Global Garden Products Lawn Mower 102 - 122 102 - 122 Hydro Instructions 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.
© 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. 6.0YEAR OF MANUFACTURE  2006
1 1 1 1
0 0 0 0
2 2 2 2
       
- - - -
       
1 1 1 1
2 2 2 2
2 2 2 2
1 1 1 1
0 0 0 0
2 2 2 2
       
- - - -
       
1 1 1 1
2 2 2 2
2 2 2 2
       
h h h h
y y y y
d d d d
r r r r
o o o o
T
T T T
C C C C
       
- - - -
       
T T T T
C C C C
P P P P
       
- - - -
       
T T T T
C C C C
R R R R
       
- - - -
       
T T T T
C C C C
B B B B
       
- - - -
       
T T T T
C C C C
X X X X
       
- - - -
       
T T T T
X X X X 
						

							5. Removal of external parts and main assem-
blies
For doing more difficult jobs, greater accessibili-
ty may be required. This can be done by taking
the unit concerned off and working at the bench,
or by removing the cover or other external parts.
Whether or not this will be useful is at the discre-
tion 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 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
connected with the electrical system.
All work can be done using a tester without hav-
ing to use special equipment.
The electrical diagrams 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 machine.
102 - 122
i.2
INDEX





1 / 2
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
CONTENTS
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 and are usually resolved by quick checks
and tunings.
© by GLOBAL GARDEN PRODUCTS
TC•
TX
GENERAL INDEX
1.1 
1Identification and procedures
2.11Safety regulations
2.21Tools
2.31Lifting
2.41Vertical positioning
2.51Practical hints
3.11Criteria for maintenance
4.10Blades engagement adjustment
4.20Blades brake adjustment
4.30Brake adjustment
4.40Drive belt adjustment 
						

							102 - 122
i.2
INDEX





2 / 2
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
4.50Drive pedal adjustment  ( ➤hydrostatic drive models)
4.60Aligning the cutting deck
4.71Steering allowance adjustment
4.80Steering geometry adjustment
4.90Checking blades alignment 
4.101Sharpening and balancing of the blades
5.10Removal of front hood 
5.22Removal of wheel cover (TC ...)
5.2a
0Removal of wheel cover (TX)
5.3
0Removal of the collector channel
5.40Removal of the dashboard (TC ...)
5.4a
0Removal of the dashboard (TX)
5.5
1Removal of the engine
5.60Removal of the rear axle
5.71Removal of the cutting deck
6.10Replacement of tyres and wheels
6.20Replacement of front wheel bearings
6.31Dismantling of the steering components
6.40Replacement of the drive belt
6.50Replacement of the small wheels for the drive belt
6.61Replacement of the blades control belt
6.71Replacement of the blades connection belt
6.80Replacement of the blades engagement cable
6.90Replacement of the supports and shafts of the blades
6.100Replacement of the accelerator
6.110Replacement of the brake pads and disc
7.12Guide to the identification of problems in the electrical system (TC ...)
7.1a
0Guide to the identification of problems in the electrical system (TX)
7.2
1Summary table for the cutting in of the safety devices (TC ...)
7.2a
0Summary table for the cutting in of the safety devices (TX)
7.3
1Safety microswitches and switches operation check (TC ...)
7.3a
0Safety microswitches and switches operation check (TX)
7.4
1Terminal board supply check (TC ...)
7.4a
0Terminal board supply check (TX)
7.5
1Carburettor solenoid valve operation check (TC ...)
7.5a
0Carburettor solenoid valve operation check (TX)
7.6
2Starter relay operation check (TC ...)
7.6a
0Starter relay operation check (TX)
7.7
1Electromagnetic clutch operation check ( ➤in models with electromagnetic engagement) (TC ...)
7.7a
0Electromagnetic clutch operation check ( ➤in models with electromagnetic engagement) (TX)
7.8
2Electronic card operation check (TC ...)
7.9
2Recharge circuit check
7.101Care and maintenance of the sealed battery
7.111Fitting safety microswitches
7.12–---
7.13a0Checking the operation of the bag emptying control (TX)
7.14a
0Replacing the clock’s buffer battery (TX)
7.15
0Electrical diagrams (TC ...)
7.15a
0Electrical diagrams (TX)
8.1
1Summary of tightening torques
8.22Summary of main assembly sizes and checking values
8.30Special tools
© by GLOBAL GARDEN PRODUCTS
TC•
TX 
						

							H)Code TC•shows that the page applies to the
machines so equipped  TC - TCP - TCR - TCB -
TCX.
Code 
TXshows that the page applies to the
machines so equipped TX.
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.


102 - 122
ii.2
INTRODUCTION





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
INTRODUCTION
This manual has been compiled to help Service
Centres with the maintenance, dismantling and
repair of the following versions of the 102-122
machine:– mechanical drive with gear box;
– hydrostatic drive (hydro).
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.
© by GLOBAL GARDEN PRODUCTS
TC•
TX
102 - 1225.5.1REMOVAL OF THE ENGINE 




1 / 2
WORKSHOP MANUALpage from 2002to  ••••
5.5 REMOVAL OF THE ENGINE
Since there are different types of drive, the stages
described here refer to those shared or similar in
all types of engine.

Remove the front hood [see 5.1].
➤ For models with lever operated engage-
ment: disengage the blades to slacken the belt.
➤ For models with electromagnetic clutch:
loosen and detach the adjuster (1)to slacken the
belt.
It is also advisable to slacken the transmission belt
for easier access to the parts involved; this is done
by ...
➤ In mechanical drive models: engaging the
parking brake. 
➤ In hydrostatic drive models:slackening the
stretcher [see 4.4].  
➤  For models with lever operated engage-
ment: Shift the mobile guide pulley (2)back-
wards undo the central screw(3)and take out the
pulley(4) from the shaft.
If it is difficult to take out, use the special extrac-
tor # code 60253000/0 inserted into the holes
(4a)of the pulley, but do not completely undo the
screw(32)so that the extractor puts pressure on
the head of the screw and does not damage the
threaded hole of the shaft.
➤  For models with electromagnetic clutch:
disconnect the connector(5), unhook the check
spring(6) from the clutch side and undo the cen-
tral screw (3a); remove the clutch(7) from the
shaft, together with the transmission control pul-
ley(8)and spacer(9).
Remove the protection from the exhaust(10)and
disconnect the cable control from the accelerator
and all the electrical wires.56
3a
7
98
4/2005
44a
3
2
1
© by GLOBAL GARDEN PRODUCTS
TC•TX
AC
F
E
F
D
GBHG 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
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) Transmission (Rear axle)
The transmission unit (both mechanical and hydro-
static) is made up of an engine block including the
rear axle. This unit is made by another manufactur-
er to our precise technical specifications which dif-
ferentiate it from similar items by this same Manu-
facturer.
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.
3) Engine
The engine is made to precise technical specifica-
tions which differentiate it from similar items by this
same 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 Manufactur-
er.A) Guarantee validity
B) Guarantee validity
The guarantee is supplied under the terms and the
limits of the contractual relations in being. As far as
the engine and the transmission unit are concerned,
the conditions given by their respective manufac-
turers 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 ofthe 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.
D) Fault notification
The Manufacturer welcomes any notifications of faults
that recur with particular frequency. It gives the oppor-
tunity for a careful inspection of the problem 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].
2
1
4/2005
102 - 122
1.1.1
IDENTIFICATION AND PROCEDURES





1 / 1
WORKSHOP MANUAL
page from 
2000to  •••• 
						

							entail particularly hazardous situations besides the
normal hazard related to mechanical operations
and 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: 
–taking out the ignition key before beginning
any repair work.
–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 
102 - 122
2.1.1
SAFETY REGULATIONS





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
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
© by GLOBAL GARDEN PRODUCTS
TC•
TX 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
2.2.1
TOOLS





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
2.2 TOOLS
All work can be carried out using the tools normally
available in a good workshop. However, it is advis-
able to have a kit of special tools
(1 ÷ 8)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 ÷ 8)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
6.Pulley centre distance checking template
7.Blades connection belt tension checking tem-
plate
8.Dynamometer
4/2005
1
234
5
7
6
8 
						

							102 - 122
2.3.1
LIFTING





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
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, plac-
ing 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.
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 back-
wards.
4/2005
3
2
2
1
© by GLOBAL GARDEN PRODUCTS
TC•
TX 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
2.4.1
VERTICAL POSITIONING





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
2.4 VERTICAL POSITIONING
WARNING! Two people will be needed for this
operation. When lifting and tipping backwards,
only solid parts should be gripped (steering
wheel, frame, rear plate, etc.) and NEVER parts
of the bodywork in plastic.
The fuel tank must be checked before putting the
machine in a vertical position to make sure that
there is no more than 2 litres of fuel inside.
To assure full stability, the machine must only be
rested on the points shown, inserting a block
(1)of
about 40 mm under the lower edge of the plate and
taking care not to damage the grass-catcher
mounts
(2).
WARNING! Before carrying out any type of work
make sure that the machine is completely sta-
ble, and avoid operations that could 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.
4/2005
140 mm
2 
						

							102 - 122
2.5.1
PRACTICAL HINTS





1 / 1
WORKSHOP MANUAL
page from 
2000to  ••••
2.5 PRACTICAL HINTS
A) Fitting snap rings
One side of the “Benzing” snap rings (1)has a
rounded edge and the other a sharp edge.
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)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
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© by GLOBAL GARDEN PRODUCTS
TC•
TX