nut for Ring gear ......45 ÷ 50 Nm 9a Nuts for the stud bolt ..... 45 ÷ 50 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 40 Adjust the drive engagement [see 4.4]. u Refit the collector channel [see 5.3]. Tightening torques 1 Nuts for small wheels......25 ÷ 30 Nm 5 - 6 Nuts for pulleys ......25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 41 (5) screwed onto the frame [see 8.2.4]. When reassembly is completed, tighten the nuts (3) to the amounts shown. Always refit the dust covers (5) of the wheels (2). © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 42 ➤ In hydrostatic drive models: reset the tension of the stretcher spring [see 4.4]. If only the front nut (1) has been loosened without having touched the rear one, the right tension will be achieved by just tightening up the nut (1). Tightening torque Nuts for small wheels...... 25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 43 (3) with the relative safety pin (2) and fully tighten the screw (1). Once assembly is completed ... u Adjust the blade engagement [see 4.1]. Tightening torque 15 Nut for idle pulley ......25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 44 Put the cable back in its path around the pulley, hook on the adjuster (1) and tighten the pulley nut (2). When reassembled ... u Adjust the alignment of the deck [see 4.6.A]. u Refit the collector channel [see 5.3]. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 45 (5). On reassembling, make sure that the washer (6) is positioned between the bracket (7) and the cable sheath (5). Once assembly is completed ... u Adjust the blade engagement [see 4.1]. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 46 (9) and to take off the pulleys (10). Dismantle the flange support (11) by unscrewing the three nuts (12). The entire support (11), including shafts and bearings, is a spare part available as single assembly unit. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 47 Fit the flange supports onto the deck, fully tighten- ing the nuts (12). Tightening torques 9 Screws for pulleys fastening .... 20 ÷ 25 Nm 12 Nuts for flanged support ....25 ÷ 30 Nm © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 48 (8) in the same «MINIMUM» posi- tion specific to each type of engine and shown in the instruction booklet. When assembly is completed … u Refit the fuel tank [see 5.4]. © by GLOBAL GARDEN PRODUCTS 3/2002...
Page 49 If it has been moved, the lever’s free movement will have to be checked [see 4.3]. When fully reassembled ... u Check the brake adjustment [see 4.3]. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 50: Electrical System
Check that the starter relay is activated [see 7.6] Activation of the self-resetting protection of the electronic card is signalled by the failure of the LED to light, by it switching off during work, by the engine running erratically or stopping. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 51 Accidental detaching of an electrical Check all wiring ting in 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...
Page 52 [see 7.2] Malfunctioning or faulty electronic Try changing the card with one that is known card to work. If the problem stops, replace the faulty card. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 53 PARKING ENGINE PILOT LAMP Absent –/– –/– Engaged –/– Stops Absent –/– Engaged –/– –/– Stops –/– Missing Engaged –/– –/– Stops –/– –/– Engaged –/– Engaged Stops Absente –/– –/– –/– Disengaged Stops © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 54 This operation must be done by making contact between the ferrules of the electronic card (2), keeping all the connectors attached, and should give this result: N° Contacts Tester reading and condition 5 (CN3) - Earth O (Always) © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 55 3 (CN5) and the red ferrule on terminal 2 (CN3 ) the wiring connectors (1). – The key in the «ON» position. The reading shows the battery voltage, which should never go below 11 Volts. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 56 ) between the power contacts of the relay. If the starter motor comes into operation, look for the fault within the relay or replace it. Otherwise, check the starter motor together with its wiring. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 57 Similarly, there might be some smoke inside the transparent box which is due to the overheating of the powder inside. WARNING! Do not touch this component of the card until it has cooled down. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 58 If this level is exceeded to a point where the engine stops due to the self-resetting protection device cutting in (at about 16 Volts), it means that the regulator is charging too much and must be replaced. © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 59 Battery voltage Operation to be carried Battery state with open circuit > 12.6 Volts Fully charged None < 12.4 Volts Low charge Recharge Check the battery voltage at least 12-24 hours after recharging. © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 60 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 61 Neutral microswitch ( ➤ Mechanical drive models) Neutral microswitch ( ➤ Hydrostatic drive models) Grasscatcher full microswitch Pilot lamp Recharge connector Headlight switch Headlight 6.3 A fuse (delayed) 25 A fuse CABLE COLOURS Black Blue Brown Grey Orange Violet White © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 62 Neutral microswitch ( ➤ Hydrostatic drive models) Grasscatcher full microswitch Pilot lamp Recharge connector Headlight switch Headlight 6.3 A fuse (delayed) 25 A fuse Recharge relay Recharge regulator CABLE COLOURS Black Blue Brown Grey Orange Violet White © by GLOBAL GARDEN PRODUCTS 3/2006...
Page 63 Screws for blades pulleys fastening . 25 ÷ 30 Nm Nuts for flange support ....25 ÷ 30 Nm Screw for blades ......45 ÷ 50 Nm Every section in this manual gives values for all the components involved in each operation. © by GLOBAL GARDEN PRODUCTS 3/2003...
Page 64 Fitting the gearchange control tie-rod ( ➤ in mechanical drive models) Fitting the drive control tie-rod ( ➤ in mechanical drive models) Fitting the pedal tie-rod ( ➤ in hydrostatic drive models) Fitting the deck lifting tie-rod 10 Fitting the blades brake tie-rod © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 65 WORKSHOP MANUAL 2003 •••• 8.2. - SUMMARY OF MAIN ASSEMBLY AMOUNTS from AND CHECKS 2 / 4 page © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 66 WORKSHOP MANUAL 2003 •••• 8.2. - SUMMARY OF MAIN ASSEMBLY AMOUNTS from AND CHECKS 3 / 4 page ➤ Mechanical drive models ➤ Hydrostatic drive models ➤ PEERLESS drive models ➤ DANA drive models © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 67 WORKSHOP MANUAL 2003 •••• 8.2. - SUMMARY OF MAIN ASSEMBLY AMOUNTS from AND CHECKS 4 / 4 page © by GLOBAL GARDEN PRODUCTS 4/2005...
Page 68 WORKSHOP MANUAL 1997 •••• 8.3. from SPECIAL TOOLS 1 / 1 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) < 8,5 Ø10 © by GLOBAL GARDEN PRODUCTS 4/2005...

Global garden products 92 Workshop Manual

Table of Contents

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Global garden products 92

Summary of Contents for Global garden products 92

Table of Contents