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Global garden products 63 - User Manual

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The Manufacturer reserves the right to make any necessary improvements to the product of a technical or
commercial nature. There may be, therefore, differences between the various series of machines and the infor-
mation given here, though the basic features and 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. 5.0
YEAR OF MANUFACTURE
2007
66
66
33
33
66
66
33
33
MM
MM
All brands, names, logos and
trademarks mentioned belong to
their respective owners.
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Summary

WORKSHOP MANUAL 63

Introduction to the Workshop Manual

Manual Symbols and Notations

Explanation of symbols used for warnings, references, and specific working methods within the manual.

Machine and Motor Identification

Machine Identification Details

Details on the machine's identification label, model, and serial number for repair requests and parts ordering.

Motor Identification Details

Information on the motor's technical specifications and serial number for requesting spare parts.

Guarantee Validity Information

Details on guarantee terms and conditions, including specific conditions for the engine.

Post-Guarantee Repair Reporting

Requirements for service centers to create repair reports, including serial number and parts used.

Fault Reporting Procedure

Manufacturer's process for receiving and acting upon recurring fault notifications.

Spare Parts Ordering Process

Procedure for requesting spare parts, emphasizing the need for code numbers and identification details.

General Safety Regulations

Operator Qualification Requirements

Specifies that maintenance must be done by expert mechanics familiar with safety regulations.

Mandatory Safety Measures

Details checks for safety devices, covers, and labels to maintain machine safety standards.

Servicing Precautions and Best Practices

Recommendations for safe servicing, including disconnecting power, using gloves, and avoiding hazards.

Required Tools and Equipment

Information on standard tools and any special equipment required for operations.

Safety Symbols and Terminology

Defines symbols and terms used to highlight critical safety information and warnings.

Tools and Special Equipment

Recommended Tools for Maintenance

Lists standard workshop tools and specific special tools required for various procedures.

Lifting Procedures

Front Lifting Method

Instructions for safely lifting the machine from the front using a jack and wooden block.

Rear Lifting Method

Instructions for safely lifting the machine from the rear, including securing wheels.

Vertical Machine Positioning

Vertical Positioning Steps

Detailed steps for safely positioning the machine vertically for easier access to lower parts.

Practical Maintenance Hints

Snap Ring Installation Guide

Guidance on the correct orientation and fitting of 'Benzing' snap rings for secure attachment.

Joint Pivot Pin Adjustment

Instructions for adjusting joint pivot pins to ensure free rotational movement without excessive play.

Crown Fastener Replacement

Advice on replacing damaged crown fasteners, emphasizing proper insertion and tool usage.

Maintenance Criteria and Programs

Machine Tuning Procedures

Describes tuning the machine whenever possible as part of maintaining optimal performance.

Customer Maintenance Program

Recommending a maintenance program to customers for prearranged intervals.

Occasional Tuning Checklist

Checklist of checks for occasional tuning, including safety devices, filters, oil, and blade.

Routine Maintenance Tasks

List of tasks for routine maintenance, encompassing items from occasional tuning plus battery, belts, and lubrication.

Blade Engagement and Brake Adjustment

Engagement System Check Steps

Procedure to check the control lever mobility and perform blade engagement adjustment.

Pedal Operation Check (Tecumseh)

Brake Adjustment Procedure

Brake Cable Adjustment Steps

Adjusting the control cable adjuster to regain reduced braking capacity and checking for wear.

Drive Engagement Adjustment

Drive Belt Stretcher Adjustment

Adjusting the stretcher to correct forward drive issues potentially caused by belt length changes.

Cutting Deck Alignment

Parallel and Height Deck Adjustment

Adjusting the cutting deck to be parallel crosswise and slightly lower at the front.

Deck Parallelism Adjustment

Compensating for differences in height between the left and right sides of the deck.

Steering Geometry Adjustment

Front Wheel Toe-in Check

Checking the exact toe-in by measuring the center distance of the connecting tie-rod.

Steering Wheel Alignment

Adjusting the tie-rod to ensure the steering wheel is straight when the machine travels straight.

Blade Alignment Check

Blade Alignment Measurement Steps

Procedure to check blade alignment using a metal rod and measuring distances to the ends.

Blade Removal, Sharpening, and Balancing

Blade Removal and Reassembly

Steps for dismantling and reassembling the blade, including torque specifications for nuts and bolts.

Blade Sharpening and Balancing

Instructions for sharpening both cutting edges and checking blade balance for vibration reduction.

Wheel Cover Removal

Components Accessible After Cover Removal

Identifies components like the fuel tank and steering gear accessible after removing the wheel cover.

Seat and Steering Column Dismantling

Steps for removing the seat, steering wheel column, and related components.

Pedal and Lever Dismantling

Procedure for removing pedals, parking brake handle, and blade engagement lever.

Accelerator Cable and Starter Unit Disconnection

Cover Securing Screw Removal

Instructions for removing the cover by undoing self-threading screws at different locations.

Collector Channel Removal

Collector Channel Removal Purpose

Explains that removing the channel is necessary for brake and drive engagement adjustments.

Cutting Deck Removal

Pre-Removal Steps for Cutting Deck

Includes removing collector channel, wheel cover, and emptying fuel tank before deck removal.

Engine Stop Connector Disconnection

Procedure for disconnecting the engine stop connector on electric start and manual start models.

Front Mask and Starter Cable Removal

Steps to remove the front mask and starter cable for manual start engines.

Guard and Drive Belt Component Removal

Drive Engagement Spring Release

Procedure to release the spring from the drive engagement mechanism.

Cutting Deck Detachment from Frame

Instructions for detaching the cutting deck using three trace rods, noting its weight.

Lifting the Cutting Deck

Refitting Cutting Deck and Adjustments

Reverse steps for refitting, checking joint pins, and performing necessary adjustments.

Engine Removal

Engine Removal Prerequisites

States that the engine can only be dismounted after removing the cutting deck and clutch.

Engine Securing Bolt Identification

Locating and undoing screws fastening the engine to the cutting deck, noting screw length variations.

Transmission Unit Removal

Transmission Unit Components

Describes the transmission unit as comprising gear change, chain drive, differential, brake, and axle shaft.

Transmission Unit Removal Preparation

Includes removing the collector channel, positioning blocks, and dismantling rear wheels.

Control Rod and Cable Disconnection

Steps for disconnecting the gear change control rod and neutral signaller cables.

Transmission Unit Frame Fastening

Transmission Unit Refitting and Checks

Reverse steps for refitting, advisories on tie-rod repositioning, and final tightening.

Tyre and Wheel Replacement

Tyre Puncture Repair Procedure

Specifies that tyre repairs after puncture must be done by a specialist.

Wheel Replacement Steps

Instructions for removing wheels using a snap ring and reassembling with grease and spacer washer.

Tyre Pressure Specifications

Lists the recommended tyre pressures for the front and rear wheels.

Front Wheel Bush Replacement

Front Wheel Bush Removal

Steps for removing force-splined bushes using a round bar and hammer.

New Bush Insertion Method

Instructions for inserting new bushes using a mallet or pad, ensuring correct pin positioning.

Steering Component Replacement

Steering Component Removal Preparation

Includes removing wheel cover and positioning machine vertically for better visibility.

Pinion and Ring Gear Shaft Dismantling

Steps for unhooking the spring, lifting the column, and removing the pinion and ring gear shaft.

Steering Component Assembly Checks

Checks for anti-friction washers, pin alignment, and ring gear shaft nut tightening.

Blade Engagement Clutch Replacement

Blade Clutch Function and Faults

Explains the clutch's dual function and when to replace the outer clutch element due to wear.

Clutch Unit Removal and Dismantling

Steps for removing the guard, springs, brake bracket, and the entire clutch unit.

Clutch Friction Surface Check

Checking the friction surface for good condition, wear, and minimum thickness, with replacement advice.

Clutch Component Checks and Peg Fitment

Drive Belt Replacement

Drive Belt Removal Preparation

Positioning machine vertically, dismantling clutch, and removing pulley from engine shaft.

Freeing and Removing Drive Belt

Steps to loosen pulleys, free the belt, and remove it using the stretcher's idle pulley.

Accelerator Cable Replacement

Accelerator Cable End Disconnection

Disconnecting the wire from the accelerator lever and the carburetor lever.

Accelerator Cable Engine Connection

Connecting the wire to the engine terminal, ensuring correct 'STARTER' position.

Blade Engagement Cable Replacement

Blade Engagement Cable Loosening and Unhooking

Steps to loosen the adjusting nut, unhook the cable end from the control lever.

Protection Cover and Spring Removal

Removing the protection cover, releasing the spring, and pulling out the cable.

Brake Cable Replacement

Brake Cable Adjuster and Terminal Loosening

Loosening the adjuster and unhooking the control cable terminal from the lever.

Brake Cable Routing Position

Ensuring correct cable positioning to pass the tie-rod and fit the adjuster securely.

Drive Engagement Cable Replacement

Drive Engagement Cable Nut and Spring Loosening

Loosening the adjusting nut and unhooking the spring from the stretcher lever.

Drive Engagement Cable End Unhooking and Positioning

Unhooking the cable end from the pedal and positioning it correctly for routing.

Brake Pads and Lever Replacement

Brake Pad and Lever Replacement Preparation

Includes removing rear wheel, engine housing, and disconnecting control cable.

Brake Caliper Unit Removal

Steps for unhooking springs, removing snap rings, and pulling out the caliper unit pins.

Brake Pad Access and Cleaning

Undo nuts to reach pads, clean with solvent if oily, and check lever screw play.

Caliper Unit Remounting and Disc Checks

Transmission Components Dismantling and Replacement

Transmission Components Procedure Overview

Procedure refers to complete dismantling of gear change, chain, and differential, depending on operation type.

Gear Change Dismantling and Replacement

Steps for removing chain tightener, neutral signaller, gear change lever, and the gear change itself.

Support Dismantling and Replacement

Procedure for unscrewing and pulling out supports, checking dust cover rings and spacers on assembly.

Brake Disc Dismantling and Replacement

Steps to remove the brake caliper and chain tightener before unscrewing nuts securing the supports.

Differential and Ring Gear Removal

Chain Replacement Procedure

Steps for replacing the chain, checking pinion and ring gear wear, and advising replacement of related parts.

Starter Cable Replacement (Manual Start)

Starter Cable Front Mask and Terminal Removal

Removing the front mask and pulling out the cable terminal to free the starter cable.

Starter Cable Pulley Extraction

Blocking the cable at the engine and pulling it out of the drive pulleys.

Electrical System Troubleshooting

Troubleshooting Electric Start Motor Issues

Diagnosing problems like poor starting, no starter motor action, and starter motor not stopping.

Troubleshooting Engine Start Failures

Diagnosing why the engine does not start, checking fuel flow and starter system.

Troubleshooting Engine Stop Issues

Troubleshooting Fuse Blowing and Manual Start Failures

Diagnosing 10A fuse blowing, engine start failures, and engine stopping during use for manual start models.

Safety Device Cut-in Summary Table

Electric Start Safety Devices - Starting

Table showing how safety devices affect starting in electric start models.

Electric Start Safety Devices - While Cutting

Table showing how safety devices affect operation while cutting in electric start models.

Manual Start Safety Devices - Starting

Table showing how safety devices affect starting in manual start models.

Manual Start Safety Devices - While Cutting

Table showing how safety devices affect operation while cutting in manual start models.

Safety Microswitch Operation Check

Electric Start Microswitch Checks

Procedure for checking microswitches (grass-catcher, seat, blade, neutral, parking) using an ohmmeter.

Engine Stop Switch Check

Method for bridging contacts to check the engine stop function.

Manual Start Microswitch Checks

Procedure for checking microswitches (grass-catcher, seat, blade, neutral, parking) using an ohmmeter for manual start.

Terminal Board Supply Check (Electric Start)

Battery Voltage Verification

Checking battery voltage at the terminal board with a voltmeter when the key is in the 'ON' position.

Starter Relay Operation Check (Electric Start)

Starter Relay Click and Motor Action Test

Testing the starter relay by bridging terminals to hear a click and checking starter motor engagement.

Starter Relay Power Contact Test

Bridging power contacts to check if the starter motor operates, indicating a fault in the relay if it doesn't.

Electronic Card Operation Check (Electric Start)

Electronic Card Power Supply Check

Checking power supply to the electronic card by positioning a jumper and measuring voltage.

Recharge Circuit Check (Electric Start)

Recharge Circuit Pre-Check Conditions

Ensuring correct connections, attached earth connections, charged battery, and unblown fuse before checking.

Lower Charging Limit Check

Measuring battery terminal voltage while engine runs to check regulator function and identify blown fuses.

Sealed Battery Care and Maintenance

General Sealed Battery Information

Details on sealed 'dual' batteries, emphasizing no need to add water or open the cover.

Correct Battery Usage Advice

Precautions for keeping the battery charged, recharging flat batteries promptly, and before/after storage.

Battery Recharging Rules

Instructions for recharging, including not recharging damaged batteries and checking for overheating.

Fitting Safety Microswitches

Microswitch Assembly Position Guidance

Importance of following exact assembly positions for correct microswitch function.

Seat Microswitch Adjustment

Adjusting the seat microswitch by changing cam position to ensure correct activation.

Electrical Diagrams (Electric Start)

Electric Start Wiring Diagram

Schematic diagram showing electrical connections for electric start models.

Manual Start Wiring Diagram

Tightening Torques and Adjustments Summary

Summary of Tightening Torques

List of specified tightening torques for fixing bolts on main parts.

Drive Engagement Adjustment Summary

Summary of the drive engagement adjustment procedure, including control positions and settings.

Blade Engagement and Brake Adjustment Summary

Summary of blade engagement and brake adjustment, showing controls and measurement settings.

Main Assembly Amounts and Checks Summary

Frame Assembly Specifications

Diagram and dimensions related to the main frame assembly.

Cutting Deck Assembly Specifications

Diagram and dimensions related to the cutting deck assembly.

Steering Geometry Assembly Specifications

Diagram and dimensions related to steering geometry assembly.

Drive Belt Development Specifications

Steering Tie-Rod Assembly Specifications

Diagram and dimensions related to steering tie-rod assembly.

Steering Tie-Rod Stub Axle Connection

Gear Lever Rod Assembly Specifications

Diagram and dimensions related to gear lever rod assembly.

Global garden products 63 Specifications

General IconGeneral
BrandGlobal garden products
Model63
CategoryLawn Mower
LanguageEnglish

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