WORKSHOP MANUAL

IMPORTANT NOTICE • The Manufacture reserves the right to make any im-
provements to the product of a technical or commercial
The information contained herein is intended for nature that may be necessary. There maybe, therefore,
Service Operations and professionals only, able differences between the various series of machines
to competently perform the operations described and that described here, though the basic features and
herein, using the appropriate equipment in order various repair methods will remain the same.
to safeguard se-curity and performance of the ma- • © by STIGA - No use of the illustrations or duplica-
chine. tion, reproduction or translation, even partial, of the
texts in this document may be made without explicit
The manufacturer is not liable for damages or authorization.
injuries arising from operations performed by • All brands, names, logos and trademarks mentioned
individuals or inadequate facilities. belongto their respective owners.

TH 102/122 - TH4 102/122 - Edition 2018--->....

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TH 102/122 - TH4 102/122 HOW TO USE THE MANUAL i 1 2018 1 of 2

GENERAL INFORMATIONS B) Identification and number of the page based on 3. Maintenance

the following criteria: This chapter covers the main aspects of a servi­c­
The purpose of this manual is to assist Service Cen- – the first field indicates the section and chapter; ing procedure.
tres service, disassemble and repair machines. – the second field indicates the revision index; A specific chapter is dedicated to a quick trouble­
– the third field indicates the chapter validity start shooting guide on the most frequent questions
The manual has left out the simplest and quickest date, i.e. the year of manufacture of the ma- and the chapter references providing information
operations that can be handled by a good mechanic, chine; on the interventions required to resolve the same.
while concentrating more on specific aspects with – the fourth field indicates the page number and
tips and advice on the best servicing procedures. total number of pages dedicated to the subject.
4. Adjustments and tuning
Please take time to read through this manual to ac- C) Chapter title. his chapter deals with the adjustments to be ma­de
quire a basic understanding of the machine, which is to remedy the more frequent performance fai­lures
necessary for working rationally without making er- D) General information, references to other chapters and are usually resolved by quick checks and tun­
rors or wasting time. in the manual, technical information related to the ings.
topic, and buttons with links to the machine oper-
All problems related to the use of the machine are ating units map can be found in the left column on
fully covered in the User manual. each initial page. 5. Removal of external parts and main assem-
blies
For doing more difficult jobs, greater accessibility
may be required. This can be done by taking the
SECTIONS OF THE MANUAL unit concerned off and working at the bench, or by
removing the cover or other external parts.
STRUCTURE OF THE MANUAL The content of the manual is divided into sections Whether or not this will be useful is at the discre­
which correspond to the various subjects and the dif- tion of the mechanic’s experience.
The manual is divided into sections and chapters. ferent types of servicing.
Each page of this manual states the following infor-
mation: 1. Rules and procedures for Service Centres 6. Repairs
This chapter covers all the main aspects of the re­ This chapter deals with all the more complex work
A) Machines or series of machines to which the con- lationship between the manufacturer and the ser­ connected with the replacement or repair of mal­
tents of the chapter are applicable. vice centres. functioning or worn parts.
A close collaboration between the manufacturer The descriptions must follow a logical sequence­
A
WORKSHOP MANUAL
TH 102/122 - TH4 102/122 C REMOVAL OF THE REAR AXLE
CHAPTER
5.6
REVISION
0 B
FROM ...
2018
PAGE
1 of 2 and the service centres is conclusive for solv­ and can include operations not specifically con­
General informations
Lift the rear part of the machine. 
ing problems in the most effective way as well as nected to a particular type of repair.
maintaining an image of efficiency and reliability. In this case, careful reading of the entire procedure
Remove the collector channel.
The rear axle (Transaxle) is made up of a single
maintenance free sealed unit which includes the Remove the rear wheels.  
transmission unit (hydrostatic) and the differen-

Compliance with these brief and simple guide­ can help you omit all those operations not connect­
tial and doesn’t need any maintenance.
It only needs to be removed to be replaced or for Model TH only:
an overhaul by the Manufacturer’s Service Cen- Completely empty the oil from the hydraulic
tre.

lines will facilitate this task and prevent general ed with the case in hand without, however, over­
system

– Disconnect the rear fittings of the hydraulic

D
system pipes (1) and (2) and loosen the fixing
Related topics block screw (3) to permit pipe mobility.


mi­sunderstandings and time-wasting for both the looking anything that may be necessary.
– Remove the clamp (4) and remove the rubber
[ 2.3] Lifting of the machine pipe (5).
– Plug the remaining open holes so that dust or
[ 4.2] Brake adjustment impurities cannot enter.

manufacturer and the service centre.


[ 4.4] Drive pedal adjustment

[ 4.9] Empting the hydraulic circuit
[ 5.3] Removal of the collector channel
[ 6.1] Removal of the wheels 

Tightening torques 2. General regulations 7. Electrical system

This chapter covers the main aspects of a servi­ This chapter deals with the problems and checks
1-2 Hydraulic system fittings ............. 23 ÷ 25 Nm
16 Rear axle support nut .................. 25 ÷ 30 Nm

c­ing procedure and the general rules for guaran­ con­nect­ed with the electrical system.
17 Rear axle fastening nuts .............. 25 ÷ 30 Nm


teeing a successful service which protects the All work can be done using a tester without ha­ving

Map of functional units Using the outlet firmly hold the two branches of the
belt (6) pulling it just enough to free it from the pulley
throat (7), overcoming the resistance of the guide pul-

en­vironment and respects the safety of both the to use special equipment.
ley stretcher.

Dismantle the drive control rod (8) by unscrewing the

nut (9) of the relative pin.

Dismantle the brake rod (10) by unscrewing the nut

placed under the lever (11).

ser­­viceman and the user of the apparatus. The electrical diagrams can be useful to you for
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TH 102/122 - TH4 102/122 HOW TO USE THE MANUAL i 1 2018 2 of 2

understanding how the system functions and to fa­ The map is a search tool that provides instant access TERMINOLOGY AND ABBREVIATIONS
cilitate the pinpointing of any problems. to all information concerning machine operational unit
or element. Some paragraphs are preceded by a definition that
Identification is simplified by the use of icons resem- highlights their importance:
8. Hydraulic system bling the various units, each of which is linked to a ta-
ble of contents that lists all related topics. NOTE General reference for the correct maintenance
It allows a better understanding of the hydraulic execution and methods..
system and its components and provides instruc­
tions on faults that could occur. IMPORTANT Specific procedures or information
necessary to avoid damage to the machine or equip­
ment.
9. Technical specifications SYMBOLS
WARNING! Non-observance will result in the
This chapter summarises all the main information In the manual some symbols are present. They are risk of injury to oneself or others.
re­garding the machine. used to draw the attention of the operator, reminding
him to perform the interventions with the necessary DANGER! Non-observance will result in the risk
attention and caution. of serious injury or death to oneself or others.

FUNCTIONAL UNITS MAP  Indicates operations that should be carried out

with utmost care to avoid impairing the function-
ality and safety of the machine.
Whenever reference is made
 Indicates operations that should be carried out to a position on the machine
with utmost care to avoid injury to operators. “front”, “back”, “left” or “right”
side, this refers to the posi-
 Highlights all those operations that require differ- tions of the seated operator.
ent working methods depending on the type of
ENGINE - FUEL TANK TRANSMISSION - BRAKE - WHEELS machine, subsequent modifications and the ac-
cessories fitted.

 Indicates cross-reference to other parts of the

manual, followed by the number of the relevant
chapter, paragraph or sub-paragraph.
The following abbreviations are used in this manual
Dx / Sx = Right / LeftV
CUTTING DECK STEERING Min / Max = Minimum / Maximum
Chap. = Chapter
PTO = Power Take Off
HST = Hydrostatic Transmission

BODY ELECTRICAL SYSTEM

 WORKSHOP MANUAL INDEX OF FUNCTIONAL UNITS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 Engine - Fuel Tank ii 0 2018 1 of 6

General informations
RELATED TOPICS:
Different fittings are foreseen for this machine
which can imply the use of different engines with­
in the same.
This manual only describes the operations re­ Adjustments and tuning
lating to the application of the machine engine;
reference to the engine’s Manufacturer’s Manual
is recommended for information regarding serv­ ---
icing, disassembly and replacement of compo­
nents.
Removal of external parts and main assemblies
Related topics
Removal of front hood ....................................................................... [ 5.1]
[ 1.1] Identification of components
Removal of the engine ....................................................................... [ 5.5]

Repairs

Replacement of the accelerator and adjustment of the carburettor ... [ 6.9]

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TH 102/122 - TH4 102/122 Transmission - Brake - Wheels ii 0 2018 2 of 6

General informations
RELATED TOPICS:
The use of outsourced third-party hydrostatic
drive units is foreseen on this machine.
This manual only describes the operations relat­
ing to the application of the machine units; refer­ Adjustments and tuning
ence to the drive unit’s Manufacturer’s Manual is
recommended for information regarding servic­
ing, disassembly and replacement of compo­ Brake adjustment .............................................................................. [ 4.2]
nents.
Drive belt adjustment . ....................................................................... [ 4.3]
Drive pedal adjustment ..................................................................... [ 4.4]
Related topics Changing oil in the hydraulic circuit (Model TH4) . .............................. [ 4.9]
[ 1.1] Identification of components
Removal of external parts and main assemblies

Removal of the rear axle ................................................................... [ 5.6]

Removal of the front axle (Model TH4) ............................................. [ 5.7]

Repairs

Replacement of tyres and wheels . ................................................... [ 6.1]

Replacement of front wheel bearings (Model TH) . ........................... [ 6.2]
Replacement of the drive belt ........................................................... [ 6.4]
Replacement of the small wheels for the drive belt ........................... [ 6.5]
Replacemnt of the pipes of the hydraulic system (Model TH4) ....... [ 6.10]

Info

Guide to understanding the hydraulic system ................................... [ 8.1]

Checking the hydraulic system ......................................................... [ 8.2]
 WORKSHOP MANUAL INDEX OF FUNCTIONAL UNITS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 Cutting Deck ii 0 2018 3 of 6

General informations
RELATED TOPICS:
The terms “Cutting deck” or “Equipment” refer to
the cutting-means assembly, connected to the
machine PTO by means of a belt.
Adjustments and tuning
Related topics
Adjusting the engagement and checking the blade brake ................. [ 4.1]
---
Aligning the cutting deck ................................................................... [ 4.5]
Checking blades alignment ............................................................. [ 4.7]
Removing, sharpening and balancing the blades ............................ [ 4.8]

Removal of external parts and main assemblies

Removal of the collector channel . .................................................... [ 5.3]

Removal of the cutting deck ............................................................. [ 5.8]

Repairs

Replacement of the blades control belt ............................................ [ 6.6]

Replacement of the blades connection belt ...................................... [ 6.7]
Replacement of the supports and shafts of the blades ..................... [ 6.8]
 WORKSHOP MANUAL INDEX OF FUNCTIONAL UNITS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 Steering ii 0 2018 4 of 6

General informations
RELATED TOPICS:
---

Related topics Adjustments and tuning

---
Steering allowance adjustment . ........................................................ [ 4.6]

Removal of external parts and main assemblies

---

Repairs

Dismantling of the steering components ........................................... [ 6.3]

 WORKSHOP MANUAL INDEX OF FUNCTIONAL UNITS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 Body ii 0 2018 5 of 6

General informations
RELATED TOPICS:
Different outfittings are foreseen for this machine
which can imply the use of different bodywork
designs.
The operations described herein are applicable Adjustments and tuning
to all versions, except for instructions provided
for each specific outfitting, recognisable accord­
ing to the type of dashboard installed on the ma­ ---
chine.

Related topics
Removal of external parts and main assemblies

--- Removal of front hood ......................................................................... [ 5.1]

Removal of the wheel cover . .............................................................. [ 5.2]
Removal of the dashboard and front cover ......................................... [ 5.4]

Repairs

---
 WORKSHOP MANUAL INDEX OF FUNCTIONAL UNITS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 Electrical System ii 0 2018 6 of 6

General informations
RELATED TOPICS:
---

Related topics Information and Verifications

---
Troubleshooting of the electrical system . ............................................ [ 7.1]
Cutting in of the safety devices ............................................................ [ 7.2]
Safety microswitches operation check ................................................ [ 7.3]
Terminal board supply check ............................................................... [ 7.4]
Carburettor solenoid valve operation check ........................................ [ 7.5].
Starter relay operation check . ............................................................. [ 7.6]
Electromagnetic clutch operation check .............................................. [ 7.7]
Grass- catcher tipping control operation check ................................... [ 7.8].
Replacing the clock’s buffer battery..................................................... [ 7.9]
Recharge circuit check ...................................................................... [ 7.10]
Maintenance of the sealed battery .................................................... [ 7.11]
Fitting safety microswitches .............................................................. [ 7.12]
Electrical diagrams ........................................................................... [ 7.13]
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 IDENTIFICATION AND PROCEDURES 1.1 0 2018 1 of 2

A) Identification
General informations
1) Machine
This chapter covers all the main aspects of the Each machine has a label attached (1) under the dri­
re­la­tionship between the Manufacturer and the ver’s seat which shows the technical specifications,
Ser­vice Centres. the model and the serial number..
A close collaboration between the Manufacturer
and the Service Centres is conclusive for solv­ The model and serial number must be shown on
ing pro­­blems in the most effective way as well as each repair sheet when requests are made un­der
main­­taining an image of efficiency and reliability. guarantee, and are indispensable for spare part
Compliance with these brief and simple guide­ orders.
lines will facilitate this task and prevent general
misunderstandings and time-wasting for both the
manufacturer and the service centre. 

Related topics The serial number on the label (2 – rear unit) or

(3 – front unit) clearly identifies the product and
--- its specifications. This number must always be
quoted when requesting spare parts or any infor-

mation from the Manufacturer.


2) Transmission

Model TH: is fitted with a rear hydrostatic

engine block transmission unit, including the dif-
ferential and rear axle.
Map of functional units
3) Engine
Model TH4: is fitted with two hydrostatic en- The engine is made to precise technical specifica-
gine block transmission units, the front is equipped tions which differentiate it from similar items by this
with a hydraulic distributor, and a rear one which same Manufacturer.
includes the differential and rear axle.
The serial number on the label clearly identifies
These units are made by another manufacturer ac- the product and its specifications. This number
cording to precise technical specifications which dif- must always be quoted when requesting spare
ferentiate them from similar items by this same Manu- parts or any information from the Manufacturer.
facturer.
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TH 102/122 - TH4 102/122 IDENTIFICATION AND PROCEDURES 1.1 0 2018 2 of 2

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 manufactur-
ers apply.

C) Service repairs after guarantee period

The Service Centre has to make out a report contain-

ing the machine’s serial number, a summary of the
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 le­
vel.

Similarly, the Manufacturer will notify of any faults

di­scovered on the machines produced, with recom-
mendations for the most suitable procedures for their
re­medy.

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.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SAFETY REGULATIONS 2.1 1 2018 1 of 2

A) Qualification of operators – not endorse any repair or modification on the ma­

General informations chine or the engine which results in a chan­ge in
All maintenance, disassembly and repairs must be performance or use that is incorrect or different
This chapter covers the main aspects of a servic­ car­ried out by expert mechanics who are familiar with from the purpose for which it was de­si­gned and ap-
ing procedure and the general rules for guaran­ all the accident prevention and safety regulations af- proved;
teeing a successful service which respects the ter reading through the procedures in this ma­nual. – warn the Customer that the failure to comply with
safety of the machine. the above points results in the automatic annulment
of the Guarantee and the Manufacturer declines
all responsibility, as also shown in the Instruction
Related topics Booklet.

[  ools
2.2] T
[  afety microswitches operation check
7.3] S B) Safety measures

All the machines are manufactured in accordance

with the strict European safety regulations in force.
C) Precautions during servicing
To maintain these levels of safety in the longer term,
the Service Centres should work to this end by ma­ The operations described in this manual do not entail
king appropriate checks every time there is the chan­ particularly hazardous situations besides the normal
ce to do so. hazard related to mechanical operations and that can
be avoided by taking the necessary care and atten-
Particularly, every time there is work done on the ma­ tion normally required for this type of work.
chine the Service Centre should:
As well as following the usual accident prevention
re­gulations that apply to most repair shops, we re­
1) check: commend you:

– that safety microswitches are working correctly; – taking out the ignition key before beginning any re-
– that the casings and protection covers have not pair work.
been removed; – protect hands with suitable working gloves, e­spe­
– that the labels with instructions or provisions have cially when working near the cutting unit;
not been removed or have become illegible (these – check that you do not cause accidental petrol leaks
form an integral part of the safety system). or other losses;
Map of functional units – do not smoke when working on the tank or when
handling petrol;
– do not inhale oil or petrol fumes;
2) they should also: – clean up all traces of spilt petrol immediately;
– test the engine in a well-ventilated environment or
– restore to proper working order any safety de­vi­ces where there are adequate exhaust fu­me extraction
which have been manipulated or re­mo­ved; systems;
– reattach inefficient, damaged or missing ca­sings – do not pollute the environment with oil, petrol or
and protection covers; other waste and dispose of all waste in ac­cor­dance
– replace illegible labels; with the laws in force;
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TH 102/122 - TH4 102/122 SAFETY REGULATIONS 2.1 1 2018 2 of 2

– ensure that other persons cannot accidentally car­

ry out actions that may physically endanger 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.
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TH 102/122 - TH4 102/122 TOOLS 2.2 0 2018 1 of 1

All work can be carried out using the tools normally

General informations a­vailable from a good workshop. However, it is ad­vi­
sable to have a set of special tools (1 ÷ 8).
This chapter covers the main aspects of a servic­
ing procedure and the general rules for guaran­ These tools (1 ÷ 8) are to be used whenever is given
teeing a successful service which respects the in the text.
safety of the machine.
1. Blocks H = 26 mm for adjusting the cutting deck
2. Blocks H = 32 mm for adjusting the cutting deck
Related topics 3. Bush for assembly of blades bearings
4. Stopper for assembly of wheel bearings
--- 5. Pulley extractor
6. Pulley centre distance checking template
7. Blades connection belt tension checking template
8. Dynamometer


  





Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 LIFTING AND STABILISING 2.3 0 2018 1 of 1

A) Lifting
General informations
There are four points on the machine that are to be
This chapter covers the main aspects of a servic­ used when lifting it:
ing procedure and the general rules for guaran­
teeing a successful service which respects the – 2 central eyelets (1) accessible from the inspection
safety of the machine. hatch (2), to support the weight of the machine;
– 2 front extensions (3) on the frame beams, to bal-
ance the machine during lifting.
Related topics

---


 
C) Stabilising the rear part

An appropriately sized wedge (5) should be placed in

front of the front wheels, to prevent the machine from
accidentally moving, the rear part can be lifted using
a block of about 100 x 150 x 550 mm (6) placed be-
neath the lower edge of the plate.
DANGER! Lifting of the machine should
be carried out using a hoist and adequately
strong cables equipped with safety hooks and DANGER! Always ensure that the machine
only hooked onto the previously mentioned four is stable before starting work in its lifted position.
points.

DANGER! To balance the weight of the ma-

chine, the two front cables should be about 30%,
longer than those attached to the central eyelets.
Map of functional units

B) Stabilising the front part 

With the parking brake is engaged, the front part of

the machine can be lifted using a wooden block of 
about 100 x 270 x 550 mm (4) placed under the front
axle of the cutting deck lifting levers.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 PRACTICAL HINTS 2.4 0 2018 1 of 2

A) Fitting snap rings A typical situation has the pin (3) fixed by a self-lock­
General informations ing nut (4) with two anti-friction washers (5) in be­tween
One side of the “Benzing” snap rings (1) has a round- the pin (3) and the support element, and be­tween this
This chapter covers the main aspects of a servic­ ed edge and the other a sharp edge. and the nut (4).
ing procedure and the general rules for guaran­
teeing a successful service which respects the For maximum grip the rounded part needs to be fa­ Since these are joints, the nut must never be tighte­
safety of the machine. cing towards the element to be held (2), with the sharp ned completely but only so much that it can ensure the
edges on the outside. free rotational movement of the pin on its axis wi­thout,
how­ever, creating excessive free play which could re-
Related topics sult in the parts concerned becoming mi­saligned and
failing to work correctly.
---




 


Map of functional units



B) Joint pivot pins

There are a large number of pivot pins, usually con-
nected to rods, that need to be able to move in va­rious 
directions.
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TH 102/122 - TH4 102/122 PRACTICAL HINTS 2.4 0 2018 2 of 2

C) Crown fasteners

Some pin ends (6) are secured by crown fasteners

(7). During dismantling, these fasteners are always
da­maged and lose their hold, so they should never
be reused.

On assembly, make sure it is inserted in the right di­

rection and push the fastener (7) onto the pin using
a pipe or socket spanner (8) with the right diameter,
so that it can be fitted without deforming the faste­ner
“crown”.

IMPORTANT A deformed fastener should always be

replaced.






 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CRITERIA FOR MAINTENANCE 3.1 0 2018 1 of 1

The Instruction Handbook has a number of

General informations operations to be carried out by the Customer
for a minimum of ba­sic maintenance, and oth-
In questo capitolo vengono trattati i criteri di in­ter­ er operations not always within his capacity.
vento per la manutenzione ordinaria.
For this reason the Service Centre should un-
dertake to keep the machine in perfect work-
Related topics ing order in two ways:
---
A) Tuning the machine whenever possible.

B) Proposing a regular maintenance pro-

gramme 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 B) Routine maintenance

– Check working order of safety devices and renew il- – All work carried out in section a), plus:
legible or missing labels, following the layout below
– Check tyre pressures – Check battery charge
– Clean air filter – Check tension of belts
– Check engine oil level – Adjust brake
– Model TH4: Check the oil level of the transmission – Adjust blade engagement
– Check for fuel leaks – Adjust blades brake
– Model TH4: Check for leaks in the hydraulic system – Check steering allowance
– Aligning the cutting deck – Model TH: Check front bearings
Map of functional units – Sharpen and balance the blades and check the – General lubrication
condition of the hubs – Model TH4: Check and/or replace the transmission
– Check for wear in the belts oil
– Check the blade brake engagement – Clean away grass cuttings and wash exterior
– Model TH: Grease front wheels lever joint pins and – Clean and wash inside cutting deck and collector
bushes chnnel
– Check tightness of engine screws – Clean and wash grass-catcher
– Check all those items indicated in the engine man- – Touching up of any damaged paint
ual.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 TROUBLESHOOTING AND REMEDIES 3.2 0 2018 1 of 3

1. Motore e Serbatoio
General informations

This chapter helps achieve a rapid identification Problem Probable cause Solution
and solution to the most recurrent problems, clas­ Low battery Recharge [7.11]
sified according to the operating unit in question. Starter motor does not No starter relay contact Check [7.6]
run Faulty connector and/or starter
Check and/or replace [*]
motor failure
Related topics Blown spark plug electrode Replace the spark plugs [*]
Uncertain connections Check the connectors –
---
The starter motor runs Coil failure Check and/or replace [*]
but the engine does not The carburettor solenoid valve
start Check [7.5]
does not open
No fuel is pumped to the Check the filter, fuel pump (if applicable)
[*]
carburettor and the carburettor
The engine runs irregu- Faulty ignition Check the spark plugs and ignition
[*]
larly and/or lacks power system
Low fuel level in the tank Top up –
Dense and/or blue ex- Dirty or old fuel Empty the fuel tank and add fresh fuel –
haust fumes Clogged carburettor filter Check and clean [*]
Black exhaust fumes Excessively oily carburetion Check the starter and command cable [*]
Spark plugs with inadequate
Check [*]
heat rating
Carburetion problems Check the carburettor [*]
Insufficient oil level Check and top up [*]
Engine overheating
Check and clean the air filter and the
Clogged suction system [*]
suction pipe
Dirty cooling flaps Clean [*]
Broken cooling fan Replace [*]
Engine idling speed is
Incorrect cable adjustment Adjust [6.9]
too high or too low.
Abnormal noise and Check and tighten to the prescribed
Loose bolts and screws [5.5]
Map of functional units vibrations values

[*] Check the engine Manufacturer’s Manual

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 TROUBLESHOOTING AND REMEDIES 3.2 0 2018 2 of 3

Important informations 2. Transmission - Brakes - Wheels

Characteristics of the original belts Problem Probable cause Solution

The standard belts on the market have different Slack belt Adjust [4.3]
characteristics compared to the requirements of Worn or oily belt Replace [6.4]
the original spare belts, supplied by the authorised [5.5]
The machine moves Broken pulleys Replace
dealer. The latter are designed and manufactured slowly, looses power or [*]
in close cooperation with the belt supplier and the doesn't move at all The brake is not adjusted
machine manufacturer. Check and adjust [4.2]
correctly
Here are the reasons why it is important to choose Check the Manufacturer's Instruction
an original belt, useful when making such deci­ Hydrostatic unit failure [*]
Manual.
sions.. Pulley splines broken Replace [*]
The machine will not
a) Adhesion on the pulley. The move in either direction Check the Manufacturer's Instruction
Hydrostatic unit failure [*]
belt rests with the sides inclined Manual.
against the walls of the pulley. The machine does not
There must be a gap between the reach the foreseen Incorrect pedal adjustment Adjust [4.4]
belt and the bottom of the groove. speed in forward drive
Uncertain or ineffective The brake is not adjusted
Check and adjust [4.2]
b) Floating pulley on cutting braking correctly
equipment. The original Power Hydrostatic unit over- Insufficient oil level Top up [*]
Take Off (PTO) belt is designed to heating Clogged oil filter Clean and/or replace [*]
work even if the pulleys move up Slack or worn belt Check and/or replace [6.4]
and down and tilt at the same time.
Check the condition of the fan, that it is
Irregular fan rotation securely fastened in place and that noth- [*]
c) Curvature in two directions.
Abnormal noise and ing interferes with the rotation movement
All the original belts, which work
with tensioning arms acting on the vibrations Incorrect positioning of the by-
Check and adjust [*]
external side, are equipped with re­ pass valve
inforcements. The reinforcement is designed spe­ Check and tighten to the prescribed [5.6]
Loose bolts and screws
cifically for these specific cases.. values [5.7]
Incorrect micro-switch
The machine moves in adjustment Adjust [4.4]
neutral gear
Slack or worn linkage system Check and/or replace [4.4]
Pushing the machine by
By-pass partially enabled Check [*]
hand is difficult
The parking brake does
not stop the machine on Incorrect brake adjustment Adjust [4.2]
a 30% slope
Excessive clearance on
Model TH: Worn bearings Replace [6.2]
the front wheels

[*] Check the transmission unit Manufacturer’s Instruction Manual.

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 TROUBLESHOOTING AND REMEDIES 3.2 0 2018 3 of 3

Important informations 3. Cutting deck

Characteristics of the original blades Problem Probable cause Solution

The original blades have design, material and The blades do not Slack belt Adjust the engagement [4.1]
processing characteristics optimised for use on engage or do not Incorrect adjustment of the
Adjust the engagement [4.1]
the equipment for which they were designed; these stop promptly within 5 engagement spring
characteristics are not present in so-called “com­ seconds when they are Electromagnetic engagement
disengaged Check and/or replace [7.7]
patible” spare parts. problems
Here are the reasons why it is important to choose Cutting deck not parallel to the Check the tyre pressures [6.1]
an original blade, useful when making such deci­ ground Align the cutting deck with the ground [4.5]
sions. Uneven mowing and
poor grass collection Check their condition and that they are
Blades cutting badly [4.8]
well sharpened
a) No breakage of the blade Misaligned blades Check the blade shafts and flanges [4.7]
ends. Using steel balls, the manu­
facturer simulates what can hap­ Loose joint bolts and screws Check and adjust [5.8]
Abnormal noise or vibra-
pen when mowing over any foreign tions Pulleys or guide pulleys are
Check and/or replace –
bodies on the lawn. This can ruin the blade edge, worn and do not rotate correctly
but no component can come loose, fall off or be
hurled away.
4. Steering
b) No breakage of the blades.
The impact test is the most severe Problem Probable cause Solution
durability test that any lawnmower Excessive clearance on [4.6]
can be subjected to. An iron tube is Worn pinion and crown teeth Adjust and/or replace
the steering wheel [6.3]
placed exactly inside the blades when the mower The machine does not
is running. The blade may deform but it will never, maintain a straight line
under any circumstances, fall off or break. This test Incorrect tie-rod adjustment Adjust [4.6]
when the steering wheel
verifies that blades and other components meet the is straight
high safety requirements.
Anomalous or uneven
Incorrect toe-in adjustment Adjust [4.6]
wear on the front tyres
c) Excellent cutting result. The
blades and blade ends supplied
by the authorised dealer are opti­
mised for the application for which
they are intended. In short, this means that the
blades are suitable for the shape of the casing and
to the number of revolutions to provide the best
possible cutting result.
 WORKSHOP MANUAL ADJUSTING THE ENGAGEMENT AND CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHECKING THE BLADE BRAKE 4.1 0 2018 1 of 1

A) Adjusting blade engagement B) Checking the blade brake

General informations
Con il piatto di taglio nella posizione più bassa, indi-
The blades are driven by the engine by means of With the cutting deck in its lowest position, look for WARNING! Correct operation of the brake,
a “V” belt and are engaged by an electromagnetic the adjuster (1) which is placed under the footboard which must ensure that the blades stop within 5
clutch. on the left side and turn the nuts, with the blades en- seconds from disengagement; longer stopping
After a certain amount of use the belt can become gaged, until the spring (2) reaches a variable length times do not comply with the safety standards.
longer which can result in malfunctioning, i.e.: «A» according to the different versions of the ma-
– belt slipping = belt stretched chine, as follows If the blades do not stop within 5 seconds from disen-
– difficulty in disengaging, with the blades con­ A = 113 ÷ 115 mm - for mod. 102 gagement, appropriate checks must be made to the
tinuing to run = belt shortened A = 90 ÷ 91 mm - for mod. 122 electrical system and the clutch must be re­plac­ed if
In both cases the stretcher needs to be adjusted. no result is achieved.
Disengaging the blades causes the cutting in
of a brake, incorporated in the electromagnetic 
clutch, whose task is to stop the blades from ro­
tating within five seconds.

Related topics 

[ 6.6] Replacement of the blades control belt 

[  lectromagnetic clutch check

7.7] E

NOTE The hook position of the spring (2) on the

plate (3) is different for the model 102 (hole 3a) and
the model 122 (3b – the only hole on the plate).

Map of functional units 




 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 BRAKE ADJUSTMENT 4.2 1 2018 1 of 1

The adjustment is to be made with the parking bra­

General informations ke engaged and consists of altering the length of the In models with cruise control:
spring (4) to the best measurement. The braking ca­
Reduced braking power is corrected by adjusting pacity is increased by screwing the nut (3) down on To adjust the release cam (11) position to the pin
the spring on the brake rod, which is accessible the rod (and thus shortening the length of the spring). (12), position the pawl (13) on any tooth on the
by removing the rear right wheel. rack (14), loosen the nuts (15) and adjust the cam
Loosen the nut (1) which holds on the bracket (2) and (11) to achieve the condition indicated in the illus-
turn the nut (3) until the length of the spring (4) is 45 tration.
Related topics ÷ 47 mm, measured from the inside of the washers.

[  emoval of the rear axle

5.6] R When the adjustment has been made, tighten the nut

(1). 



 



  
 

NOTE Never go under these amounts to avoid over­

2 mm
loading the brake unit.  
1 mm

WARNING! When the adjustments have

been made, the par­king brake should prevent the
Map of functional units machine from moving on a slope of 30% (16°)
with the driver in position.  

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 dis-
mantle the whole rear axle of the machine and con­tact
one of the manufacturer’s Service Centres.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 DRIVE BELT ADJUSTMENT 4.3 1 2018 1 of 1

The tensioner is to the right of the steering unit and

General informations accessible from the front hood, turning the wheels
fully to the right.
If it seems that the forward drive is not working
pro­perly after a long period of use or after repla­ Adjust the tension of the spring (1) by suitable work-
cing the belt, this may be caused by a change in ing on the nuts (2) until a measure of 114 ÷ 116 mm is
the length of the belt. obtained, measured on the outside of the turns with a
– A loose belt reduces output from the drive and gauge, with the transmission controls in neutral.
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 both cases the stretcher needs to be adjusted.



Related topics

[  eplacement of the drive belt

6.4] R 




When the adjustment has been made, tighten the

nuts (2).

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 DRIVE PEDAL ADJUSTMENT 4.4 0 2018 1 of 2

A) Adjusting the pedal in the “neutral” position the nuts (4) until reaching the desired situation. Taking
General informations care not to accidently change the position of the lever
Adjustment of the pedal position must be carried out (1) during the adjustment.
This operation should be carried out every time with the hydraulic unit lever in the “neutral” position
the rear axle, pedal or control rod is removed, in (1); this position «N» can be easily recognised as it is
order to get the correct travel for the pedal and to forced to stay there by a fastening sphere.
reach the envisaged speeds both forwards and
in reverse. Open the inspection hatch which is placed at the base
of the seat; the drive control pedal is in its ideal posi-
tion when the lever
Related topics (1) of the hydrostatic unit is in “neutral”, and the inter-
nal lever (2) on the pedal axle is perfectly vertical.
[ 
7.12] Fitting safety microswitches
This is obtained using a bracket (3), by working on

B) Adjusting the “neutral” position of the

micro­switch

IMPORTANT This is a very important adjust­

ment for the correct operation of the safety devices

 for starting and stopping of the machine during work.




Map of functional units


The neutral position «N» is signalled by the micro­

switch (5) of the cam (6), accessible from the inspec-
tion hatch which is placed at the base of the seat.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 DRIVE PEDAL ADJUSTMENT 4.4 0 2018 2 of 2

After checking that the adjustment “A” has been cor-

rectly made, make sure that the pedal is released and
in neutral “N” then loosen the screws (7) that fasten
the microswitch support (8), until the roller is in line
with the tip of the cam, so that the microswitch re-
mains activated.

By moving the pedal to the forward gear and neutral

position, you should hear the click of the button at
each gear change before the wheels start moving.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 ALIGNING THE CUTTING DECK 4.5 0 2018 1 of 2

Check the tyre pressures. If one or more tyres have
General informations been replaced or you find differences in diameter, do 
not attempt to compensate these differences by 
Lowering of the cutting deck is controlled by a giving different tyre pressures, but make the ad­
linkage activated by the lever and is moved by justments as in point “B”.
two connecting rods at the front; the descent is
limited by a cam that returns the deck to the pre­
set height. A) Synchronization of the control lever with the
In order to get a good cut it is essential that the cam
cutting deck is parallel with the ground crosswise,
and slightly lower at the front. This adjustment is fundamental to allow use of all nine
There are three types of possible adjustments: positions of cutting height. 
a) synchronization of the control lever to the
height setting cam;
b) a combined adjustment to the parallel and the  
minimum front and back height, to be carried
out if the cutting is irregular; Turn the screw (6) until the tip can be placed on the
c) adjustment of the longitudinal deck position, cam step (7) corresponding with position “1”, then
Loosen the screw   tighten the screw by half a turn and fasten the nut (5).
is only necessary when, during cutting deck (1) and remove the
replacement operations, the original position handle (2).
has been lost and the correct distance to the
engine pulley must be restored.
B)  Combined adjustment to the parallel and
Remove the inspec- the minimum front and rear height
Related topics tion hatch (3) se-
cured by the screw Put the machine onto a flat and stable surface (such
[  ools
2.2] T (4). as a work bench) and put blocks beneath the cutting
deck in line with the centre lines of the blades:

Tightening torques Loosen the locknut (5) and the screw (6) and move – at the front 26 mm (11)
the cam (7) into position “1” by using the control lever – at the rear 32 mm (12)
in its completely lowered position.
Front .......................................................... 1,0 Bar
Rear ........................................................... 1,4 Bar  


Map of functional units





 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 ALIGNING THE CUTTING DECK 4.5 0 2018 2 of 2

Move the cam (7) to position “2” and loosen the nuts C) Adjustment of the longitudinal position
(13), the screws (15) and the locknuts (14-16) on the  
right and left-hand side, so that the deck is resting Put the machine onto a flat and stable surface (such
firmly on the blocks. 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 (11)
– at the rear 32 mm (12)


 Move the cam (7) to position “2” and loosen the nuts
(13), the screws (15) and the locknuts (14-16) on the
right and left-hand side, so that the deck is resting
firmly on the blocks. 

Distance «B» is set by using the corresponding front

right connecting rod nuts to obtain the same meas-
urement, so that the outlet is perfectly centred with
respect to the collector channel; then fully tighten the
nuts (18) and locknut (19).
   
 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 (15) until both the left and

right side of the rear part of the deck begin to rise and
then tighten the relative locknuts (16).

Loosen the nuts (18) and the locknut (19) of the two Push the two connection rods backwards (17) and
front connecting rods (20) and adjust the nuts of the tighten the nuts to the respective rods (13) until both
front left connecting rod (18) until achieving the length the left and right side of the front part of the deck be-
“A” of: gin to rise and then tighten the locknuts (14).
– 489 mm (mod. 102)
Turn both the rear screws (15) until both the left and – 474 mm (mod. 122)
right side of the rear part of the deck begin to rise and between the centre of the engine pulley hub and the
then tighten the locknuts (16). centre of the left blade shaft.

Push the two connecting rods backwards (17) and This operation is facilitated by using the checking cali-
tighten the nuts to the respective rods (13) until both per (21) suitably positioning the engine side terminal
the left and right side of the front part of the deck be- (21a) at the side marked with «CLUTCH»
gin to rise and then tighten the locknuts (14).
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 STEERING GEOMETRY ADJUSTMENT 4.6 0 2018 1 of 2

NOTE Before any other action, check that the joint B) Adjustment of the steering wheel
General informations fastenings have not become loose.
Firstly check the toe-in (point “A” and align the front
The correct steering geometry is given by the A) Toe-in adjustment wheels.
values of the centre distance between the joints
of the tie-rod and the wheel connection rod. Any Model TH only: If the steering wheel is not straight:
faults caused by knocks or accidents result in re­ An exact toe-in is achieved with a centre distance
duced driving precision and increased wear on of 549 mm which is measured between the cen- - unscrew the nuts (8) and remove both joints (5);
the tyres. These can be overcome as follows: tres of the articulated joints (1) of the wheel con- - align the front wheels and steering wheel;
– uneven or excessive wear on the front tyres = nection rod (2). - screw the joints (5) in or out of the tie rods (6) enough
toe-in adjustment (Model TH only), If a different distance is found, dismantle one or to align the joint pins (5) with the rod holes (10).
– the machine does not maintain a straight line both the joints and screw the necessary amount
when the steering wheel is straight = adjust­ down or up on the rod.
ment of tie-rod. On assembly, fully tighten the locknuts (3) and the
Furthermore, the steering allowance should nev­ fastening nuts (4) of the joints.   
er be excessive if driving is not to be impaired.


Related topics

---  

Tightening torques

3-4 Nuts and locknuts of the rod joints.75 ÷ 85 Nm

7-8 Nuts and locknuts of the tie-rod joint. 125÷135 Nm 
 
34 Nut for sector bearing fastening..... 45 ÷ 50 Nm
IMPORTANT NOTE The adjustment must always be
performed on both tie-rods.

On assembly, fully tighten the locknuts (7) and the fas-

tening nuts (8).
Map of functional units



C) Steering allowance adjustment
 Check that the movement is not caused by loose link-
 age nuts and tighten all the nuts of the tie-rods and
ball joints.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 STEERING GEOMETRY ADJUSTMENT 4.6 0 2018 2 of 2

If allowance is due to coupling between the pinion

and toothed sector, adjust the reciprocal positions be-
tween the two parts.

Loosen the nut (11) and move the toothed sector (12)
longitudinally until allowance is reduced to a minimum
between sector teeth and the pinion; then tighten the
nut (11) and grease concerned parts.

 
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHECKING BLADES ALIGNMENT 4.7 0 2018 1 of 1

Remove the cutting deck.

General informations

Excessive vibration when cutting and an uneven WARNING! Always wear strong gloves 
cut can be due to misalignment of the blades when handling the bla­des.
o­wing to deformation of the flanges or the shafts
as a result of accidental knocks. NOTE Take note of the unscrewing and screwing di­
rection of the central screw (1a - 1b) of each blade.
Related topics


[  emoving, sharpening and balancing the
4.8] R 
blades
[  emoval of the cutting deck
5.8] R
[  eplacement of the supports and shafts of
6.8] R
the blades 


Tightening torques

1a Screw for left blade ........................45 ÷ 50 Nm

1b Screw for right blade . ....................45 ÷ 50 Nm

To check the alignment 

of the blades, one of
them must first be re-
moved and refitted af- If higher amounts are found, check that the blades are
ter having re­mo­ved the not distorted. If this is not the case, check the sup­
shaft key (2), to permit ports or the shafts for the blades, re­placing if neces-
independent bla­de rota- sary, and check the condition of the point where the
tion. flanges rest on the cutting deck.
Map of functional units
IMPORTANT Always replace damaged blades
and do not at­tempt to repair or straighten them. Al­
ways use ma­nufacturer’s genuine spare parts!

With the blades disengaged, firmly hold each blade IMPORTANT Having made the check, remem­
and bring the cutting edges together in the various ber to refit the shaft key (2) and check that the rotating
positions possible (A-B; A-B1; A1-B1; A1-B). At each blades do not interfere with each other during a whole
position they should be aligned to within 2 mm. revolution.
 WORKSHOP MANUAL REMOVING, SHARPENING AND BA­LANCING CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 THE BLADES 4.8 0 2018 1 of 2

 Remove the cutting deck

General informations 

A badly sharpened blade causes grass to be­co­ WARNING! Always wear protective gloves
me yellow and reduces grass collection capabil­ when handling the blades and protect eyes when
ity. If not balanced, excessive vibration can be sharpening.
cau­sed during use. 

WARNING! The blades are connected to
Related topics each other, the rotation of each blade engages
the rotation of the other.
[  emoval of the cutting deck
5.8] R 
A) Removing and reassembling

Tightening torques For removing a blade it must be firmly held and the
cen­tral screw (1) undone, bearing in mind that:
– the screw on the left blade (1a) is unscrewed anti- On assembly, be careful to:
1a Screw for left blade ........................45 ÷ 50 Nm clockwise
1b Screw for right blade . ....................45 ÷ 50 Nm – the screw on the right blade (1b) is unscrewed – correctly position the keys (3) on the shafts;
clockwise. – correctly locate the right and left blades, with the
fins facing towards the inside of the plate;
– fit the flexible disc (4) so that the concave part is
 
pressing against the knife;
– tighten the screws (1 – 1a) with a torque wrench set
to 45-50 Nm.


 

Map of functional units

Always check that

the fins are intact with
cracks or breaks. Al- 
ways replace damaged
blades. 

 WORKSHOP MANUAL REMOVING, SHARPENING AND BA­LANCING CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 THE BLADES 4.8 0 2018 2 of 2

B) Sharpening and balancing

Always sharpen both cutting edges of the blade (2)

u­sing a medium grade grinder. Sharpening must on­
ly be done from the rounded side, removing as lit­tle
material as possible.

The blade is to be replaced when the cutting edge has

worn down to 10 mm.




Using the appropriate equipment, check the ba­lance

to make sure that there is a maximum diffe­rence of 2
grams between one side and the other.


 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHANGING OIL IN THE HYDRAULIC CIRCUIT 4.9 0 2018 1 of 3

A) Draining oil from the transmission units

General informations: and hydraulic circuit
Oil in the hydraulic circuit is subject to high pres­ 
sures and temperatures and is thus susceptible NOTE Oil is easily drained when hot, after removing
to deteriorating in time. the protection arch (1) and unscrewing the tank cap
For this reason, oil must be changed after the first (2).
50 hours of operation and, subsequently, every
200 hours.
Both transmission by-pass valves must be open to 
drain oil from the transmission units and hydraulic cir-
Related topics: cuit. This is achieved:

[  uide to understanding the hydraulic sys-

8.1] G
tem – at rear transmission, moving the rod (3) to the re-
lease position «B»;
– at front transmission, loosening the locknut (4) and

Tightening torques unscrewing the screw (5) about 3 turns, avoiding to 
undo completely the screw.
6 Front drain caps .............................. 13 ÷ 16 Nm 
8 Front breather cap .......................... 13 ÷ 16 Nm
9 Rear inspection cap ................................ 20 Nm Place a container to collect oil near each front wheel
and unscrew the two drain caps (6) being careful not
11 Rear quick coupling .............................. 25 Nm
to lose the sealing washers (7).

Technical informations
When oil flow starts to slow, unscrew the breather cap
– SAE 10W30 oil ..................................... ~ 4 litres (8) near the right wheel.

Map of functional units




 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHANGING OIL IN THE HYDRAULIC CIRCUIT 4.9 0 2018 2 of 3

Place a container to collect oil near the rear transmis- B) Filling the transmission units and ● Final operations
sion. hydraulic circuit
IMPORTANT NOTE In the first hours of use, after
Using a 3/8” spanner, unscrew the inspection cap (9) NOTE Filling must be performed from the tank, with emptying and topping up with hydraulic oil, the oil lev­
being careful of the gasket underneath (10) and un- by-pass devices (3) and (5) open, after making sure el in the tank could decrease quite noticeably and the
screw the quick coupling (11) to facilitate oil flow. that the breather valve (8) is also open. transmission may be rather unstable.

NOTE Draining the circuit may take several minutes. This is absolutely normal since due to small amounts
 of air in the transmission units.



When oil no longer drips from the drain holes, 
To prevent the user from having to question himself on
– tightly screw-in the two front caps (6) with their  whether the work is being performed correctly or not,
gaskets (7); it is recommended to perform an additional “dynamic”
– fully screw-in the bleed operation following the procedure below.
inspection cap 
(9) being careful
to correctly repo- – Remove the fuel tank cap (2) and close the filler
sition the sealing ● Front transmission unit with a cloth, or something similar, which prevents
ring (10); any dirt or dust from entering but still allows the air
– screw-in the Fully fill the oil tank and keep the breather hole under to filter.
quick coupling control (8); as soon as oil starts to spill, replace the
(11) without screw (8) fully tightening it and fill the tank again.
tightening it in  – With the engine running at minimum speed,
order to trap air in     – push the forward run pedal to around 3/4 of its
the rear unit and stroke, and keep the machine running for about
facilitate front unit ● Rear transmission unit 1 minute, without pushing the pedal down all the
filling. way.
Unscrew the quick coupling (11) so that it acts as a
breather to eliminate air and place a container under
it to collect oil when all air is drained.



Constantly check the oil level in the tank and top up to
compensate rear transmission filling.

NOTE The tank must never be emptied to prevent 

emitting air in the circuit.


When oil starts to flow out continuously, screw-in and

fully tighten the quick coupling (11). At this point filling 
 
is complete.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHANGING OIL IN THE HYDRAULIC CIRCUIT 4.9 0 2018 3 of 3

   – push the reverse run pedal to around 3/4 of its

stroke, and keep the machine running for about 2
minutes, without pushing the pedal down all the
way.

– With the engine running at maximum speed,

   – push the forward run pedal to around 3/4 of its
stroke, and keep the machine running for about
1 minute, without pushing the pedal down all the
way.
   – push the reverse run pedal to around 3/4 of its
stroke, and keep the machine running for about 2
minutes, without pushing the pedal down all the
way.

– With the engine running at maximum speed,

   – push the forward run pedal all the way down, and
keep the machine running for about 1 minute.
   – push the reverse run pedal all the way down, and
keep the machine running for about 1 minute.

Switch the engine off, check the oil level in the tank
and top-up so that it is between the two «MIN» and
«MAX» marks.

Check for leaks in the pipes and fittings, then replace

the tank cap (2) and replace the protection arch (1).





 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF FRONT HOOD 5.1 0 2018 1 of 1

To remove the hood, disconnect the headlight con-

General informations nector (1).
The removal of the front hood gives greater ac­ 
ces­sibility to:
– the engine and its accessories Take out the split pin (2) from the right-hand side and
– the silencer and protection devices remove the hood (3) by moving it to the right.

Related topics

---
 

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE WHEEL COVER 5.2 1 2018 1 of 2

Loosen the screw (1) and remove the handle (2). Disconnect the cables from the auxiliary mains socket
General informations (9), taking care to label them so that no reversal errors
Remove the inspection hatch (3) which is secured by are made on assembly.
Removing the wheel cover gives access to: the screw (4).
– the mount for the lever to raise the deck;
– the supports of the footboards.
 

Related topics

---
 


Tightening torques

9 Lower cover fixing screw ................4,0 ÷ 4,5 Nm

10 Upper cover fixing screw............. 4,0 ÷ 4,5 Nm

Dismantle the spring (5) which holds the battery in

place, taking care to prevent it from accidentally short-
circuiting. First disconnect the black earth cables,
then the positive red cable and remove the battery (6).

Remove the caps (7) from the springs and undo the Remove the seat after having taken out the two pins
screws inside (8). (10).

 

Map of functional units




 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE WHEEL COVER 5.2 1 2018 2 of 2

The cover (11) is fixed by two screws (12) located un- For assembly, follow the procedure described above
der the side footboards and four screws (13) fixing it in reverse, taking care to correctly insert the two side
to the rear plate. tongues (14) of the cover in the housings in the foot-
boards.

  

 





 

 



The cover can be removed after the cutting height When connecting the cables (9) make sure to replace
adjustment lever has been set to its highest position them in the right position:
(11).
A = Black = Terminal « – »
B = Brown = Terminal « + »
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE COLLECTOR CHANNEL 5.3 0 2018 1 of 1

The conveyor (1) is connected to the rear plate (2) by

General informations two plastic clamps (3), removable with the help of a
screwdriver.
Removing the collector channel gives access to:
– the small side wheels of the drive belt;
– the traction engagement control rod
Removal of the collector channel is indispensa­ 
ble for dismantling the cutting deck and if the rear
pla­te is to be removed.
  
Related topics

---

On assembly, ensure the free vibration of the convey-

or at each cutting deck height variation.

Map of functional units

 WORKSHOP MANUAL REMOVING THE DASHBOARD CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 AND FRONT COVER 5.4 0 2018 1 of 2

A) Removing the dashboard

General informations
Models with front tank:
Use a screwdriver to remove the central cover (1a) of Remove the tank cap (9) and protect the noz-
Removing the dashboard gives better access to: the steering wheel (1), being careful not to damage it.
– the accelerator zle to prevent foreign bodies from falling into the
– the ignition block, tank.
– various electrical components.
  Models with dashboard extension:
 Remove the dashboard extension (10), secured
Related topics by screws (11) and (12).

--- 


 


Unscrew the screw (2), remove the Belleville washer

(3) and washer (4) and remove the steering wheel (1).


Unscrew nut (5) and dismantle the ignition key block 
(6) without disconnecting the electric cables, to pre-
vent reassembly errors. 

Models with cruise control:

Loosen the screw (7) and remove the control knob
(8).


Map of functional units


  



 WORKSHOP MANUAL REMOVING THE DASHBOARD CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 AND FRONT COVER 5.4 0 2018 2 of 2

Disconnect the accelerator cable terminal from the B) Removing the front cover
engine and disconnect all remaining electrical con-
nections and the starter cable (where present). Remove the dashboard [see point “A”].

The dashboard (13) can be removed at this point; it is Remove the parking brake lever knob (21) or (22) and
fix­ed to the chassis by two upper screws (14), co­vered dismantle the front guard (23) fixed to the chassis by
by plastic caps, and three lower screws (15). six screws (24).



 



 

On assembly, follow the steps described in reverse,

being careful to restore wheel alignment with the
steering wheel, install the Belleville washer (3) with
the concave part facing down and fully tighten the 
screw (2). 

 





 
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE ENGINE 5.5 2 2018 1 of 2

Remove the front hood.

General informations 

Since there are different types of drive, the stag­ 

es de­scribed here refer to those shared or similar Loosen and uncouple the adjuster (1) to loosen the 
in all types of engine. blade control belt (2).

Related topics 

[  djusting the engagement and checking
4.1] A
the blade brake

[  rive belt adjustment
4.3] D


[  emoval of front hood

5.1] R
Unscrew the central screw (5) and remove the clutch
[  eplacement of the accelerator and ad-
6.9] R (6) from the shaft, together with the transmission com-
justment of the carburettor mand pulley (7) and the spacer (8).

Tightening torques
For better access to the parts concerned the transmis-
5 Screw for pulley .............................. 45 ÷ 50 Nm sion belt should also be slackened: this is obtained by
- Screws for engine fastening . ........... 25 ÷ 30 Nm loosening the stretcher.
IMPORTANT To remove the clutch (6) from the en­
gine shaft, absolutely do not use a lever to force the
pulleys or the outer cover. In case of difficulty, apply
Uncouple the return spring (3) from the clutch side an unlocking spray and gently tap on the hub with a
and disconnect the connector (4). hammer, to facilitate extraction.

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE ENGINE 5.5 2 2018 2 of 2

NOTE Some engines are held with screws of differ­

ent length and in different positions, so it is best to
label them so that no errors are made on reassembly.



 

Remove the protection from the exhaust (9) and di­

sconnect the cable control from the accelerator and
all the electrical wires.

Detach the fuel line pipe, taking care not to spill On reassembly, fully tighten the screws for the en­gi­ne
fuel. and the pulley to the amounts shown.

Reassemble the spacer (8), with the countersink fac-

Identify and undo all the screws that fasten the ing the engine. En­su­re that the pin (10) is inserted into
engine to the chassis, then carefully lift and remove the clutch spli­ne (6) and remember to refit the spring
the engine using equipment suitable for the weight of (3).
the engine (about 45-50 kg) and the designated lifting
points to guarantee safe working conditions.
Remember to fit the clamps back on the fuel
pipe and check that it does not leak.

Refit the protection (9) and restore accurately the

mass and all the electrical contacts, taking care to se-
cure them in such a way that they do not interfere with
the movement of the two steering tie rods.

Reattach the accelerator cable and ...

Adjust the «MINIMUM» position.

Refit the front hood.
Re­set the adjuster (1) and check the spring ten-
sion.
Reset the tension of the stretcher spring if it has
been loosened.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE REAR AXLE 5.6 0 2018 1 of 2

 Lift the rear part of the machine. 

General informations
 Remove the collector channel.
The rear axle (Transaxle) is made up of a single
maintenance free sealed unit which includes the  Remove the rear wheels.  
transmission unit (hydrostatic) and the differen­
tial and doesn’t need any maintenance.
It only needs to be removed to be replaced or for Model TH only:
an overhaul by the Manufacturer’s Service Cen­  Completely empty the oil from the hydraulic
tre. system

– Disconnect the rear fittings of the hydraulic
system pipes (1) and (2) and loosen the fixing
Related topics block screw (3) to permit pipe mobility.


– Remove the clamp (4) and remove the rubber

[  ifting of the machine
2.3] L pipe (5).
– Plug the remaining open holes so that dust or
[  rake adjustment
4.2] B impurities cannot enter.

[  rive pedal adjustment
4.4] D

[  mpting the hydraulic circuit
4.9] E
[  emoval of the collector channel
5.3] R
[  emoval of the wheels
6.1] R 

Tightening torques

1-2 Hydraulic system fittings .............. 23 ÷ 25 Nm

16 Rear axle support nut ................... 25 ÷ 30 Nm
17 Rear axle fastening nuts ............... 25 ÷ 30 Nm



Map of functional units Using the outlet firmly hold the two branches of the
belt (6) pulling it just enough to free it from the pulley
throat (7), overcoming the resistance of the guide pul-
ley stretcher.

Dismantle the drive control rod (8) by unscrewing the

nut (9) of the relative pin.

Dismantle the brake rod (10) by unscrewing the nut 

placed under the lever (11).
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE REAR AXLE 5.6 0 2018 2 of 2

Remove the ring gear fastener (12) from the clamp On assembly follow the above indicated steps in re-
(13) of the release lever connection (14). verse order, taking care that the ring gear fastener
must always be replaced (12).

 



   

 

The unit is supported by a support (15) fixed by a Check that the spacers (18 - 19 - 20 - 21) are correctly
screw with nut (16) and is fixed to the chassis by four fitted to the shafts, in the sequence given.
screws with relative nuts (17).

Model TH only:
– Reconnect the rear fittings of the hydraulic sys-
tem pipes (1) and (2), tightening them to the
Undo the nut (16) and then carefully undo the nuts of prescribed value and reassemble the rubber
the four lower screws (17), that hold up the unit so that pipe (5) with the clamp (4).
it does not fall. – Tighten the screw (3) to return the pipes in posi-
tion.
Completely fill the hydraulic system

Reattach all the connections, and then …

Check the brake.

Reassemble the collector channel.
Reassemble the rear wheels.

If the the drive control rod has been replaced or com-

 
pletely pulled down:
 

   djust the travel and the position of “neutral” for

A
the pedal
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE FRONT AXLE 5.7 2 2018 1 of 2

Lift the front part of the machine.

General informations:
Remove the front wheels.
The front axle is made up of a sealed single block 
which includes the hydrostatic transmission unit  ompletely empty the oil from the hydraulic sys-
C
and a torque transfer box and doesn’t require tem.
maintenance.
It only needs to be removed to be replaced or for Remove the silencer guard (1) and the silencer (2) 
an overhaul by the Manufacturer’s Service Cen­ fixed by the screws (3
tre.

Related topics

[  ifting of the machine

2.3] L
[  rake adjustment
4.2] B

[  rive pedal adjustment
4.4] D
Remove the clamp (6) and slide out the rubber pipe
[  teering geometry adjustment
4.6] S (7).
[  mpting the hydraulic circuit
4.9] E
[  emoval of the wheels
6.1] R
Plug the open holes so that dust or impurities cannot
enter.
Tightening torques

4-5 Hydraulic system fittings .............. 25 ÷ 30 Nm 
8 Steering tie-rod joint nut . .............125 ÷ 135 Nm
11 Front axle fastening nut . ..................... 280 Nm
15-17 Screws for bracket fastening .. 45 ÷ 55 Nm

Map of functional units

 

Disconnect the front fittings of the hydraulic system

pipes (4) and (5), marking them so that they can be
correctly repositioned.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE FRONT AXLE 5.7 2 2018 2 of 2

unit so that it does not fall.

Unscrew the nuts (8) and remove both steering tie- If the unit needs to be replaced, the supporting bracket  
rods (9). should be removed (14), which is fixed by the screws
(15) and the tie-rod bracket of the steering (16) is fixed 
by the screws (17). 


On assembly follow the above indicated steps in re-
verse order, taking care to correctly reposition the
bush square (13) into their respective housings in the
support (10).


When reassembling the fittings (4) and (5) take care 

to respect the positions indicated on the connection
diagram. 

The unit is supported by a support (10) to which it is

fixed by a screw (11) with a nut (12). Reassemble the front wheels.

Check front wheel and steering wheel alignment.

   Completely fill the hydraulic system.

 


Unscrew the nut (11) and then carefully undo the
screw (12) and the bush square (13), holding up the
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REMOVAL OF THE CUTTING DECK 5.8 0 2018 1 of 1

Remove the collector channel.

General informations
After moving the cutting deck into position «1», loos-
Removing the cutting deck facilitates all opera­ en the adjuster of the cable (1) and slide it away from
tions involving the blade connecting toothed belt its housing.
and the overhaul and replacement of the hubs,
bea­rings or blade shafts.

With some practice and experience it is possible
to do this work with the deck still in position.


Related topics

[  ligning the cutting deck

4.5] A
[ 
5.3] Removal of the collector channel On assembly ensure that the two rear holes of the cor-
ner joints (9) are used for fixing the pins (3), without
fixing the relative nuts (2).

Unscrew the two nuts (2) of the two pins (3) from the 
two front connecting rods (4), without loosening or
changing the position of the nuts (5) and locknuts (6).

 




   


Map of functional units
  
After having restored all the connections, ...
NOTE For some preparations, the pins (3) are fixed
using the split pins (2a). Refit the collector channel.

Remove the two flexible split pins (7) of the rear pins If the nuts and locknuts (5 – 6) were accidentally
(8). Then check that there are no obstructions, the moved...
deck can be removed by pulling it out so that all the
pins come out of housings. The deck must be properly adjusted.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REPLACEMENT OF TYRES AND WHEELS 6.1 0 2018 1 of 1

A) Tyres On assembly it is advisable to spread grease on the

General informations shaft to facilitate the next wheel removal.
After replacing one or more tyres or the wheels, it is
The tyres used are of the “Tubeless” type and so al­ways necessary to check the pressure and to check
e­ve­ry repair of a hole in the tyre must be done by the alignment of the cutting deck. ● For the front wheels: replace the shoulder washer
a ty­re specialist according to the methods used (2) and the flexible ring (1) with the bevel facing in­
for this type of tyre. wards.

ATTENZIONE Replace distorted wheel rims ● For the rear wheels: replace the shoulder washer
Related topics as they could impair the tyre’s hold. (2) and the flexible ring (1) with the bevel facing in-
wards and check the axial gap of the wheel on the
[  ifting of the machine
2.3] L shaft; if it is greater than 3 mm, a spacer (3) must be
fitted between the wheel hub and the shoulder wa­
[  ligning the cutting deck
4.5] A sher (2).

Tyre pressures

Front .......................................................... 1,0 Bar B) Wheels

Rear ........................................................... 1,4 Bar The wheels are held by a snap ring (1) which can be


removed with the help of a screwdriver. 



Map of functional units

NOTE If a wheel is jammed onto the shaft, use a

releasing spray, directing it around the splining hole.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REPLACEMENT OF FRONT WHEEL BEARINGS 6.2 0 2018 1 of 1

Dismantle the front wheel.

General informations

--- The front wheel bearings (1) are force splined into the
front wheel hub.
Related topics
A 10 - 12 mm diameter round bar (2) must be used to
[  ools
2.2] T extract a bearing, inserted from the opposite side and
struck with a hammer around various points of the in-
[  ifting of the machine
2.3] L ner circumference of the bearing.
[  eplacement of tyres and wheels
6.1] R

The new bearing must be fitted with the help of a pla­

stic mallet or of a bronze pad (3) that only acts on the
bearing’s outer ring.

Map of functional units




 WORKSHOP MANUAL DISMANTLING OF THE STEERING CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 COMPONENTS 6.3 0 2018 1 of 3

NOTE Removing steering parts requires removing Empty the tank of petrol (7).
General informations the enti­re unit from the vehicle.
---
A) Removing the steering unit from the vehicle

Related topics Remove the wire clamp (1), accessible through the
inspection hatch in front of the seat.
[  djusting the drive engagement
4,3] A  

[  teering geometry adjustment

4,6] S For TH4 only:

– Remove the two clamps (2) to free the hydraulic

Tightening torques system pipe (3).
– Remove the protective bow (4), unscrew the 

19 Nut for pulley fastening ................ 25 ÷ 30 Nm two nuts (5) and laterally move the oil tank (6),
being careful not to spill oil.
21 Screws for steering unit fastening . 50 ÷ 55 Nm
24 Nuts for support fastening.............. 35 ÷ 40 Nm
31 Nuts for bearing support fastening..25 ÷ 30 Nm 
 
Detach the level indicator connector (8), remove the
34 Nut for sector bearing fastening . ...... 55 ÷ 60 Nm petrol guard (9) and unscrew the two screws (10) to
remove the tank (7).


Extract the retention spring (11) and disconnect each
articulated head (12) from their relevant pins (13).



Map of functional units  








 WORKSHOP MANUAL DISMANTLING OF THE STEERING CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 COMPONENTS 6.3 0 2018 2 of 3

Using a drift of suitable diameter, extract the pin (14) 

from the upper cardan joint (15) and extract the steer-  
ing wheel (16) with relevant column, being careful not
to remove the bushing (17).



 
 

 




B) Part removal Remove the upper bushing (28).



Extract the pin (22) and remove the lower cardan joint Check sliding plate wear (29) and replace if neces-
Unhook the spring (18) from the drive belt tensioner. (23). sary.

Unscrew the two nuts (24) and remove the support Check toothed sector allowance (30) compared to the
(25). support (31); if excessive, replace the bearing.

Slide out the shaft with the pinion (26) and lower bush- Unscrew the three nuts (32), remove the support (33)
ing (27). and slide out the bearing (34), secured by the nut (35)
to replace.





 




Working from the lower part of the vehicle, unscrew

the nut (19) and remove the pulley (20) to access the 
steering unit fastening screws.


Unscrew the 4 screws (21) and remove the unit.
 WORKSHOP MANUAL DISMANTLING OF THE STEERING CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 COMPONENTS 6.3 0 2018 3 of 3

C) Part reassembly and allowance adjustments Reassemble the upper bushing (28) and cardan joint D) Steering unit reassembly on the vehicle
(23) with relevant pin (22), then remove the screw (36).
Follow the steps in point “A” in reverse order.

 When assembly is completed:

 Check front wheel and steering wheel alignment.

   
Adjust the drive belt.




Reassemble the lower bushing (27) and support (25)

fully tightening the two nuts (24).

Loosen the nut (35) to let the toothed sector (30)

move.

Place an M8 screw (36) in the toothed sector hole and Move the toothed sector (30) longitudinally until allow-
reassemble the shaft with pinion (30) so that the pin ance is reduced to a minimum between sector teeth
and tooth face the screw head (36). and the pinion. Then tighten the nut (35) and grease
concerned parts.

 


 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REPLACEMENT OF THE DRIVE BELT 6.4 0 2018 1 of 1

Dismantle the engine pulley On assembly, make sure that the belt (5) is correctly
General informations positioned in the pulleys, the small side wheels and
Remove the collector channel. inside the rims.
---
It is advisable to slacken the transmission belt to work Always reassemble the dust cover (6).
on the parts involved more easily. This is done by
Related topics slackening the stretcher. When assembly is completed …

[  rive belt adjustment

4.3] D

Refit the engine pulley.

[  emoval of the collector channel

5.3] R Adjust the drive engagement.
[  emoval of the engine
5.5] R Refit the collector channel.
[  elts assembly
9.2] B
Tighten the spring of the stretcher.


Tightening torques

2 Nut for pulley..................................... 25 ÷ 30 Nm

3 Nuts for small wheels . ..................... 25 ÷ 30 Nm

Dismantle the stretcher pulley (1) which is fixed by the

nut (2).

Loosen the nut (3) of the right rear wheel (4) just
enough to allow passage of the belt (5) and to remove
the belt.


Map of functional units


 WORKSHOP MANUAL REPLACEMENT OF THE SMALL WHEELS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 FOR THE DRIVE BELT 6.5 1 2018 1 of 1

Remove the collector channel. that the left rear small wheel should be placed in the
General informations rear hole of the chassis plate.
It is advisable to slacken the transmission belt to work
--- on the parts involved more easily. This is done by Make sure it is fed through the two forks (5).
slackening the stretcher.
Always reassemble the dust covers (4).
Related topics The two small side wheels are fixed to the chassis
with a nut (2).
[  rive belt adjustment
4.3] D
The small wheels differ in:
[  emoval of the collector channel
5.3] R – sizes (1a - Ø 63 mm) or (1b - Ø 50 mm); Once assembly is completed ...
– spacer length (3a - 21,5 mm), (3b - 30,6 mm).
[  elts assembly
9.2] B Adjust the drive engagement.

Refit the collector channel.

Tightening torques On assembly it is important to follow both specifica-
tions, as shown on the diagram, taking into account Tighten the spring of the stretcher.
2 Nuts for small wheels . .................... 25 ÷ 30 Nm

 

 

 

 

Map of functional units




 WORKSHOP MANUAL REPLACEMENT OF THE BLADES CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CONTROL BELT 6.6 0 2018 1 of 1

NOTE The blade belt guards could have different

General informations configurations and fixings; in any case they must all  
be removed, after having identified all the fixing points.  
---

Pull a branch of the belt (1) to free it from the engine

Related topics pulley (2).

[  djusting the engagement and checking

4.1] A
the blade brake
[  elts assembly
9.2] B


Tightening torques
Loosen the nut almost completely (4) without disman-
4 Nut for idle pulley ............................ 20 ÷ 25 Nm tling the guide pulley (5) so it is possible to slide the
7 Screw for pulley .............................. 20 ÷ 25 Nm belt out

Keeping the blade locked, unscrew the screw (6) and

dismantle the command pulley (7) to remove the belt
 (1).

On assembling, make sure that the belt is correctly

positioned to the pins and in the pulley rims.
Set the cutting deck in the lowest position, to obtain When assembly has been carried out, it is recom-
greater accessibility, and then dismantle the upper mended...
casing (3).
Check the blade engagement adjustment.


Map of functional units

 WORKSHOP MANUAL REPLACEMENT OF THE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 BLADES CONNECTION BELT 6.7 0 2018 1 of 2

NOTE The blade belt guards could have different Remove the protection casing (8), slackening off the
General informations configurations and fixings; in any case they must all six surround screws (9) and extract it from its slots.
be removed, after having identified all the fixing points.
---

Related topics  


[  pecial tools
2.2] S 

[  djusting the engagement and checking

4.1] A
the blade brake

[  elts assembly
9.2] B

Tightening torques

4 Blade pulley screws ........................ 20 ÷ 25 Nm

6 Stretcher plate articulation screw .... 35 ÷ 40 Nm
Set the cutting deck to the lowest position to obtain
11-12 Pin fixing nuts .......................... 30 ÷ 35 Nm greater access, then slacken off and uncouple the ad­
13-14 Pulley fixing nuts . .................... 30 ÷ 35 Nm juster (1) to unload the spring (2) .

Dismantle the upper casing (3), undo screw (4) and Record the reading on the adjuster (10) (this must
di­smantle the control pulley (5); undo the articulation be reset at reassembly to give a preliminary belt ad­
screw (6) and remove the stretcher plate (7). justment) and slacken it off completely.


Map of functional units

 
 WORKSHOP MANUAL REPLACEMENT OF THE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 BLADES CONNECTION BELT 6.7 0 2018 2 of 2

  
Fit the new belt so that, when the two long sections
are held taut, the two blades are at 90° to each other.

Refit everything by reversing the operations de­scri­ When refitting the

bed above. Reset the adjuster reading recorded pre­ spring (2), make sure 
viously and check that the blades are at 90° to each that it is con­nected to
other before locking the pin (11) and pulleys (13) and the hole provided for 
(14). each model.


  
IMPORTANT On reassembly, check that the washer
Dismantle the pin (11), slacken off the fixing nuts of under the pin (11) is not damaged and that the outer Finally, when reassembly is complete, it is advisable
the three pins (12) and the pulleys (13) and (14) to al- pin rol­lers run freely. to …
low removal of the belt.
Check the adjustment of the blades engagement.






 
Use the specific tool (15) to check the piston (16) for
the belt give values and the force applied, and use the
stretcher until a give of 9 ÷ 10 mm is ob­tai­ned, exert-
ing a force of:
– 3,5 kg mod. 102
– 4,2 kg mod. 122

Reassemble the casing, stretcher and blades control

belt, taking care over their exact positioning with re-
spect to the pins and containment guides.
 WORKSHOP MANUAL REPLACEMENT OF THE SUPPORTS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 AND SHAFTS OF THE BLADES 6.8 0 2018 1 of 2

Remove the cutting deck.

General informations

--- NOTE This operation is not strictly necessary since,

with a lit­tle practice and experience, it is possible to
dismantle the deck supports without removing the
Related topics cutting deck.

[  pecial tools
2.2] S
Remove the blade control belt.
[  emoving, sharpening and balancing the
4.8] R
blades Remove the blade connection belt.
[  emoval of the cutting deck
5.8] R Remove the blades and take off the hubs.


[  eplacement of the blades control belt

6.6] R
Dismantle the flanged support (4) by unscrewing the
[  eplacement of the blades connection belt
6.7] R three fixing screws (5).
Extract the two toothed pulleys (1) from the blade
Tightening torques shafts, undo the seven screws (2) fixing the plate (3)
and remove it. The entire support (4), including shafts and bea­rings,
2 Plate fixing screws .......................... 30 ÷ 35 Nm is a spare part available as a single as­sem­bly unit.
5 Flanged support fixing nuts.............. 25 ÷ 30 Nm    

If only the shaft or bearings are to be replaced, re­mo­

ve the key or the two keys (6) and hit the shaft on the
pulley side with a plastic mallet to extract the shaft to-
gether with the lower bearing (7).

Map of functional units  


 WORKSHOP MANUAL REPLACEMENT OF THE SUPPORTS CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 AND SHAFTS OF THE BLADES 6.8 0 2018 2 of 2

After having removed the key (8), the snap ring (9) On reassembly, having first inserted the shaft in the lo­
and the dust cover (10), the bearing (11) splined onto wer bearing hole and inserted everything into the sup­
the shaft can be removed using a normal ex­trac­tor, port, fit the upper bearing using the specific stopper
being careful to close the threaded hole (12) with a (14) that acts on the inner ring, hitting it squarely with
suitable screw to prevent the tip of the ex­trac­tor from a mallet until the bearing is fully driven home.
damaging the thread.



 







The second bearing still in place must be removed by NOTE Refit the flanged supports onto the deck, fully
hitting it from the inside of the flange using a 12 ÷ 15 tighte­ning the nuts (5) and checking that the sup-
mm diameter round bar (13). port with the longer shaft is on the left.

IMPORTANT When refitting the plate (3), the holes

correspon­ding to the support axes must meet
perfectly in the centring step (15) cut into the up­
 per part of each support.

Reassemble the blades.

Reassemble the blade connection belt.

Reassemble the blade control belt.

 WORKSHOP MANUAL REPLACEMENT OF THE ACCELERATOR AND CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 ADJUSTMENT OF THE CARBURETTOR 6.9 0 2018 1 of 1

Remove the dashboard. On reassembling, put the accelerator lever in the «MI­
General informations NIMUM» position, connect the end of the cable (2) to
the terminal (3) on the engine after having mo­ved the
--- Take off the knob (1) and disconnect the cable (2) cursor (5) in the same «MINIMUM» position specific
from the connection terminal (3) on the engine. to each type of engine and shown in the in­struc­tion
booklet.
Related topics
Undo the two fixing screws (4) and take out the ac­ce­
lerator together with the wire.
[  emoval of the dashboard
5.4] R
 




When assembly is completed ...

Refit the dashboard.

Map of functional units

 WORKSHOP MANUAL REPLACEMENT OF THE PIPES OF THE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 HYDRAULIC SYSTEM 6.10 2 2018 1 of 3

Lift the front part of the machine.

General informations: 
Dismantle the front left wheel.
The hydraulic circuit has two different types of
pipes: Remove the collector channel.
– rigid pipes with flexible ends, and screwed on
fittings for the delivery and return of high pres­  ompletely empty the oil from the hydraulic sys-
C
sure oil to and from the two transmission units; tem 
– flexible hoses to connect the transmission
units to the tank, at low pressure (atmospheric
pressure).
 

Related topics: A) High pressure pipes

[  ifting of the machine

2.3] L NOTE The high pressure pipes are those that con­
nect the rear transmission to the front transmission
[  mpting the hydraulic circuit
4.9] E and that run along the left beam of the chassis.
[  emoval of the collector channel
5.3] R 
[  emoval of the wheels
6.1] R
Unscrew the screws (5), remove the plate (6) and (7)
from the fixing blocks.

Tightening torques Disconnect the rear fittings (1) and (2) and the front
fittings (3) and (4) from the pipes of the hydraulic sys- 
1-2 Hydraulic system fittings .............. 35 ÷ 40 Nm tem and remove the pipes (8) and (9).
3-4 Hydraulic system fittings .............. 25 ÷ 30 Nm




Map of functional units




 
 WORKSHOP MANUAL REPLACEMENT OF THE PIPES OF THE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 HYDRAULIC SYSTEM 6.10 2 2018 2 of 3

 



  



 

The pipes differ, so on assembly take care not to in-

vert their position (8) and (9), and to correctly fit the
front and rear fittings into their attachments on the
transmission.

 

After connecting the two front fittings (3) and (4),
check that the swing of the front transmission doesn’t
cause the flexible tubes to scrape against the chassis.




B) Low pressure pipes


The low pressure pipes connect the oil tank to the two 
transmission units.
     

The two pipes (11) and (12) are fixed to the attach-
ments on the fuel tank and to the transmission unit
fittings by the pipe clamps (13) and (14).


 WORKSHOP MANUAL REPLACEMENT OF THE PIPES OF THE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 HYDRAULIC SYSTEM 6.10 2 2018 3 of 3

On assembly take care to restore the correct pipe po-

sitions, fixing them to the chassis at the points indi- 
cated on the diagram, using:

– 2 clamps (15) on the right side for the rear pipe (11);
– 2 central clamps (16) and 1 clamp (17) for the front 
pipe (12), checking that the pipe does not come
     
into contact with the steering tie-rod or other mov-
ing parts.

Fill the hydraulic system.

Reassemble the collector channel.



  





 

 
 WORKSHOP MANUAL TROUBLESHOOTING OF THE ELECTRICAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SYSTEM 7.1 0 2018 1 of 3

General informations PROBLEM CAUSE REMEDY

In the following some of the problems connected 1. Activation of the self-re-

to the malfunctioning of the electrical system are setting protection 1) ....
shown, with their probable cause and the reme­ Battery terminal crossed Check the battery connections
dial action to be taken. a) ... on inserting the key in
position «ON» Check the connectors and wiring of the
Should the problem continue after the appro­ Short circuit to earth
microswitches
priate checks, seek assistance from your lo­cal
Service Centre. Sulphated battery (it no longer ac-
Replace the battery
cepts recharging)
 b) ... in position «START» Check and dry with low pressure tepid

or after a few seconds use, Faulty or wet electronic card
air (hair-dryer)
following an attempt
 at starting with outside Reconnect the battery. It must always be
means: Disconnected or missing battery
connected
Battery terminals corroded or with
Check and clean the connections
poor contact
Related topics Poor or missing earth contact on the Check the earth connections and the
charge regulator screws fastening the regulator
[  table for the cutting in of the safety de-
7.2] T c) ... after several minutes’ Overvoltage from a malfunction in
Check the recharge circuit
vices use: the regulator
Battery disconnected or faulty dur-
[  afety microswitches operation check
7.3] S ing use
Check the battery or wiring
[  tarter relay operation check
7.6] S Check the connection cables
The battery is not supplying the card
[  eplacing the clock battery
7.9] R
2. The dashboard remains
Check the battery’s condition

[  echarge circuit check

7.10] R off with the key in posi- Battery or card not earthed to frame Check and put right
tion «ON»
[  aintenance of the sealed battery
7.11] M 10 A fuse blown Replace fuse (10 A)
Battery terminal crossed Check connections

Map of functional units WARNING! The self-setting guard reaches very high temperatures (around 180 °C) which are to be consid­
ered normal. Similarly, there might be some smoke inside the box which is due to the overheating of the powder
inside. Do not touch this component of the circuit board until it has cooled down.

1)
 he cutting in of the self-resetting protection of the electronic card is signalled by a beep, except in cases where the
T
battery is missing, flat or with the terminal crossed. The signal stops when the key is returned to position «OFF»; then
wait a few seconds before returning to position «ON».

IMPORTANT Faulty electronic cards must always be replaced without trying to repair them or re­place single
components.
 WORKSHOP MANUAL TROUBLESHOOTING OF THE ELECTRICAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SYSTEM 7.1 0 2018 2 of 3

PROBLEM CAUSE REMEDY

The battery is not supplying sufficient current Recharge the battery

Badly earthed battery, or the starter relay or engine not
3. The dashboard switches on but, with Check and put right
earthed
the key in position «START», the starter
After checking that the conditions are met, check all the micros-
does not turn or lacks power (poor start- Starting not permitted
witches and the relative wiring
ing)
Malfunction in the electronic card Try replacing the card with one that is known to work
Starter relay is faulty Check that the starter relay is activated
Check the leads for the carburettor solenoid valve opening con-
No fuel flowa
trol (if provided) or check the fuel stopcock and filter
4. The starter turns but the engine does
Check that the spark plug cap is positioned correctly
not start
Impaired starter system Check that the spark plug electrodes are clean and have the
correct gap
Mechanical difficulties with the contact breakers of the
Replace the starter relay
5. The starter continues to turn after starter relay
engine has started, and does not stop Starter works erratically for mechanical or electrical
when the key is removed reasons taking excessive current and causing binding Check the starter
of relay contacts
Replace the panel/board group (NOTE: it is possible to com-
6. The starter operates as soon as the Fault in the card plete the work in any case, but the panel/board group must be
key is in the «ON» position, and can be replaced as soon as possible)
turned off only by removing the key
Starter block operating faults Replace the block

7. The battery warning light does not come Replace the panel/board group (NOTE: it is possible to com-
on with the key in position «ON» but the Fault in the electronic circuit or in the signalling LED plete the work in any case, but the panel/board group must be
machine operates replaced as soon as possible)
Check that the charging cable has not detached
Check that there are no current leakages caused by cables with
Insufficient charge
8. The battery warning light remains on damaged insulation
Check the recharge circuit
Charger fuse blown Replace fuse (25 A) and check the recharge circuit

IMPORTANT Faulty electronic cards must always be replaced without trying to repair them or re­place single components.
 WORKSHOP MANUAL TROUBLESHOOTING OF THE ELECTRICAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SYSTEM 7.1 0 2018 3 of 3

PROBLEM CAUSE REMEDY

Recharge overvoltage Check the recharge circuit

9. The battery light is blinking
Battery insufficiently charged at startup Recharge the battery
10. Abnormal, uncontrolled lighting up of Faulty or wet electronic card Check and dry with low pressure tepid air (hair-dryer)
the LEDs or irregular card operation Bad earthing of the electronic card Check and put right
Check the operation of the microswitch operation and the rel-
The safety devices have cut in or are faulty
evant wiring
11. The 10 A fuse cuts in Accidental detaching of an electrical wire Check all wiring
After checking that the conditions are met, check all the micros-
Starting of engine not permitted
witches and the relative wiring.
Short circuit or overload on the power side of the card
(ignition block, starter relay, headlamps and recharger Find and replace the defective user
connector)
12. The 10 A fuse cuts in
Replace the panel/circuit board group with one that is known to
Short circuit or damage to the electronic card protec-
work; if the problem does not reoccur replace the faulty group
tion (power side)
definitively
13. The 25 A fuse cuts in Faults in the battery charging circuit Replace fuse (25 A) and check the recharge circuit
Check the microswitches and wiring.
Malfunctioning or faulty blade microswitches and WARNING! - Check that the blades microswitch stops the
grass-catcher signalling engine or prevents if from being started if the acknowledgement
14. No audible signal for the “grass- conditions are not met..
catcher full” condition
Replace the panel/circuit board group with one that is known to
Malfunctioning or faulty electronic card work; if the problem does not reoccur replace the faulty group
definitively
15. The clock does not keep time after the
Buffer battery flat Replace
machine is switched off.

IMPORTANT Faulty electronic cards must always be replaced without trying to repair them or re­place single components.
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CUTTING IN OF THE SAFETY DEVICES 7.2 1 2018 1 of 1

General informations This table shows the various situations in which the sa­fety devices intervene.
---
A) STARTING («START» position)
Related topics The engine DOES NOT start, when:
Operator –/– –/– Absent
[  afety microswitches operation check
7.3] S
Grass-Catcher –/– –/– –/–
Blades –/– Engaged –/–
Drive Engaged –/– –/–
Parking –/– –/– –/–

Indication on the
Dashboard

B) WHILE CUTTING

The engine STOPS start, when:

Operator Absent Absent –/– –/– Absent Seated
Grass-Catcher –/– –/– Missing –/– –/– Fitted
Blades –/– Engaged Engaged Engaged –/– Engaged
Drive Engaged –/– –/– –/– –/– Reverse
Consent Button –/– –/– –/– –/– –/– Released
Parking –/– –/– –/– Engaged –/– –/–
Map of functional units

Indication on the
Dashboard

–/– Irrelevant condition for the triggering of safety devices

Ж = Pilot lamp on Ж = Pilot lamp off Ж = Pilot lamp uninfluential

 WORKSHOP MANUAL SAFETY MICROSWITCHES OPERATION CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHECK 7.3 2 2018 1 of 1

This check is done by disconnecting connector CN1

General informations and using the tester in Ohmmeter mode. CN2
10 20

This o­peration must be performed without the opera- 9 19

--- tor a­board, making contact with the ferrules on the
1 8 18
2 7 17 CN1
contacts of the wiring connector (1) and must give 3 6 16
these results: 19 20
Related topics 4 5 15 17 18
15 16
4 14 13 14
No. of Contacts    Tester reading and condition 11 12
10

---
3 13 8 9
6 7
GRASS-CATCHER ATTACHED MICROSWITCH 2 12 4 5
2 3
1-6 ∞ (without g.catc) O (with g.catcher) 1 11 1

OPERATOR PRESENCE

1 - 14 ∞ (absent) O (seated)
PARKING MICROSWITCH
1 - 17 O (free) ∞ (engaged)
10 20
BLADES SWITCH CN2
9 19
1 - 16 ∞ (engaged) O (disengaged) 1 8 18
“IN NEUTRAL” SIGNAL 2 7 17 CN1
3 6 16
1-7 O (drive) ∞ (neutral) 20
4 5 15 18 19
GRASS-CATCHER FULL MICROSWITCH 15 16 17
4 14 13 14
1 - 13 ∞ (empty) O (full)
10
3 13 11 12 8 9
6 7
FUEL LEVEL GAUGE (if present) 2 12 4 5
1 11 2 3
1-5 O (reserve) ∞ (from 1/2 to full) 1

1-8 O (full) ∞ (from reserve to 1/2)


OIL WARNING LIGHT (if present)
1 - 15      O (always)
IGNITION KEY 10 20
CN2
+ Battery - 11 ∞ (OFF) O (ON) O (START) 9 19
+ Battery - 12 ∞ (OFF) ∞ (ON) O (START) 1 8 18
2 7 17 CN1
3 6 16
Engine Stop 5 15
19 20
4 17 18
This operation must be done making contact with the 4 14 15 16
13 14
ferrules on the contacts of connector CN1 of the card, 3 13 11 12 8 9
10
6 7
keeping all other connectors con­nected, and must 2 12 4 5
Map of functional units give this result:  1 11 1
2 3

No. of Contacts    Tester reading and condition

1-3 O (Always)
Reverse Consent No. of Contacts    Tester reading and condition
This check is made by detaching all the connector (3).
REVERSE CONSENT BUTTON
The following results must be achieved using the
Ohm-meter function tester with the probes in contact 1 (CN1) - 3 violet ∞ (released) O (pressed)
with the contacts of circuit board connector (3) and REVERSE GEAR MICROSWITCH
the contact «1-CN1» of the card: 1 (CN1) - 3 bleu O (free) ∞ (pressed)
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 TERMINAL BOARD SUPPLY CHECK 7.4 0 2018 1 of 1

This check is made with the tester operating as a

General informations Voltmeter (Volts DC 0 ÷ 20), with the black ferrule on CN2
10 20
9 19
terminal 1 and the red one on terminal 11of the con-
---
1 8 18
nector (1) of the wiring. 2 7 17 CN1
3 6 16
Related topics – The key in the «ON» position 4 5 15
4 14
--- The reading shows the battery voltage, which should 3 13 20
18 19
never go below 11 Volts. 2 12
15 16 17
1 11 13 14 10
11 12 8 9
6 7
4 5
 1
2 3

Map of functional units

 WORKSHOP MANUAL CARBURETTOR SOLENOID VALVE CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 OPERATION CHECK 7.5 0 2018 1 of 1

Connector CN1 must be connected to make this

General informations check.
10 20
CN2
--- When the key is set to «ON», a click must be heard
9 19
1 8 18
from the carburettor solenoid valve coil.
Related topics 2 7 17 CN1
3 6 16
5 15
---
4
4 14
3 13
2 12
1 11

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 STARTER RELAY OPERATION CHECK 7.6 1 2018 1 of 1

General informations WARNING! Remove the cap of the spark­ CN2

10 20
9 19
ing plug (or plugs), since the safety systems that
---
1 8 18
nor­mally prevent accidental starting of the en­ 2 7 17 CN1
gine are cut out when the checking procedure is 3 6 16
Related topics carried out. 4 5 15
4 14
--- To do this requires: 3 13 20
2 12 18 19
15 16 17

– operator seated; 13 14
1 11 10
11 12 8 9
– blades disengaged; 4 5
6 7

– the key in the «ON» position.  2 3

1

Detach connector CN1 and then, when a bridge is

made between terminals 11 and 4 of connector CN1
of the wiring (1), the relay bobbin must be heard to
click and the starter must start.

 except Honda engines: 

If the bobbin clicks but the starter does not start,
make a bridge (2) with a large section cable (5
mm2) between the power contacts of the relay.

If the starter comes into operation, look for the fault

within the relay or replace it. Otherwise, check the
starter together with its wiring.

Map of functional units

 WORKSHOP MANUAL ELECTROMAGNETIC CLUTCH OPERATION CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 CHECK 7.7 0 2018 1 of 1

General informations WARNING! This check must be made with CN2

10 20
9 19
the engine off. 1
--- 2
8 18
7 17 CN1
Disconnect connector CN1 and bridge terminals 2 3 6 16
and 11 of cabling connector CN1 (1). 4 5 15
Related topics 4 14
With the key set to «ON», when the switch is ope­ 3 13
18 19
20

 afety microswitches operation check rated a click must be heard from the moving part of
2 12
[ 7.3] S 1 11 13 14
15 16 17

the clutch, due to excitation of the electric wiring. 11 12 8 9

10
6 7
4 5

If this is not so, check the operation of the cabling and 1
2 3

control switch.

The clutch must be replaced if engagement does not

take place after these checks.

Map of functional units

 WORKSHOP MANUAL CHECKING THE OPERATION OF THE BAG CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 EMPTYING CONTROL 7.8 0 2018 1 of 1

The following conditions must be ensured to make

General informations this check: CN2
10 20
9 19
---
1 8 18
– key set to «ON», 2 7 17 CN1
– connector CN2 connected, 3 6 16
– operator seated, 4 5 15
Related topics – blades disengaged. 4 14
3 13
--- The check is made with the tester in Voltmeter mo­de 2 12

(0 ÷ 20 Volts DC) and with the probes on the connec- 1 11

tor (2) output cabling terminals. 

When one of the two keys is pressed the instrument

reading shows the battery voltage (positive or nega-
tive); this value must never fall below 11.5 Volts.

If no power is detected it means that the 15 A fuse has

blown or that there is a fault in the actuator board.

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 REPLACING THE CLOCK’S BUFFER BATTERY 7.9 0 2018 1 of 1

NOTE The lower panel/board group guard, fixed by

General informations two nuts, must be removed to carry out this o­pe­ration.  
---
Use a screwdriver to remove the flat battery (1).
Related topics Only use 3 Volt 24 mm Ø batteries of types CR 2450
or CR 2430.
---
When fitting the new battery make sure that the end
marked «+» faces towards the check spring.

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 RECHARGE CIRCUIT CHECK 7.10 0 2018 1 of 1

The job of the voltage regulator is to supply a flow of With the voltmeter tester, measure the voltage at the
General informations current to the battery at a constant voltage of about battery terminals. If the value does not rise but tends
14 -15 Volts, cutting in every time that the output volt- to fall, even slowly, it means that the regulator is not
--- age from the generator exceeds this threshold. charging sufficiently and must be replaced.

A faulty regulator may recharge the battery insuf- If the voltmeter shows no value it means that the
Related topics ficiently (therefore needing frequent recharging) or, charger fuse is blown.
otherwise, may supply overloading that causes the
--- self-resetting protection to cut in.

Before checking the recharge circuit, make sure that:

B) Checking the upper charging limit
– all connections are correct;
– the earth connections are firmly connected, espe- Start the engine and take it to maximum speed. With
cially the earth connection to the regulator; the tester in the voltmeter function, measure the
– the battery is charged and not sulphated; voltage at the battery terminals. The amount should
– the charger fuse is not blown. slowly rise and settle at 14-15 Volts after about 10-15
minutes.

A) Checking the lower charging limit If this value is exceeded to the extent that the engine
stops due to the self-resetting protection cutting in
Start the engine and keep running at minimum with (at approximately 16 Volts) it means that the regulator
the headlights on. is charging too much and must be replaced.

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 MAINTENANCE OF THE SEALED BATTERY 7.11 0 2018 1 of 1

A) General information C) Rules for recharging the battery

General informations
In a sealed “dual” battery, the electrolyte for each el- La ricarica è una operazione particolarmente IMPOR-
--- ement is carefully measured out during manufacture Recharging is a particularly important operation for
and sea­led at source, in order to ensure maximum the life of the battery and must be carried out accord-
performance during the battery’s entire life. ing to the­se instructions:
Related topics
– do not recharge the battery when its case is broken
--- or damaged;
– carefully read the instructions for using the battery
With a battery of this type, it is not necessary to add charger and the battery;
water or acid, and the cover must never be opened or – use a suitable battery charger;
re­moved. – recharge at a room temperature of between +10
and +30 °C;
– check that the battery does not heat to beyond 50
°C while recharging. If it should do so, stop recharg-
ing immediately and dispose of the battery since it
B) Recommendations for correct use will be unusable.

To keep the battery performing at optimum levels and With the battery disconnected (and at rest for at least
to increase its life, various precautions should be tak- 12 hours) and the tester in voltmeter function, meas-
en: ure the voltage between the terminals. The amount
given (open circuit voltage) gives an indication of the
– always keep the battery fully charged; operations to be carried out, as per the following table:
– always recharge a flat battery within 1 month, oth-
erwise the elements could be damaged and no Battery voltage Operation to be
Battery state
longer able to take the charge (sulphated); with open circuit carried out
– always recharge the battery before and after peri- > 12.6 Volt Fully charged None
ods of prolonged inactivity or storage.
< 12,4 Volt Flat Recharge
IMPORTANT! Only recharge with a constant voltage
battery charger. Use of other types of battery charger Check the battery voltage at least 12-24 hours after
could damage the battery. recharging.

Map of functional units

 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 FITTING SAFETY MICROSWITCHES 7.12 0 2018 1 of 1

General informations IMPORTANT! If the microswitches are to func­

tion correctly, it is important to follow the exact assem­
--- bly positions by re­ferring to the drawings that indicate
the various usages of each type.
Related topics
A = Free
--- B = Activated

min. 1 mm
 

 
Map of functional units

15 mm 2 ÷ 6 mm
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 ELECTRICAL DIAGRAMS 7.13 4 2018 1 of 2

General informations Engines: B&S

--- 12 5 23 NO - 2
7
B C
WH G BL BK
NC - 3

Related topics M
S VI
VI
BL
BR
10
9
20
19
1 VI
BL
BK RE BK YG 8 18
BK RE GY 7 17 VI 10
--- RE 1 BR 6 16 BL
BR BL 2 YW 5 15 YW
BR 3 VI 4 14 OR BK
BK 4 BK 3 13 WH BK
OR 2 12 WH
BK 1 11 BL GY

19a 19b 19c 19d 6 24

BK NC - 3

NO - 2 C
BR BK
BL
BR RE
BL RE
BL 16
RE 17
OR OR
BK
BL BL WH RE 22 BK
BK

BR

BL
9
13 BR BK BK
OR BK
RE BK BL YW
RE
BK RE
BK RE
cde
VI +Bt Mot.Avv WH a YG
11
BK YW
AVV GND
BK
RE b BK
BK WH NO
BK

3 4 2 18
14 BK
BK
8
BK BK
BK BR BK
BK
BK BK

1 Circuit board 10 Neutral microswitch 24 Reverse gear microswitch

Map of functional units 2 Engine 11 Full grass-catcher microswitch
   2a    Generator 12 Recharge connector
   2b    Starter motor 13 Headlight switch CABLE COLOURS
   2c    Engine stop 14 Headlights
   2d    Carburettor 16 Clutch switch BK Black
   2e    Oil 17 Clutch BL Blue
3 Battery 18 Tank BR Brown
4 Starter relay 19a 10A fuse GY Grey
5 Key ignition switch 19b 25A fuse OR Orange
6 Auxiliary socket 19c 5A fuse RE Red
7 Brake microswitch 19d 15 A Fuse ( electric tipping models) VI Violet
8 Grass-catcher microswitch 22 Actuator ( electric tipping models) YW Yellow
9 Operator’s presence microswitch 23 Reverse consent button WH White
 WORKSHOP MANUAL CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 ELECTRICAL DIAGRAMS 7.13 4 2018 2 of 2

General informations Engines: Honda

--- 12 5 23 NO - 2
7
B C
WH G BL BK
NC - 3
BL GY 10 20 BK VI
Related topics 1
S VI
M VI BR 9 19 BK
BL
BK RE BK YG 8 18
BK RE GY 7 17 VI 10
--- RE 1 BR 6 16 BL
BR BL 2 YW 5 15 YW
BR 3 VI 4 14 OR BK
BK 4 BK 3 13 WH BK
OR 2 12 WH
BK 1 11 BL GY

BK
19a 19b 19c 19d 6
24
NC - 3
BR BK
NO - 2 C

BL
BR
RE
RE
RE
17 BL
BK
21 BL 16
WH RE
WH GY GY BY BK WB 22 OR OR
BK
WH GY GY BK BK
BL BK
BL

BR
9
BK
RE
13 BR RE BK BL YW GY OR BK

BK RE
BK a cdeg
YG
VI BK
BK YW 11
BK BK
f 2 BK WH NO
3
14 BK 8
BK BK
BK
BK
18 BR BK

BK BK

1 Circuit board 10 Neutral microswitch 23 Reverse consent button

Map of functional units 2 Engine 11 Full grass-catcher microswitch 24 Reverse gear microswitch
   2a    Generator 12 Recharge connector
   2c    Engine stop 13 Headlight switch CABLE COLOURS
   2d    Carburettor 14 Headlights BK Black
   2e    Oil 16 Clutch switch BL Blue
   2f    Starter relay 17 Clutch BR Brown
   2g    RPM signal 18 Tank GY Grey
3 Battery 19a 10A fuse OR Orange
5 Key ignition switch 19b 25A fuse RE Red
6 Auxiliary socket 19c 5A fuse VI Violet
7 Brake microswitch 19d 15 A Fuse ( electric tipping models) YW Yellow
8 Grass-catcher microswitch 21 Charge regulator WB White/Blue
9 Operator’s presence microswitch 22 Actuator ( electric tipping models) WH White
 WORKSHOP MANUAL GUIDE TO UNDERSTANDING THE HYDRAULIC CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SYSTEM 8.1 0 2018 1 of 4

General informations:

The information provided forms a basic under­

standing of the working principles of the hydraulic
system when using the machine.

Related topics:
A) Front axle components
[  hecking the hydraulic system
8.2] C
1. Oil drain cap
2. Breather cap
3a. Transmission release screw
(by-pass)
3b. Nut
4. Fittings for entrance of low pres-
sure oil
5. Fitting for high pressure pipes

B) Rear axle components

1. Oil drain cap

2. Quick coupling and breather
Map of functional units 3. Transmission release lever (by-
pass)
4. Fitting for entrance of low pres-
sure oil
5. Fitting for high pressure pipes
 WORKSHOP MANUAL GUIDE TO UNDERSTANDING THE HYDRAULIC CHAPTER REVISION FROM ... PAGE
TH 102/122 - TH4 102/122 SYSTEM 8.1 0 2018 2 of 4

C) Working principles

1. In forward gear

– The pump (2), is activated by the transmission belt (1), which keeps the oil under 
pressure; by pressing the pedal for forward gear, the lever (6) sends oil to the hy-     
draulic engine (3) in the rear unit.

– With the rear by-pass valve closed (7), the hydraulic engine moves the rear wheels
and sends the oil under pressure to the front transmission.

– With the front by-pass valve closed (5), the oil is divided between the two front
hydraulic engines (4), moving the front wheels and then going back to the pump.
 

2. In reverse gear

– The pump (2), is activated by the transmission belt (1), which keeps the oil under 
pressure; by pressing the pedal into reverse gear, the lever (6) sends oil to the front     
transmission.

– With the front by-pass valve closed (5), the oil is divided between the two front
hydraulic engines (4), moving the front wheels and then going back to the rear
transmission.

– With the rear by-pass valve closed (7), the oil under pressure activates the hydrau-
lic engine (3) of the rear wheels and goes back to the pump.  


 WORKSHOP MANUAL GUIDE TO UNDERSTANDING THE HYDRAULIC CHAPTER REVISION FROM ... PAGE
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3. Both by-passes open

The pump (2), activated by the transmission belt (1), keeps the oil under pressure.

a) In forward gear


– By operating the pedal in forward gear, the by-pass opens causing a fall in pres-     
sure and therefore the hydraulic engine (3) is not activated and the oil does not
reach the front transmission.

 

b) In reverse gear 
    

– By operating the pedal in reverse gear, oil reaches the front transmission but on
finding the by-pass open (5) does not activate the hydraulic engines (4) and so
goes back to the pump.

– In this case, the machine can be moved manually without difficulty both forwards
and backwards.
 


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4. R
 ear by-pass closed and the front by-pass open 5. R
 ear by-pass open and the front by-pass closed

In forward and reverse gears, the same situations indicated in points 1 and 2 occur, a) In forward gear, the by-pass opens (7) preventing the oil under pressure to ac-
with the difference that the front by-pass open (5) impedes the two front hydraulic tivate the rear hydraulic engine (3) and from reaching the front transmission; in this
engines from being activated (4). case, the machine remains without front and rear wheel drive.

In this case, the machine only works with the rear wheel drive.


    


    

 

 


b) In reverse gear, the oil under pressure reaches the front transmission and can
be divided between the two hydraulic engines (4), but the opening of the bypass (7)
stops the hydraulic engine from being activated (3); in this case, the machine will only
work in reverse, with front wheel drive only.

 
         

   

 
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a) Engine tests c) Transmission unit and hydraulic system tests

General informations:
– Check that the engine reaches the maximum fore-
If any transmission problems should arise (insuf­ seen rpm. – Check that the rear transmission fan is intact.
ficient power or general malfunction) it is recom­ – Check that the rear by-pass is closed and that the
mended to carry out a series of preliminary tests b) Machine tests control tie-rod is able to complete its travel stroke to
to exclude the possibility that the malfunction has achieve complete opening and closing.
been generated upstream of the transmissions; – Check that the belt is not worn, dirty or soaked in – Check that the front by-pass is closed and the lock-
if the tests listed below do not help in identifying oil and check that the tension regulator is adjusted nut is firmly tightened.
and resolving the problem, it will be necessary to properly. – Check that the connection pipes have not been in-
remove the unit in question so that the necessary – Check that the pedals and levers are all intact and verted.
repair work can be done. regulated properly. – Check that there are no leaks in the hydraulic sys-
– Check that the wheel hubs are intact and that the tem and, where necessary, bleed the circuit to elim-
front wheels have keys which are part of the hub. inate any residual air from the system.
Related topics:

[  uide to understanding the hydraulic sys-

8.1] G
tem

Map of functional units

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A) Tightening torques
General informations
Below are the specified tightening torques for the fix­ing
--- bolts on the main parts.
 

1 Screws for engine fastening .................. 25 ÷ 30 Nm

Related topics 2 Screw for engine pulley ......................... 45 ÷ 50 Nm
3 Screws for rear axle fastening ............... 25 ÷ 30 Nm
[  djusting the engagement and checking
4.1] A 4  Blade pulley screws .............................. 25 ÷ 30 Nm
the blade brake 5 Flanged support fixing nuts ................... 25 ÷ 30 Nm
6 Screw for blade ..................................... 45 ÷ 50 Nm
[  rake adjustment
4.2] B
Every section in this manual gives values for all the com-
[  rive belt adjustment
4.3] D ponents involved in each operation.    

B) Adjustments

Operation Position Position of controls Adjustment


a) Brake adjustment

 

 
b) Drive belt adjustment

Map of functional units 


 
c) Blades engagement adjustment  
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General informations: 1
---

Related topics

[  eplacement of the drive belt

6.4] R
[  eplacement of the blades control belt
6.6] R
[  eplacement of the blades connection belt
6.7] R

1 Drive belt development

3
2 Blades control belt development

3 Blades connection belt development

Map of functional units