Global Garden Products Lawn Mower 102 - 122 102 - 122 Hydro Instructions Manual

							102 - 122
6.4.0
REPLACEMENT OF THE DRIVE BELT





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
6.4 REPLACEMENT OF THE DRIVE BELT

Dismantle the engine pulley [see 5.5] to release
the belt.

Remove the collector channel [see  5.3].
It is advisable to slacken the transmission belt to
work on the parts involved more easily.
This is done by  ...
➤In mechanical drive models:engaging the
parking brake.  
➤In hydrostatic drive models:slackening the
stretcher [see 4.4].
Dismantle the drive pulley
(1)and the stretcher pul-
ley
(2), fixed by nuts (3)and(4)respectively, and
slacken the belt guide
(5)enough to free the belt (6).
➤In mechanical drive models:
only slacken off the fixing nuts(7) of the two
small front wheels 
(8). 
➤In hydrostatic drive models:
slacken off the fixing nuts (7)of both small
wheels
(8a) and remove the pin(9)from the brake
rod to allow passage of the belt.
On reassembly ensure the exact positioning of the
belt
(6) with respect to the pulleys, the small side
wheels and the containment guides [see 8.2.4], with
special reference to its passage through the belt
guide fork
(5).
Always refit the dust covers 
(10)of the wheels (8).
When assembly is completed …

Refit the engine pulley [see 5.5].

Adjust the drive engagement  [see  4.4].

Refit the collector channel [see  5.3].
➤In hydrostatic drive models:  tighten the
spring of the stretcher [see 4.4]. 
Tightening torques
3 - 4Nuts for pulleys............................ 25 ÷ 30 Nm
7Nuts for small wheels  ..................... 25 ÷ 30 Nm
9
3/2002
➤ mecc.➤ hydro
88a
7
8
10
3
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5
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							102 - 122
6.5.0- REPLACEMENT OF THE SMALL
WHEELS FOR THE DRIVE BELT




1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
6.5 REPLACEMENT OF THE SMALL WHEELS
FOR THE DRIVE BELT

Remove the collector channel [see  5.3].
It is advisable to slacken the transmission belt to
work on the parts involved more easily.
This is done by ...
➤In mechanical drive models:engaging the
parking brake. 
➤In hydrostatic drive models: slackening the
stretcher [see 4.4].
The small side wheels
(1), two or four depending on
the type of drive, are fixed to the frame by a nut 
(2),
with a spacer 
(3)between which is of different
height, 
(3a)or (3b), depending on the assembly
position and type of drive.
When reassembling, you should bear in mind that:
➤In mechanical drive models:
the tall spacer(3a)must be fitted under the small
right front wheel 
(1a)and the low one (3b)under
the other three
(1b).
➤In hydrostatic drive models:
the tall spacer(3a)must be fitted under the small
right wheel
(1a)and the low one (3b)under the
left wheel 
(1b).
Always refit the dust covers 
(4)of the wheels (1).
Once assembly is completed ...

Adjust the drive engagement [see  4.4].

Refit the collector channel [see  5.3].
➤In hydrostatic drive models:tighten the
spring of the stretcher [see 4.4]. 
Tightening torque
2Nuts for small wheels  ..................... 25 ÷ 30 Nm
3/2002
➤hydro
3b
3a
1b
1a
➤mecc.
3b
3a
1b
1a1b
1b
3
1
2
4
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							102 - 122
6.6.1- REPLACEMENT OF THE BLADES 
CONTROL BELT




1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
6.6 REPLACEMENT OF THE BLADES CONTROL
BELT
➤For models with lever operated engage-
ment: 
disengage the blades to slacken the belt.
Shift the mobile guide pulley
(1)forwards just
enough to free the belt 
(2)from the motor pulley
(3).
➤For models with electromagnetic clutch:
there is no pin(1)and it is enough to tug at a sec-
tion of the belt  to free it from the pulley.
Set the cutting deck to the lowest position to obtain
greater access, then dismantle the upper casing
(4)
and almost totally undo the nut(5)without disman-
tling the jockey pulley
(6) so that the belt can be
removed.
➤For models with lever operated engage-
ment: 
engage the blades to withdraw the brake
pad 
(7)from the pulley (8).
Keeping the blade locked, undo the screw
(9)and
dismantle the control pulley
(8)to remove the belt.
On reassembly, ensure that the belt is positioned
perfectly in line with respect to the pins and rims
[see 8.2.5].
When it has been reassembled, it is a good idea to
…

Check the adjustment of the blade engagement
lever  [see 4.1].
Tightening torques
5Nut for idle pulley   ............................ 20 ÷ 25 Nm
9Screw for pulley   .............................. 20 ÷ 25 Nm
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							102 - 122
6.7.1- REPLACEMENT OF THE BLADES 
CONNECTION BELT




1 / 2
WORKSHOP MANUAL
page from 
2000to  ••••
6.7 REPLACEMENT OF THE BLADES 
CONNECTION BELT
Set the cutting deck to the lowest position to obtain
greater access, then slacken off and uncouple the
adjuster
(1) to unload the spring(2).
Dismantle the upper casing
(3), undo screw (4)and
dismantle the control pulley 
(5); undo the articula-
tion screw
(6)and remove the stretcher plate (7).
Remove the protection casing 
(8), slackening off
the six surround screws 
(9)and extract it from its
slots.
Record the reading on the adjuster 
(10)(this must
be reset at reassembly to give a preliminary belt
adjustment) and slacken it off completely.
Dismantle the pin
(11), slacken off the fixing nuts of
the three pins
(12)and the pulleys (13)and (14)to
allow removal of the belt.
Fit the new belt so that, when the two long sections
are held taut, the two blades are at 90° to each
other.
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							102 - 122
6.7.1REPLACEMENT OF THE BLADES 
CONNECTION BELT




2 / 2
WORKSHOP MANUAL
page from 
2000to  ••••
Refit everything by reversing the operations
described above. Reset the adjuster reading
recorded previously and check that the blades are
at 90° to each other before locking the pin
(11)and
pulleys
(13)  and(14).
NOTE
On reassembly, check that the washer under the
pin (11) is not damaged and that the outer pin
rollers run freely.
Use the specific tool(15)# Code 60205001/0 to
check the piston
(16)# Code 60208000/0  for the
belt give values and the force applied, and use the
stretcher until a give of 9 ÷ 10 mm is obtained,
exerting a force of:
–3.5 kg mod. 102, 
–4.2 kg mod. 122.
Reassemble the casing, stretcher and blades con-
trol belt, taking care over their exact positioning
with respect to the pins and containment guides
[see 8.2.6].
When refitting the spring
(2), make sure that it is
connected to the hole provided for each model [see
4.1].
Finally, when reassembly is complete, it is advisable
to …

Check the adjustment of the blades engage-
ment spring [see 4.1]
Tightening torques
4Blade pulley screws  ......................... 20 ÷ 25 Nm
6Stretcher plate articulation screw   ... 35 ÷ 40 Nm
11 - 12Pin fixing nuts  ......................... 30 ÷ 35 Nm
13 - 14Pulley fixing nuts  .................... 30 ÷ 35 Nm
15
16
3/2002
1312
13
141112
131212
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102 - 122
6.8.0- REPLACEMENT OF THE BLADES 
ENGAGEMENT CABLE




1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
6.8 REPLACEMENT OF THE BLADES
ENGAGEMENT CABLE  (
➤For lever operat-
ed engagement models)

Remove the right-hand rear wheel [see 6.1].
With the cutting deck in the lowest position and the
lever in the disengaged position, loosen the
adjuster
(1), remove it from its housing and unhook
the spring
(2).
Take the end barrel
(3)off the fork(4)which is near
the joint for the lever, and take out the whole cable
(5). 
On reassembling, make sure that the washer
(6)is
positioned between the bracket 
(7)and the cable
sheath
(5).
When refitting the spring
(2), make sure that it is
connected to the hole provided for each model [see
4.1].
Once assembly is completed ...

Adjust the blades engagement spring [see 4.1].
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							102 - 122
6.9.0- REPLACEMENT OF THE SUPPORTS
AND  SHAFTS  OF THE BLADES




1 / 2
WORKSHOP MANUAL
page from 
2000to  ••••
6.9 REPLACEMENT OF THE SUPPORTS AND
SHAFTS  OF THE BLADES

Remove the cutting deck [see 5.7].
NOTE
This operation is not strictly necessary since, with a
little practice and experience, it is possible to dis-
mantle the deck supports without removing the
deck.

Remove the blades control belt and the blades
connection belt [see 6.6 - 6.7]

Remove the blades [see 4.10] and take off the
hubs.
Extract the two toothed pulleys 
(1)from the blade
shafts, undo the seven screws 
(2)fixing the plate(3)
and remove it.
Dismantle the flanged support
(4)by unscrewing
the three fixing screws
(5).
The entire support (4), including shafts and bear-
ings, is a spare part available as a single assem-
bly unit.
If only the shaft or bearings are to be replaced,
remove the key or the two keys
(6)and hit the shaft
on the pulley side with a plastic mallet to extract the
shaft together with the lower bearing 
(7).
After having removed the key 
(8), the snap ring(9)
and the dust cover (10), the bearing (11)splined
onto the shaft can be removed using a normal
extractor, being careful to close the threaded hole
(12)with a suitable screw to prevent the tip of the
extractor from damaging the thread.
The second bearing still in place must be removed
by hitting it from the inside of the flange using a 12
÷15 mm diameter round bar 
(13).
On reassembly, having first inserted the shaft in the
lower bearing hole and inserted everything into the
support, fit the upper bearing using the specific
stopper # Code 60800030/0 
(14) that acts on the
inner ring
, hitting it squarely with a mallet until the
bearing is fully driven home.
118
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4
7
4
5
15
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TC•
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© by GLOBAL GARDEN PRODUCTS
102 - 122
6.9.0- REPLACEMENT OF THE SUPPORTS
AND  SHAFTS  OF THE BLADES




2 / 2
WORKSHOP MANUAL
page from 
2000to  ••••
Refit the flanged supports onto the deck,fully
tightening the nuts (5)
and checking that the sup-
port with the longer shaft is on the left.
When refitting the plate 
(3),the holes correspond-
ing to the support axes must meet perfectly in
the centring step (15) 
cut into the upper part of
each support.
Tightening torques
2Plate fixing screws  ........................... 30 ÷ 35 Nm
5Flanged support fixing nuts .............. 25 ÷ 30 Nm
3/2002
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1415
13
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102 - 122
6.10.0
REPLACEMENT OF THE ACCELERATOR





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
6.10 REPLACEMENT OF THE ACCELERATOR

Remove the dashboard [see 5.4].
Take off the knob
(1)and disconnect the cable(2)
from the connection terminal (3)on the engine.
Undo the two fixing screws 
(4)and take out the
accelerator together with the wire.
On reassembling, put the accelerator lever in the
«MINIMUM» position, connect the end of the cable
(2)to the terminal (3)on the engine after having
moved the cursor 
(5)in the same «MINIMUM» posi-
tion specific to each type of engine and shown in
the instruction booklet.
When assembly is completed …

Refit the dashboard [see 5.4].
3/2002
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							102 - 122
6.11.0- REPLACEMENT OF THE BRAKE PADS
AND DISC 




1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
6.11 REPLACEMENT OF THE BRAKE PADS
AND DISC  
( ➤In mechanical drive mod-
els)

Remove the left-hand rear wheel [see 6.1].
Disconnect the control rod
(1)from the lever (2)and
undo the two screws
(3)which hold on the support
(4).
The support 
(4)contains a pad (5a)separated from
the control pistons
(6)by a plate(7).
The other pad
(5b) can be reached by taking off the
disc 
(8).
If there is oil on the pads, clean with solvent and go
over them with fine-grade abrasive paper.
Both pads should be replaced if the depth of either
of them is less than 5 mm.
Renew the disc if it is damaged, distorted or less
than 4 mm thick.
On reassembly, carefully reposition all the compo-
nents and refit the complete support. When con-
necting the rod 
(1)be sure to use the lower hole in
the lever 
(2).
NOTE
During all these operations it is better to not
unscrew or loosen the central screw
(9) to avoid
altering the calibration of the cam driving the pis-
tons.
If it has been moved, the lever’s free movement will
have to be checked  [see 4.3].
When fully reassembled ...

Check the brake adjustment [see  4.3].2
9
4/2005
5b8
4
6
7
5a
1
2
43
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