Global Garden Products Lawn Mower 63 63M Instructions 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.
WORKSHOP
MANUAL
Rel. 4.0YEAR OF MANUFACTURE 2006
6 6 6 6
3 3 3 3
6 6 6 6
3 3 3 3
       
M M M M 
						

							© by GLOBAL GARDEN PRODUCTS
63
i.2
INDEX





1 / 2
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
MAIN CHAPTERS
1. Rules and procedures for Service Centres 
This chapter covers all the main aspects of the
relationship between the manufacturer and the
service centres.
A close collaboration between the manufacturer
and the service centres is conclusive for solving
problems in the most effective way as well as
maintaining an image of efficiency and reliability.
Compliance with these brief and simple guide-
lines will facilitate this task and prevent general
misunderstandings and time-wasting for both
the manufacturer and the service centre.
2. General and safety regulations
This chapter covers the main aspects of a servic-
ing procedure and the general rules for guaran-
teeing a successful service which protects the
environment and respects the safety of both the
serviceman and the user of the apparatus.
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 that are usually resolved by quick checks
and tunings.
5. Removal of external parts and main assem-
blies
Greater access may be required for more difficult
jobs. This can be done by taking off the unit con-
cerned and working at the bench, or by removing
the covers and external parts.
It is up to the mechanic with experience to
decide whether these operations are useful.
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 con-
nected to a particular type of repair.
In this case, careful reading of the entire proce-
dure can help you omit all those operations not
connected with the case in hand without, how-
ever, overlooking anything that may be neces-
sary.
7. Electrical system
This chapter deals with the problems and checks
regarding the electrical system.
All work can be done using a tester without hav-
ing to use special equipment.
The electrical diagrams, inserted in the spare
parts pamphlet, can be useful in understanding
how the system functions and to facilitate trou-
ble-shooting.
8. Technical data
This chapter summarises all the technical infor-
mation regarding the machine.
GENERAL INDEX
1.1
1Identification and procedures
2.11Safety regulations
2.21Tools
2.31Lifting
2.41Positioning the machine vertically
2.51Practical hints
3.11Criteria for maintenance
4.12Engagement and blade brake adjustment
4.22Brake adjustment
4.30Drive engagement adjustment
4.40Cutting deck alignment 
						

							4.50Steering geometry adjustment
4.60Blade alignment check
4.70Sharpening and balancing the blade
5.11Removal of the wheel cover
5.20Removal of the collector channel
5.32Removal of the cutting deck
5.40Removal of the engine
5.51Removal of the transmission unit
6.10Replacement of tyres and wheels
6.20Replacement of the front wheel bushes
6.31Replacement of the steering components
6.42Replacement of the blade engagement clutch
6.50Replacement of the drive belt
6.61Replacement of the accelerator cable
6.70Replacement of the blade engagement cable
6.81Replacement of the brake cable
6.90Replacement of the drive engagement cable
6.101Replacement of the brake pads and lever
6.110Dismantling and replacement of transmission components
6.121Replacement of starter cable(➤Only in manual start models)
7.12Trouble-shooting in the electrical system
7.22Summary table for the cutting in of safety devices
7.32Safety microswitches operation check
7.42Terminal board supply check(➤Only in electric start models)
7.52Starter relay operation check(➤Only in electric start models)
7.62Electronic card operation check(➤Only in electric start models)
7.72Recharge circuit check(➤Only in electric start models)
7.81Care and maintenance of the sealed battery(➤Only in electric start models)
7.91Fitting safety microswitches
7.102Electrical diagrams
8.11Summary of tightening torques
8.20Summary of main assembly and checking values
8.31Special tools
3/2006
63
i.2
INDEX





2 / 2
WORKSHOP MANUAL
page from 
2006to  ••••
© by GLOBAL GARDEN PRODUCTS 
						

							© by GLOBAL GARDEN PRODUCTS
63
ii.2
INTRODUCTION





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
4/2005
INTRODUCTION
This manual has been compiled to help Service
Centres with the maintenance, dismantling and
repair of the following versions of “Rider” 63 riding
mower:
– 
electric start models;
– manual start models.
Each page of this manual states the following infor-
mation:
A)Machine or machine series to which the page
applies.
B)Page number, specifically: 
–the first two figures separated by a point indi-
cate the section and the chapter
–the third figure indicates the modification
index.
C)Temporary validity of the page, with reference to
the year of manufacture or serial numbers.
D)Date of release.
E)Page number and total number of pages dedi-
cated to the subject.
F)Any previous or ensuing pages dedicated to the
subject.
G)Any chapters before or after the current one.The manual refers to the following symbols:
Warns of operations that should be carried
out with utmost care to avoid impairing the func-
tionality and safety of the lawnmower.
Warns of operations that should be carried
out with utmost care to avoid injury to the oper-
ator. 
Reference to another procedure or part of
the manual.
#Indicates that a special tool should be used
[see 2.2].
➤This symbol highlights all those operations
that require different working methods depend-
ing on the type of machine, subsequent modifi-
cations or accessories fitted.
NOTE
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. 
The manual has left out the simplest and quickest
operations that can be handled by a good mechan-
ic, while concentrating more on specific aspects
and the best servicing procedures.
You are asked to read through this manual to
acquire a basic understanding of the machine,
which is necessary for working rationally without
making errors or wasting time.
All problems related to use are fully covered in the
user manual.


© by GLOBAL GARDEN PRODUCTS
635.3.2REMOVAL OF THE CUTTING DECK 




2 / 3
WORKSHOP MANUALpage from 2002to  ••••
Take off the guard (12)secured by five screws (13)
and release the spring (14)from the clutch (16).

Put the machine back on a flat surface [see 2.4].
Engage the parking brake to loosen the drive belt.
Loosen the two nuts(17), remove the guide pulley
(18)and free the belt (19)from the pulley (20).
Loosen the adjusting nut (21)and release the spring
(22)from the drive engagement and the spring(23).
At this point, the cutting deck is connected to the
machine by just three trace rods. Keep it supported
as you remove it, as the total weight of the plate /
engine unit is approx. 30 kg.
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
21
2223
1416
1719
1720
18
1213
13
911
4/2005
AC
F
E
F
D
GBG 
						

							1.1 IDENTIFICATION AND PROCEDURES
A) Identification
1) Machine
Each machine has a label attached(1) under the
driver’s seat which shows the technical specifica-
tions, 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.
2) Motor
The engine is made to precise technical specifica-
tions which differentiate it from similar products by
this 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. 
B) Guarantee validity
The guarantee is supplied under the terms and lim-
its of the contractual relations in force. As far as the
engine is concerned, the conditions given by the
manufacturer apply.
C) Service repairs after guarantee period
The Service Centre has to make out a report con-
taining 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 Cus-
tomers.
D) Fault notification
The Manufacturer welcomes any notifications of
faults that recur with particular frequency. It gives
the opportunity for a careful inspection of the prob-
lem and the implementation of corrective action at
production level.Similarly, the Manufacturer will notify of any faults dis-
covered on the machines produced, with recommen-
dations for the most suitable procedures for their rem-
edy.
E) 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 [


point A].
1
4/2005
63
1.1.1
IDENTIFICATION AND PROCEDURES





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
© by GLOBAL GARDEN PRODUCTS 
						

							© by GLOBAL GARDEN PRODUCTS
63
2.1.1
SAFETY REGULATIONS





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
4/2005
2.1 SAFETY REGULATIONS
A) Qualification of operators
All maintenance, disassembly and repairs must be
carried out by expert mechanics who are familiar
with all the accident prevention and safety regula-
tions after reading through the procedures in this
manual.
B) Safety measures
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,
the Service Centres should 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
machine the Service Centre should:
1) check:
–that safety microswitches are working cor-
rectly  [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).
2) they should also:
–restore to proper working order any safety
devices which have been manipulated or
removed;
–reattach inefficient, damaged or missing cas-
ings and protection covers;
–replace illegible labels;
–not endorse any repair or modification on the
machine or the engine which results in a
change in performance or use that is incorrect
or different from the purpose 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 Manufac-
turer declines all responsibility, as also shown
in chapter 1 of the Instruction Booklet.
C) Precautions during servicing
The operations described in this manual do not
entail particularly hazardous situations besides the
normal hazard related to mechanical operationsand that can be avoided by taking the necessary
care and attention normally required for this type of
work.
As well as following the usual accident prevention
regulations that apply to most repair shops, we rec-
ommend you: 
–disconnect the ignition key (➤in electric start
models)
and the spark plug cap before starting
any work on the machine; 
–protect hands with suitable working gloves,
especially when working near the cutting unit; 
–check that you do not cause accidental petrol
leaks or other losses;
–do not smoke when working on the tank or
when handling petrol; 
–do not inhale oil or petrol fumes; 
–clean up all traces of spilt petrol immediately; 
–test the engine in a well-ventilated environ-
ment or where there are adequate exhaust
fume extraction systems;
–do not pollute the environment with oil, petrol
or other waste and dispose of all waste in
accordance with the laws in force;
–ensure that other persons cannot accidentally
carry out actions that may physically endan-
ger those working on the machine.
D) Necessary equipment
All the operations can be carried out with the tools
normally used in a good garage.
Some operations require special equipment and
tools [

2.2].
E) Symbols and terms used for safety purposes
Some paragraphs in this manual are preceded by
symbols which indicate the following:
Operations that should be carried out with
utmost care to avoid impairing the functionality
and safety of the lawnmower.
Operations that should be carried out with
utmost care to avoid injury to operators. 
“WARNING” stresses the risk of injury to oneself
and others if instructions and regulations are not
observed. 
						

							© by GLOBAL GARDEN PRODUCTS
63
2.2.1
TOOLS





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
4/2005
2.2 TOOLS
All work can be carried out using the tools normally
available from a good workshop. However, it is
advisable to have a set of special tools 
(1 ÷ 4),
which are already part of a set (Code 82180040/2),
or  which can be made following the instructions
given in chapter 8.3.
These tools 
(1 ÷ 4)are to be used whenever the
symbol «#» is given in this text.
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
1
2
4
3 
						

							© by GLOBAL GARDEN PRODUCTS
63
2.3.1
LIFTING





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
2.3 LIFTING
The machine must never be lifted using a hoist
or other lifting equipment which uses cables.
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. Place
a wooden block 
(1)between the base of the jack
and the frame and check that the free movement of
the front spring equaliser has not been obstructed.
B) Rear
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.
3
2
2
1
4/2005 
						

							© by GLOBAL GARDEN PRODUCTS
63
2.4.1
POSITIONING THE MACHINE VERTICALLY





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
4/2005
2.4 POSITIONING THE MACHINE VERTICALLY
For easier access to the lower part of the machine it
is possible to lift it vertically.
WARNING! Two people will be needed for this
job. When lifting the front of the machine, only
grip the firm parts (like the seat or frame, etc.)
and NEVER the plastic parts of the body.
Empty the fuel tank.
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.
Fit a block 
(1)of about 60 mm underneath the rear
plate, taking care to place it between the plate edge
and the collector channel outlet.
Lift the machine from the front, holding it by the
parts with a firm grip (
not by the steering wheel)
and rest it in the points shown, in such a way that it
does not damage the grass-catcher supports
(2).
WARNING! Be sure of the good stability of the
machine before carrying out any type of work on
the machine and avoid operations that may
cause it to fall over.
WARNING! Be just as careful when putting the
machine back on a flat surface; two people are
needed for this operation.
1
60 mm
2 
						

							© by GLOBAL GARDEN PRODUCTS
63
2.5.1
PRACTICAL HINTS





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
2.5 PRACTICAL HINTS
A) Fitting snap rings
“Benzing” snap rings(1)have a rounded edge on
one side and a sharp edge on the other.
For maximum grip, the rounded part needs to be
facing 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 var-
ious directions.
A typical situation has the pin 
(3)fixed by a self-
locking nut 
(4)with two anti-friction washers (5)
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 play
which could result in the parts concerned becoming
misaligned 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.
7
6
7
6
8
3
55
4
3
45
1
2
1
4/2005