Global Garden Products Lawn Mower 63 63M Instructions Manual

							© by GLOBAL GARDEN PRODUCTS
63
6.11.0- DISMANTLING AND REPLACEMENT OF
TRANSMISSION COMPONENTS




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WORKSHOP MANUAL
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6.11 DISMANTLING AND REPLACEMENT OF
TRANSMISSION COMPONENTS
NOTE
The following procedure refers to the complete dis-
mantling of the transmission unit elements, that is,
the gear change, the chain transmission and the dif-
ferential with axle shaft with supports. Your decision
as to whether to carry out some or all of the steps
below depends on the type and purpose of the
operation.
In any case, you need to …

Remove the transmission unit [see 5.5].
A) Dismantling and replacing the gear change
Remove the chain tightener (1), the “neutral” sig-
naller 
(2)and the gear change lever (3).
Unscrew the four nuts 
(4)and remove the gear
change, freeing the pinion from the chain.
On assembly, tighten the chain slightly by sliding
the stud bolts 
(5)along the bracket slots (6), then
tighten the nuts 
(4). Do not tighten the chain too
much, to allow the chain tightener
(2)to function.
B) Dismantling and replacing the supports
The central and left supports (11)are fastened to
the bracket by two screws 
(12)and their nuts (13).
The right-hand support can be positioned anywhere
on the axle shaft for fixing onto the frame.
Unscrew the nuts 
(13)and pull out the supports.
On assembly, check that the dust cover rings 
(14)
are intact and securely fitted in their seats. Put the
spacers 
(15)and (16)and the washers (17)back in
their positions.
C) Dismantling and replacing the brake disc

Remove the brake caliper [see  6.10].
Remove the chain tightener 
(21)secured by two
screws 
(22).
Unscrew the four nuts 
(23)securing the supports
12
232324
22
21
14
16
171517
1212
131113
1
23
44
4
4
5
56
6
56
3/2002 
						

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63
6.11.0- DISMANTLING AND REPLACEMENT OF
TRANSMISSION COMPONENTS




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WORKSHOP MANUAL
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3/2002
(24) and remove the whole axle, freeing the ring
gear from the chain.
The brake disc 
(25)is fastened onto the differential
by four nuts
(26). Undo the four nuts (26)without
loosening the four nuts underneath 
(27), which
secure the ring gear 
(28)and fix the two halves of
the differential box together
(29).
D) Dismantling and replacing the differential
and/or ring gear

Remove the brake caliper [see  6.10].

Remove the supports [see point “B”].

Remove the brake disc [see point “C”].
Undo the four nuts 
(27), which secure the ring gear
(28)and fix the two halves of the differential box
(29) together.
When handling the axle shaft and the differential,
take care not to open the two halves of the box
(29)
to prevent the internal components from slipping
out or being badly positioned.
E) Replacing the chain

Remove the gear change [see point “A”].

Remove the supports [see point “B”].
Before mounting the new chain, check that the pin-
ion and the ring gear are not worn or damaged. If
they are, replace them.
NOTE
It is generally advisable to replace the chain along
with the pinion and the ring gear.
Tightening torques
4Gear change nuts   ...................................... 8 Nm
13Support nuts  ............................................ 8 Nm
26Brake disc nuts  ...................................... 10 Nm
27Differential and ring gear nuts   ............... 10 Nm
2529
26
27
28 
						

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63
6.12.1
REPLACEMENT OF THE STARTER CABLE





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WORKSHOP MANUAL
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4/2005
6.12 REPLACEMENT OF THE STARTER CABLE
(➤Only in manual start models)
Remove the front mask (1)covering the housing of
the handle 
(2)of the starter cable (3).  
Pull out the cable terminal 
(3)from the handle (2)
and loosen the knot in order to free the cable.
Block the cable at the level of the engine using pli-
ers to prevent it from rewinding, and then pull it out
of the two drive pulleys 
(4)and(5 -➤only with a
B&S engine
).
Replace the cable following the procedures indicat-
ed by the engine manufacturer, then unwind it for a
length of approx. 90 - 100 cm and block it with pli-
ers so that it does not hinder the following opera-
tions.
Reposition the starter cable 
(3).
Ensure that the cable 
(3)is correctly wound around
the two drive pulleys 
(4)and (5 -➤only with a B&S
engine
), so that it is secured by the respective con-
tainment pegs.
Fit the end of the cable
(3)in the handle (2)and knot
it so that the handle cannot slip out.
3
3
5
2
1
4
3
1
32 
						

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63
7.1.2
TROUBLE-SHOOTING IN THE ELECTRICAL SYSTEM





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WORKSHOP MANUAL
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3/2006
7.1 TROUBLE-SHOOTING IN THE ELECTRICAL SYSTEM
Some problems related to the malfunctioning of the electrical system are shown
below, with their probable causes and the remedial action to be taken.
Should the problem continue after the necessary checks, seek assistance from your
local Service Centre.
Faulty electronic cards must always be replaced without trying to either repair
them or to replace single components.
START
ON
OFF
PROBLEM CAUSE SOLUTION
The battery is not supplying the cardCheck the connection cables and the battery
connector.
1. With the key in the
«START» position, the
starter motor lacks power
(poor starting)The battery is not supplying enough
currentRecharge the battery [see 7.8]
Badly earthed battery, or the starter
relay or motor not earthed
Starter relay is faulty
Check and put right
Check that the starter relay activates  [see
7.5]
Battery or card not earthed to frameCheck and put right
10 A fuse blownReplace fuse (10 A)
Battery terminal crossedCheck wiring.WARNING!In this case, the card is irrepara-
bly damaged and needs replacing since it is
no longer usable! The recharge circuit is also
damaged.
Check the battery’s condition [see 7.8]
2. With the key in the
«START» position, the
starter motor does not runStarting not permitted  [see summary
logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and the
relative wiring.
Fault in the electronic cardTry replacing the card with one that is known
to work
Starter relay is faultyCheck that the starter relay activates  [see
7.5]
3. The starter motor runs but
the engine does not startNo fuel flowCheck the stop cock and the fuel filter 
4. The starter motor contin-
ues to turn after engine
has started, and does not
stop when the key is
removedMechanical difficulties with the con-
tact breakers of the starter relayReplace the starter relay.
Starter works erratically for mechani-
cal or electrical reasons, taking exces-
sive current and causing binding of
relay contactsCheck the starter motor
Impaired starter systemCheck that spark plug caps are fastened
correctly
Check that the spark plug electrodes are
clean and that the gap is correct
➤In electric start models: 
						

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63
7.1.2
TROUBLE-SHOOTING IN THE ELECTRICAL SYSTEM





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3/2006
PROBLEM CAUSE SOLUTION
5. The starter motor oper-
ates as soon as the key is
in the «ON» position, and
can be turned off only by
removing the key
Insufficient chargeCheck that the charging cable has not
detached6. The engine stops while in
use
12. The engine stops while in
use
The safety devices have cut in or are
faultyCheck the functioning of the microswitches
and their wiring [see 7.3]
Accidental disconnection of an electri-
cal wireCheck all wiring
Starting of engine not permitted [see
summary logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and
their wiring.
The safety devices have cut in or are
faultyCheck the microswitch’s operation and the
relevant wiring [see 7.3]
Accidental disconnection of an
electrical wireCheck all wiring
Starting of engine not permitted [see
summary logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and the
relative wiring.
Check that there are no current leakages
caused by cables with damaged insulation
Check that the regulator is working properly
[see 7.7]
7. The 10 A fuse blowsShort circuit or overload on the power
side of the electronic card (start-up
unit, starter relay and recharger con-
nector)Find and replace the defective user [see 7.4
and 7.5]
➤In manual start models:
11. The engine does not startStarting not permitted  [see summary
logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and
their wiring.
Malfunction in the electronic cardTry replacing the card with one that is known
to work
No fuel flowCheck the stop cock and the fuel filter 
Impaired starter systemCheck that spark plug caps are fastened
correctly
Check that the spark plug electrodes are
clean and that the gap is correct.
Fault in the cardReplace the card
Starter block operating faultsReplace the block
Faults in the battery charging circuitCheck that the regulator is working properly
[see 7.7] 
						

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63
7.2.2- SUMMARY TABLE FOR THE CUTTING IN OF
THE SAFETY DEVICES




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WORKSHOP MANUAL
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7.2 SUMMARY TABLE FOR THE CUTTING IN OF THE SAFETY DEVICES
This table shows the various situations in which the safety devices cut in.
–/–    =    Uninfluential
➤In electric start models
A) STARTING («START» position)
OPERATOR GRASS-CATCHER BLADE TRANSMISSION PARKING ENGINE
Absent–/– –/– –/–DisengagedDoes NOT start
–/– –/– –/–Engaged–/– Does NOT start
–/– –/–Engaged–/– –/– Does NOT start
B) WHILE CUTTING
OPERATOR GRASS-CATCHER BLADE TRANSMISSION PARKING ENGINE
Absent–/– –/–Engaged–/– Stops
Absent–/–Engaged–/– –/– Stops
Absent–/– –/– –/–DisengagedStops
–/–Missing Engaged–/– –/– Stops
–/– –/–Engaged–/–EngagedStops
➤In manual start models
A) STARTING («START» position)
OPERATOR GRASS-CATCHER BLADE TRANSMISSION PARKING ENGINE
Absent–/–Engaged–/– –/– Does NOT start
–/– –/– –/–Engaged–/– Does NOT start
–/–Missing Engaged–/– –/– Does NOT start
–/– –/–Engaged–/–EngagedDoes NOT start
B) WHILE CUTTING
OPERATOR GRASS-CATCHER BLADE TRANSMISSION PARKING ENGINE
Absent–/– –/–Engaged–/– Stops
Absent–/–Engaged–/– –/– Stops
–/–Missing Engaged–/– –/– Stops
–/– –/–Engaged–/–EngagedStops 
						

							© by GLOBAL GARDEN PRODUCTS3/2006
63
7.3.2
SAFETY MICROSWITCHES OPERATION CHECK





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7.3 SAFETY MICROSWITCHES OPERATION
CHECK
➤In electric start models:
This check is made by detaching all the connectors
and using the Ohm-meter tester. This operation
should be done without the driver on board, by
making contact with the ferrules on the contacts of
the wiring connector 
(1)and should give this result:
No Contacts Tester reading and condition
“GRASS-CATCHER ATTACHED” MICROSWITCH
1 - 6 (CN1)∞(without g.catcher)O(with g.catcher)
SEAT MICROSWITCH
7 - 6 (CN1)∞(absent) O (seated)
BLADE MICROSWITCH
4 - 6 (CN1)∞(engaged) O (disengaged)
“IN NEUTRAL” SIGNALLER
8 - 4 (CN1)∞(drive) O (neutral)
PARKING MICROSWITCH
5 - 6 (CN1) O (out)∞(engaged)
STARTER UNIT
+ Battery  - 10∞(OFF) O (ON) O (START)
+ Battery  - 11∞(OFF)∞(ON) O (START)
ENGINE STOP
This operation must be done by making a bridge
between contacts 5 (CN1) of the wiring connector
(1) and the card connectors (2), so making contact
with the ferrules of the electronic card 
(2). You
should obtain the following result:
No Contacts Tester reading and condition
2 - Earthing to frameO(Always)
➤In manual start models:
This check is made by detaching all the connectors
and by using the Ohm-meter tester. This operation
should be done without the driver on board, by
making contact with the ferrules on the contacts of
the wiring connectors 
(3)and should give this result
No Contacts Tester reading and condition
“GRASS-CATCHER ATTACHED” MICROSWITCH
1 - 3 (CN1)∞(without g.catcher    O(with g.catcher)
SEAT MICROSWITCH
1 - 5 (CN1)∞(absent) O (seated)
BLADE MICROSWITCH
1 - 6 (CN1)∞(engaged) O (disengaged)
“IN NEUTRAL” SIGNALLER
1 - 4 (CN1)∞(drive) O (neutral)
PARKING MICROSWITCH
1 (CN1) - 2 (CN2)O(out)∞(engaged)
12
63
52
41
CN 1
CN 2
3126
4
32153
321
654
7
12 11 10
98
CN 1
2123
9658471110121
1
321
654
7
12 11 10
98
CN 1
123
965847111012 
						

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63
7.4.2
TERMINAL BOARD SUPPLY CHECK





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3/2006
7.4 TERMINAL BOARD SUPPLY CHECK  (➤Only
in electric start models)
Check that the battery connector (1)is connected
correctly.
–The key in the «ON» position
This check is done with the Voltmeter tester (Volt
DC 0 - 20), with the red ferrule on terminal 10 and
the black one on terminal 6 of the wiring connector
(2).
The reading shows the battery voltage, which
should never go below 11 Volts.
1
321
654
7
12 11 10
98
CN 1
123
965847111012
2
1 
						

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63
7.5.2
STARTER RELAY OPERATION CHECK





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WORKSHOP MANUAL
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3/2006
7.5 STARTER RELAY OPERATION CHECK
(➤Only in electric start models)
WARNING! - Remove the cap of the sparking
plug, since the safety systems that normally pre-
vent accidental starting of the engine are cut out
when the checking procedure is carried out.
To do this requires:
- engaging the parking brake;
- disengaging the blade;
- the key in the «ON» position.
Disconnect connector CN1. On making a bridge
between terminals 10 and 9 of the wiring connector
(1), you should hear the click of the relay bobbin
and the starter motor should come into action.
If the relay clicks but the starter motor does not go,
make a bridge 
(2)with a large section cable (5 mm2)
between the power contacts of the relay.
If the starter motor comes into operation, look for
the fault in the relay or replace it.
2
1
321
654
7
12 11 10
98
CN 1
123
965847111012 
						

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63
7.6.2
ELECTRONIC CARD OPERATION CHECK





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WORKSHOP MANUAL
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7.6 ELECTRONIC CARD OPERATION CHECK
(➤Only in electric start models)
Safety and service supply check
This check is done by positioning a jumper between
terminal 10 of the wiring 
(2)and terminal 10 of the
card 
(1)in order to supply power to the card.
- The key in the «ON» position.
With the Voltmeter tester (Volt DC 0 ÷ 20), earth the
black ferrule and the red one on terminals 4 - 5 - 7 -
8 of the wiring connector 
(1). In every case, the
tester should indicate the battery’s voltage. 
This value should never go under 11 Volts.
321
654
7
12 11 10
98
CN 1
1123
965847111012
3/2006