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Gianni Ferrari PG 180 Diesel User Manual

Gianni Ferrari PG 180 Diesel
65 pages
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MANUALE PER I CENTRI DI ASSISTENZA
WORKSHOP MANUAL
MANUEL D’ATELIER
KUNDENDIENSTHANDBUCH

Table of Contents

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Gianni Ferrari PG 180 Diesel Specifications

General IconGeneral
Engine TypeDiesel
Power18 HP
Engine Power18 HP
Cylinders3
TransmissionHydrostatic
Drive4WD
Width1100 mm
Length2300 mm

Summary

Gianni Ferrari Workshop Manual

Introduction and General Information

Main Maintenance Operations Overview

Maintenance Task Frequency

Overview of primary maintenance tasks and recommended service intervals.

Play Green Anchorage Points

Chapter 01: Disassembling the Mowing Deck

Remove Deck Fixing Pin

Slip out pin 01A which fixes the deck to the anchorage point.

Remove Mowing Deck

Slip out mowing deck 02A from the PLAY GREEN.

Chapter 02: Assembling the Mowing Deck

Attach Mowing Deck Arms

Approach deck, slip tool-holding arms 01A-01B into seat.

Couple Drive Shaft Connectors

Couple female plug 02B with male plug 02A for perfect connection.

Insert Deck Fixing Pin

Insert eye pin "R" 05A fixing deck to tool-carrying arm.

Chapter 03: Dismantling Front Body Panels

Remove Front Left Body Panel

Unscrew lever knobs (1-2-3), air filter (4), and fixing screws (5).

Remove Front Right Body Panel

Loosen fixing screws (1-2), remove electric plugs (3).

Chapter 03: Dismantling Rear Body Panels

Remove Rear Left Body Panel

Loosen fixing screws (1-2-3).

Remove Rear Right Body Panel

Loosen fixing screws (1-2-3).

Chapter 03: Dismantling Middle Panel and Hopper

Remove Middle Body Panel

Lift hopper (1) and slip out the middle body panel.

Remove Hopper

Dismantle the hopper by removing screws and parts.

Chapter 04: Assembling Front Body Panels

Assemble Front Left Body Panel

Fix screws (1), position lever knobs (-2-3-4), and air filter (5).

Assemble Front Right Body Panel

Tighten fixing screws (1-2), connect electric terminals (3).

Chapter 04: Assembling Rear Body Panels

Assemble Rear Left Body Panel

Position and fix screws (1-2-3).

Assemble Rear Right Body Panel

Position and fix screws (1-2-3).

Chapter 05: Replacing Hydrostatic Drive Belt

Relieve Belt Tension

Lift belt tightener 01A to relieve tension on belt 01B.

Remove Hydrostatic Drive Belt

Remove belt 03A from pulley 03B.

Chapter 06: Adjusting PTO Belt Tension

Position PTO Lever

Position the PTO lever as indicated in the figure.

Adjust Belt Tension Nuts

Turn adjusting nuts 07A - 07B and rotate pulleys.

Chapter 07: Replacing Engine Belt

Remove Belt Tightener Spring

Using a tool, remove spring 09A of the belt tightener.

Remove Engine Belts

Slip belts 10A from pulley 10B.

Chapter 08: Replacing Turbine and PTO Belts

Remove PTO Lever Tie-rod

Remove pin 11A and slip out tie-rod of PTO lever cable.

Remove Turbine Belts

Use lever 15A to force plate 15B and remove belts 15C.

Chapter 09: Belt Tightener Pulley Procedures

Remove Pulley Fixing Screw

Loosen screw 01A fixing pulley 01B to turbine side.

Remove Internal Pulley Components

Remove components inside pulley, respecting sequence shown in Fig. 03.05.

Chapter 10: Replacing Turbine Rotor

Locate and Remove Turbine Lid Screws

Locate 6 screws 02A holding turbine lid and remove them.

Check Rotor Wear

Check wear condition of rotor 04A and replace if necessary.

Chapter 10: Turbine Rotor Removal Steps

Unlock Rotor from Shaft

Use plastic hammer 07A to unlock rotor 07B from shaft 07C.

Check Shaft, Bush, and Bearing

Check thread of shaft 09A, conical bush 09B, and bearing 09C.

Chapter 11: Turbine Pulley Procedures

Chapter 12: Replacing Cardan Protection

Disassemble Cardan Protection

Loosen nut 12A, slip pulley 12B, remove pin 12C, remove protection 12D.

Reassemble Cardan Protection

Insert shaft 12H, position seeger 12G, position protection 12D, insert pulley 12B, tighten nut 12A.

Chapter 15: Steering Plate Disassembly

Remove Chain Link

Locate and unfasten fake link 01A of the chain 01B.

Phase Pinion and Crown

Ensure pinion and crown are phased by matching hole 03A and tooth 03B.

Chapter 15: Steering Plate Disassembly Steps

Disassemble Pinion and Supports

Loosen screws 06B fixing supports 06C to plate 06D.

Replace Bearings

Replace bearings 07A, remove seeger 07B.

Chapter 15: Steering Plate Disassembly Steps (Continued)

Remove Support Seeger

To remove support 12A, remove seeger 12B.

Dismount Shim Seeger

Dismount shim o-ring 13A.

Chapter 15: Steering Plate Assembly Steps

Position Shim Seeger

Position shim o-ring 16A.

Fix Steering Plate

Position plate 18A on support 18B, insert screws 18C, lock using hole 18D.

Chapter 16: Adjusting Braking Distance

Reduce Braking Distance

Loosen nut 21A, tighten nut 21B, adjust spacers 21C/21D, lock nut 21A.

Adjust Neutral Pedal Position

Loosen nut 21F, adjust nut 21G, lock nut 21F.

Chapter 17: Greasing Operations

Grease Indicated Points

Regularly grease points indicated on Fig. 01.17, 02.17, and 03.17.

Assemble Gear Pump to Gear Box

Remove oil seal 04A, join pump 04C to box 04D with screws 04E, insert seal 04F.

Chapter 17: Air Filter and Battery Maintenance

Maintain Air Filter

Unscrew nut 04A, open filter, clean filter, reset microswitch.

Maintain Filter Cartridge

Loosen fixing knob 06A or hook 07A to access filter cartridge.

Chapter 17: Radiator Grille Maintenance

Remove Radiator Grilles (3-Wheel)

Move control rod 07C to remove grilles 07A-07B.

Clean Radiator Grilles (4-Wheel)

Remove radiator grid and clean regularly.

Chapter 17: Belt Tensioner Maintenance

Replace Turbine Belt Tensioner Pulley

Slip out pin 09A to replace turbine belt tensioner pulley.

Position and Fix Turbine Tensioner

Position and fix turbine tensioner pulley with pin 11A.

Chapter 17: Wheel Hub and Lifting Arm Maintenance

Replace Wheels

Loosen 4 screws 13A to replace wheels on wheel hub.

Check/Replace Drive Shaft Pin

Check efficiency of pin 15A and replace if necessary.

Chapter 18: Electrical System (Briggs & Stratton)

Access Electrical Box

Loosen two screws 13A, lift lid 13B, unlock terminal 13C for maintenance.

Briggs & Stratton Fuse Box Details

Detail of fuse box for Briggs & Stratton engine.

Chapter 18: Electrical System (Kohler)

Kohler Engine Electrical Box

Detail of electrical box for Kohler petrol engine.

Kohler Fuse Box Details

Detail of fuse box for Kohler petrol engine.

Chapter 18: Electrical System (Lombardini)

Lombardini Engine Electrical Box

Detail of electrical box for Lombardini diesel engine.

Chapter 18: Electrical System (Kubota)

Kubota Engine Electrical Box

Detail of electrical box for Kubota diesel engine.

Chapter 18: Microswitch Diagnostics (PTO)

Check PTO Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Check Hopper Full Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Chapter 18: Microswitch Diagnostics (Brake, Seat, Hopper, Motor)

Check Brake Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Check Seat Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Check Hopper Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Check Motor Compartment Microswitch

Activate microswitch; if display shows no message, it's damaged and needs replacement.

Chapter 18: Error Code Display (Lombardini)

Error Codes E1-E4 (Initial Test)

Displays error codes for initial test phase related to sensors.

Error Codes E10-E24 (Operating Cycle)

Displays error codes for operating cycle related to safety tests.

Error Code E30 (Water Temp.)

Error code for engine exceeding 115°C water temperature.

Error Code E31 (Lombardini)

Error code for full hopper or clogged air filter on Lombardini.

Error Codes CC1-CC3 (Short Circuits)

Error codes for short circuits in glow plug, engine stop, or buzzer circuits.

Chapter 01: Disassembling Blade Disc

Remove Cutting Blades

Loosen nuts 01A to remove cutting blades from disc.

Remove Center Element

Remove center element 02A from blade-carrying dish 02B.

Chapter 02: Disassembly of Driving Gears

Remove Wheel Carriage

Remove wheel carriage 01A from deck by slipping out pins 'R' 01B.

Remove Upper Guards

Remove screws 02A fixing upper guards of mowing deck.

Remove Driving Unit

Remove driving unit 05A and divide into two half-units 05B-05C.

Chapter 03: Disassembling Blade Disc (Continued)

Remove Cutting Blades

Loosen nuts 01A to remove cutting blades from disc.

Remove Center Element

Remove center element 02A from blade-carrying dish 02B.

Chapter 04: Assembling Blade Driving Unit

Couple Driving Shafts

Ensure shaft seats A and B are orthogonal at 90° and join shafts.

Position Driving Unit on Deck

Position driving unit in its seat on the mowing deck.

Fix Cardan Shaft

Fix cardan shaft by locking screw 03A.

Chapter 05: Assembling Blade Disk

Assemble Cutting Blades

Tighten nuts 01A to assemble cutting blades on disc.

Assemble Center Element

Assemble center element 02A on blade-carrying dish 02B.

Chapter 06: Assembling Blade Disk on Mowing Deck

Position Mowing Deck

Place mowing deck in suitable position for comfortable work.

Position Blade Disk on Shaft

Position blade disk on driving shaft, aligning deck seat with shaft seat.

Mount Blades Orthogonally

Mount blades 90° orthogonal to each other for perfect functioning.

Chapter 01: Elevator Preparation and Assembly

Lift Hopper and Remove Panel

Lift hopper and remove the center body panel.

Remove Hopper Lifting Cylinder Pin

Slip out fixing pin 03A for hopper lifting cylinder 03B.

Remove Hopper Fixing Screws

Slip out screws 04A fixing hopper to frame and remove hopper 03B.

Chapter 01: Elevator Mounting Steps

Prepare Machine Body for Elevator

Prepare machine body 06A with two fixing plates 06B for elevator.

Position Elevator on Machine Body

Position elevator on Play Green body using lifting points shown in Fig. 07.01.

Fix Hopper to Elevator

Fix hopper to elevator using points 09A and connect terminals 09B.

Chapter 02: Hydraulic Connection Preparation

Disconnect Ventil Pipes

Disconnect all pipes from the 2-way ventil and remove unused hopper pipes.

Replace Hydraulic Distributor

Replace 2-way ventil/PTO lever 02A with new 3-way distributor/lever 02B.

Chapter 03: Hydraulic Connection

Connect Elevator Hydraulic Pipes

Connect hydraulic pipes for the elevator according to the provided scheme.

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