Global Garden Products Lawn Mower 72 72 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. 7.0YEAR OF MANUFACTURE 2006
7 7 7 7
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h h h h
y y y y
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o o o o 
						

							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.
GENERAL INDEX
1.1
1Identification and procedures
2.11Safety regulations
2.21Tools
2.31Lifting
2.41Placing the machine on its side 
2.51Opening the wheel cover
2.61Practical hints
3.11Criteria for maintenance
4.11Blade engagement adjustment
4.21Blade brake adjustment
4.32Brake adjustment
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.
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INDEX





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							4.41Drive belt adjustment (➤mechanical drive models)
4.52Drive lever adjustment (➤hydrostatic drive models)
4.60Aligning the cutting deck
4.70Steering allowance adjustment
4.80Steering geometry adjustment
4.90Check on blade alignment 
4.101Sharpening and balancing of the blade
4.110Adjustment of the collector channel guide
5.11Removal of the steering column protection cover 
5.20Removal of the footboard
5.32Removal of wheels covers
5.41Removal of the rear plate
5.50Removal of the collector channel
5.61Removal of the engine
5.73Removal of the rear axle
5.81Removal of the cutting deck
6.10Replacement of tyres and wheels
6.20Replacement of front wheel bearings
6.30Replacement of steering components
6.40Replacement of drive belt
6.51Replacement of the blade belt
6.60Replacement of the support and shaft of the blade
6.70Replacement of the accelerator
6.81Replacement of the brake pads and disc
6.91Replacement of the drive lever unit (➤hydrostatic drive models)
6.100Replacement of the lever return cable (➤hydrostatic drive models)
6.110Replacement of the friction discs in the clutch device (➤hydrostatic drive models)
7.12Guide to the identification of problems in the electrical system
7.21Summary table for the cutting in of the safety devices
7.32Safety microswitches operation check
7.42Terminal board supply check
7.52Starter relay operation check
7.62Electronics card operation check
7.72Recharge circuit check
7.81Care and maintenance of the sealed battery
7.91Fitting safety microswitches
7.103Electrical diagrams
8.11Summary of tightening torques
8.22Summary of main assembly amounts and checks
8.30Special tools
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							INTRODUCTION
This manual has been compiled to help Service
Centres with the maintenance, dismantling and
repair of the following versions of “Rider” 72 riding
mower:
– 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.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.


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INTRODUCTION





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there is a free play of 0.5 mm between the shoe (10)
and the release rod (11).
C) Adjusting the clutch device
When in motion, the lever is held in the selected
position by a clutch device which is made up of a
sliding sector (12)between two friction discs (13),
pressed together by a spring (14).
The spring tension (14)is adjusted at the nut (15)
until a length of 18 mm is obtained with the pedal
released.
Check that the friction discs (13)are in good condi-
tion and with no traces of oil. Otherwise replace
them [see 6.11]. 
D) Adjusting the lever return cable

Lift the wheels cover [see 2.5].
With the control lever in the “neutral” position and
the pedal released.
Check the length of the spring (16)and regulate the
adjuster (17)until a length of 74 - 76 mm is obtained
measured from the outside of the eye-rings.
When this adjustment has been made, with the
parking brake engaged, there should be free play of
0.5 ÷ 1 mm between the lever (18)and the limit stop
(19).

Close up the wheels cover [see 2.5].
E) Adjusting the limit stop position of the levers
If the stop hook has been dismantled or replaced,
the position of the terminal (20)will need to be
adjusted compared to the levers (21)and (22).
This must be a position which prevents the terminal
(20) from interfering with the swinging movement of
the lever (21)and blocking the lever (22)at the
same time. 

Lift the wheels cover [see 2.5].
Put the control lever in “neutral” and engage the
parking brake.
2120
22
190,5 - 1 mm
18
16
74 - 76 mm17
18
mm
131214
15
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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].
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2.1.1
SAFETY REGULATIONS





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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: 
–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
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2.2.1
TOLLS





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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 ÷ 5)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 ÷ 5)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 blade bearings
4.Stopper for assembly of wheel bearings
5.Pulley extractor
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4
5 
						

							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.
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2.4.1
PLACING THE MACHINE ON ITS SIDE





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2.4 PLACING THE MACHINE ON ITS SIDE
WARNING! Two people will be needed for this
work. 
When moving the machine onto its side it should
only be gripped at strong parts (steering wheel,
seat, frame, etc.) and NEVER by the plastic parts
of the body.
The fuel tank must be totally emptied before placing
the machine on its side.
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.
The machine must only be laid on its right hand
side, resting the seat 
(1)and one of the corners of
the grass-catcher 
(2)as shown. When doing this,
firmly grip the steering wheel and the seat and tip
the machine over until it is resting on the grass-
catcher, taking care not to damage the body’s plas-
tic parts.
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.
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2.5.1
OPENING THE WHEEL COVER 





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2.5 OPENING THE WHEEL COVER
The engine and the mechanical units can be
reached by turning back the wheel cover
(1).
There are specific indications for opening the cover
which are shown below and also in the instruction
handbook.
Remove the grass-catcher or stoneguard and move
the machine to a flat floor. Raise the cutting deck to
its maximum height and place blocks 
(2)of about
65 – 70 mm beneath its edge in order to support the
deck during subsequent operations.
➤ Mechanical drive models:engage the park-
ing brake;
➤ Hydrostatic drive models:put the drive
release lever in the «ENGAGED» position. This is
because the parking brake needs to be disen-
gaged to ensure the necessary movement to the
speed lever.
Unscrew the knob on the lever 
(3)and ...
➤ In mechanical drive models:put it into neu-
tral «N»
➤ In hydrostatic drive models:put it into posi-
tion «R»
Open the access hatch 
(4)and unscrew the nut (5)
with a 13 mm spanner. 
Release the lever 
(6)so that the deck rests on the
blocks, and keep it held to the side so that it does
not slip into any of the notches. Grip the base of the
seat 
(7) and turn back the cover.
When closing, make sure that the channel 
(8)is
properly fitted onto the support 
(9)and resting on
the right-hand guide. Put the lever 
(3)into position
«R» and lower the cover 
(1) at the level of the levers
(3)and (6).
First put the lever 
(6)into its housing, and then lever
(3), lower the cover until it centres on the fixing
screw.
If this has been done correctly and the guide
(9)is
properly positioned, the opening of the channel will
easily slip into the hole in the plate 
(10) without any
need to guide it in manually.
8
8
9
10
7
10
8
6
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5