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

							102 - 122
3.1.1
CRITERIA FOR MAINTENANCE





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WORKSHOP MANUAL
page from 
2000to  ••••
4/2005
3.1 CRITERIA FOR MAINTENANCE
The Instruction Handbook has a number of operations to be carried out by the Customer for a minimum of
basic maintenance, and other operations not always within his capacity.
For this reason the Service Centre should undertake to keep the machine in perfect working order in two
ways:
a)Tuning the machine whenever possible.
b)Proposing a regular maintenance programme to the Customer to be carried out at prearranged intervals
(for example, at the end of the summer or prior to a long period of inactivity).
a) Occasional tuning
–Check working order of safety devices and renew  illegible or missing labels
–Check tyre pressures
–Clean air filter
–Check engine oil level
–Check for fuel leaks
–Aligning the cutting deck
–Sharpen and balance the blades and check the condition of the hubs
–Check for wear in the belts
–Check the blade brake engagement
–Grease front wheels lever joint pins and bushes
–Check tightness of engine screws
–Check all those items indicated in the engine manual
b) Routine maintenance
–All work carried out in section a), plus:
–Check battery charge
–Check tension of belts
–Adjust drive engagement 
( ➤mechanical drive models)
–Adjust brake
–Adjust blade engagement
–Adjust blades brake
–Check steering allowance
–Check front bearings
–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
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102 - 122
4.1.0
BLADE ENGAGEMENT ADJUSTMENT





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WORKSHOP MANUAL
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2000to  ••••
4.1 BLADE ENGAGEMENT ADJUSTMENT
The blades are moved by the engine by means of
a “V” belt and are engaged by a stretcher operat-
ed by the lever  ( 
➤in models with lever eoperated
ngagement) or by a combined clutch/brake group
( 
➤in models with electromagnetic engagement).
After a certain amount of use, the belt and the
cable can change in length ( 
➤in models with
lever engagement) which can result in malfunc-
tioning, i.e.:
–belt slipping = belt or cable stretched
–difficulty in disengaging, with a stiff lever and
the blades continuing to run = belt shortened
In both cases the stretcher needs to be adjusted.
With the cutting deck in the lowest position, identify
the adjuster 
(1)located under the left footboard and
suitably turn the nuts until, with the blades
engaged, the length of spring 
(2)equals «A», which
varies depending on the different versions of the
machine, that is:
122 ÷ 124 mm- for mod. 102 - lever operated
engagement
92,5 ÷ 93,5 mm- for mod. 122 - lever operated
engagement
113 ÷ 115 mm- for mod. 102 - electromagnetic
engagement
90 ÷ 91 mm- for mod. 122 - electromagnetic
engagement
NOTE
The coupling position of spring(2)on the plate (3)is
different for model 102 (hole 
3a) and model 122 (3b
-  
single hole in the plate).
3/2002
3b
3a
3
2
1
A
2 
						

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102 - 122
4.2.0
BLADES BRAKE ADJUSTMENT





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WORKSHOP MANUAL
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4.2 BLADES BRAKE ADJUSTMENT
Disengaging the blades causes a brake to come
into action. This is to stop the blade turning within
five seconds.
Longer braking times do not comply with safety
regulations, but adjusting the brake so that it
stops more quickly than this can cause premature
wear of the brake pad ( 
➤in models with lever
operated engagement) or the slipping of the belt
on the pulleys, resulting in overheating and the
typical smell of burnt rubber.

Check that the engagement spring is adjusted
to the right length [see 4.1].
Correct brake operation must ensure that the
blades stop within 5 seconds of disengagement.  
If this is not the case:
➤For models with lever operated engage-
ment: 
check that the brake pad (1)is not worn.
➤For models with electromagnetic clutch: 
since this problem is due to malfunction of the
electromagnetic clutch, the clutch must be
replaced if the checks described [see 7.3 and
7.7] do not lead to any improvement.
3/2002
1 
						

							102 - 122
4.3.0
BRAKE ADJUSTMENT 





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WORKSHOP MANUAL
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2000to  ••••
4.3 BRAKE ADJUSTMENT
Reduced braking power is corrected by adjusting
the spring on the brake rod, which is reached
through the inspection hatch beneath the seat.
The adjustment is to be made with the parking
brake engaged and consists of altering the length of
the spring 
(4)to the best measurement. The braking
capacity is increased by screwing the nut 
(3)down
on the rod (and thus shortening the length of the
spring).
Loosen the nut
(1)which holds on the bracket (2)
and turn the nut (3)until the length of the spring (4)
is: 
A=47.5 ÷ 49.5 mm ➤For mechanical drive mod-
els 
B=45 ÷ 47 mm➤For hydrostatic drive models:  
measured from the inside of the washers.
When the adjustment has been made, tighten the
nut
(1).
Never go under these amounts to avoid overloading
the brake unit.
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.
➤In mechanical drive models: 
If braking is still poor or unsteady even after mak-
ing the adjustment, remove the control rod
(5)
from the lever (6)and check that the latter has an
idle stroke of 20 mm (measured on the vertical in
correspondence with the pin axis) before braking
starts; otherwise the idle stroke can be adjusted
using the screw 
(7), unless the brake pads or disc
are so worn that they need replacing [see 6.11].
When connecting the rod
(5)be sure to use the
lower hole in the lever(6)and then check the
length of the spring again
(4).
76
20
mm
3/2002
5
6
1
2
3
B
4
A
3
2
1
4
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							102 - 122
4.3.0
BRAKE ADJUSTMENT 





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WORKSHOP MANUAL
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3/2002
➤In hydrostatic drive models
If braking is still poor or unsteady even after making the adjustment, you cannot make any further adjust-
ments from the outside. Therefore you need to dismantle the whole rear axle of the machine [see 5.6] and
contact one of the manufacturer’s Service Centres
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102 - 122
4.4.0
DRIVE BELT ADJUSTMENT





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WORKSHOP MANUAL
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4.4 DRIVE BELT ADJUSTMENT
If it seems that the forward drive is not working
properly after a long period of use or after replac-
ing the belt, this may be caused by a change in the
length of the belt.
–A loose belt reduces output from the drive and
limits forward movement power;
–a belt which is too tight increases noise and
results in jerky movements or tipping up when
engaging the drive.
In these cases the stretcher will need to be adjust-
ed.
The stretcher can be accessed from the inspection
hatch beneath the seat; adjust the tension of spring
(1)using nuts(2)to set length «A» of:
–114 ÷ 116 mm 
➤in mechanical drive models
–109 ÷ 111 mm ➤in hydrostatic drive models
measured from the outer ends of the springs with
the drive commands disengaged.
Following adjustment, fully tighten the nuts
(2)and
the locknut 
(3).
3/2002
2
A
1
3 
						

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4.5.0
DRIVE PEDAL ADJUSTMENT





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WORKSHOP MANUAL
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4.5 DRIVE PEDAL ADJUSTMENT 
(➤Hydrostatic drive models)
This operation should be carried out every time
the rear axle, pedal or control rod is removed, in
order to get the correct travel for the pedal and to
reach the envisaged speeds both forwards and in
reverse.
A) Adjusting the pedal in the “neutral” position
The pedal position is to be adjusted starting with
the lever 
(1)of the hydrostatic unit in the “neutral”
position. This position «
N» is easily recognised,
since it is held fast by a check ball.
The pedal
(2)is in the ideal position when the lever
(1)of the hydrostatic unit is “neutral”, and the lower
rubber edge 
(3)on the reverse side is 24 -27 mm
from the footboard.
This is obtained by opening the inspection hatch
beneath the seat and by turning the nuts
(4)appro-
priately until the required measurement is reached.
Take care not to accidentally modify the position of
the lever
(1)during the adjustment.
B) Adjusting the “neutral” position of the micro-
switch
IMPORTANT!
This is a very important adjustment for the cor-
rect operation of the safety devices for starting
and stopping of the machine during work.
The “neutral” position «N» is indicated by the
microswitch 
(5)of the cam (6), which is reached by
the inspection hatch beneath the seat.
After having ensured that adjustment “
A” has been
made correctly, with the pedal released and thus in
neutral position «
N», slacken off the microswitch
fixing screws 
(7)and position it in line with the tip of
the cam, so that it remains pressed [see 7.11].
By moving the pedal in the forward, neutral and
reverse positions, make sure that the push-button
clicks at every position change before the wheels
start moving.
6
5
7
7
3/2002
4
4
2
24 - 27 mm3
1
N
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							102 - 122
4.6.0
ALIGNING THE CUTTING DECK





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WORKSHOP MANUAL
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4.6 ALIGNING THE CUTTING DECK
Lowering of the cutting deck is controlled by a
linkage operated by the lever and is guided by two
front articulation connecting rods.
In order to get a good cut it is essential that the
cutting deck is parallel with the ground crosswise,
and slightly lower at the front.
Two types of adjustment are possible:
a)combined adjustment to the parallel and mini-
mum front and rear height, to be done in the
case of cutting irregularities;
b)longitudinal deck position adjustment, only
needed if the original position was lost during
cutting deck replacement and the correct dis-
tance from the engine pulley must be reset.
Check the tyre pressures. If one or more tyres have
been replaced or you find differences in diameter,
do not attempt to compensate these differences
by giving different tyre pressures
, but make the
adjustments as in point “
A”.
A) Combined adjustment to the parallel and the
minimum front and rear height
Put the machine onto a flat and stable surface (such
as a work bench) and put blocks beneath the cut-
ting deck in line with the centre lines of the blades:
–at the front 26 mm  
(1)# code 60700000/0,
–at the rear 32 mm 
(2)# code 60700001/0;
then set the lifting lever to position «1» and slacken
off the nuts
(3), screws (5)and locknuts (4 - 6)on
both the right and left hand sides, so that the deck
rests firmly on the blocks.
Turn both the rear screws
(5)until the rear of the
deck begins to rise both at the right and the left,
and then tighten the relevant locknuts
(6).
Push the two connecting rods
(7)to the back and
screw down the two nuts
(3)on each rod until the
front part of the deck just begins to rise both at the
right and the left, and then tighten the relevant lock-
nuts
(4).
B) Adjustment of the longitudinal position
Put the machine onto a flat and stable surface (such
11
A
11a
3/2002
6
5
3
7
4
10
988
B
1 - h = 26 mm
2 - h = 32 mm
1 - 2
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							102 - 122
4.6.0
ALIGNING THE CUTTING DECK





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WORKSHOP MANUAL
page from 
2000to  ••••
3/2002
as a work bench) and put blocks beneath the cutting deck in line with the centre lines of the blades:
–at the front 26 mm 
(1)# code 60700000/0,
–at the rear 32 mm 
(2)# code 60700001/0;
then set the lifting lever to position «1» and slacken off the nuts
(3), screws(5)and locknuts(4 - 6)on both the
right and left hand sides, so that the deck rests firmly on the blocks.
Slacken off the nuts 
(8)and locknut (9)of the two front connecting rods (10)and adjust nuts(8)of the front left
connecting rod to set the exact distance «
A» of:
–489 mm (mod. 102)
–474 mm (mod. 122) 
between the centre of the engine pulley hub and the centre of the left blade shaft.
This operation is facilitated by using the checking caliper 
(11)# code 60205000/0 illustrated in chap. 8.3, suit-
ably positioning the engine side terminal
(11a)depending on whether the electromagnetic clutch is present or
not.
Distance «
B» is set by using the corresponding front right connecting rod nutsto obtain the same measure-
ment, so that the outlet is perfectly centred with respect to the collector channel
; then fully tighten the
nuts 
(8)and locknut (9).
NOTE
It is very important that distance «B» is the same on both the left and right hand sides, to prevent the belt from
rubbing against the collectorn channel.
Turn both the rear screws 
(5)until the rear of the deck begins to rise both at the right and the left, and then
tighten the relevant locknuts
(6).
Push the two connecting rods
(7)to the back and screw down the two nuts(3)on each rod until the front part
of the deck just begins to rise both at the right and the left, and then tighten the relevant locknuts
(4).
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							102 - 122
4.7.1
STEERING ALLOWANCE ADJUSTMENT





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WORKSHOP MANUAL
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2000to  ••••
4.7 STEERING ALLOWANCE ADJUSTMENT
The steering allowance should never be excessive
if driving is not to be impaired.
Check that the movement is not caused by loose
linkage nuts and tighten all the nuts of the tie-rods
and ball joints.
If the movement is due to the ring gear / pinion cou-
pling, it will be necessary to adjust the arrangement
of the set of blocks between the ring gear and the
frame.
Release the spring
(1)and lift the steering column
(2) enough to be able to draw out the pinion(3).
Undo the nut
(4)and take out the whole ring gear
shaft
(5) without dismantling the tie-rod(6).
Take away one or both of the blocks 
(7)under the
ring gear depending on the amount of free play to
be reduced.
Reassemble the pinion and the ring gear shaft, lin-
ing up the two reference points ( 
➜- ) punched
on them, and making sure that the notch
(8) on the
frame slots into one of the housings in the bush.
Put the whole assembly back together and fully
tighten the nut 
(4).
If the movement is still there after having removed
all the spacers, check and, if necessary, replace the
ring gear/pinion unit [see 6.3], or look for other pos-
sible causes.
Tightening torque
4Nut for Ring gear  ............................ 45 ÷ 50 Nm
4/2005
14
8
7
5
3
5
6
2
1
4
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