Global Garden Products Lawn Mower 72 72 Hydro Instructions Manual

							6.9 REPLACEMENT OF THE DRIVE LEVER UNIT
( ➤hydrostatic drive models)

Lift up the wheels cover [see 2.5].

Remove the collector channel [see 5.5]
With the pedal released, detach the rod 
(1)con-
necting to the rear axle by unscrewing the nut of the
pin 
(2), and the rod (3)connecting to the pedal by
unscrewing the nut of the pin 
(4).
Unhook the barrel 
(5)and detach the return cable
(6).
Unscrew the two screws 
(11)and remove the sup-
port 
(10)with the whole lever unit.
The whole unit (Code 84066000/0) is available as a
spare part in a single assembly unit.
Fit the new unit keeping it to the right, fixing it using
the two screws 
(11).
Hook the barrel 
(5)of the cable (6)and refit the pins
(2)and (4)without fully tightening their nuts, and
after having loosened the adjuster nuts of the rods
(1) and (3).
Check that the end 
(12)of the hook is positioned in
a way that does not impede the lever’s 
(13)travel
and that it stops the movement of the lever 
(14). 
If necessary, only loosen the back screw 
(15)and
move the terminal 
(12)just enough to achieve the
condition described above.
If you accidently loosen both screws 
(15)and (16),
thus losing their original position, you need to ….

Adjust the stop [see 4.5.E].1312
14
15
16
10
11
5
6
21
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6.9.1
REPLACEMENT OF THE DRIVE LEVER UNIT





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							When this has been done ….

Find the lever’s “neutral” position [see 4.5.A.

Adjust the release rod for the clutch device [see 4.5.B].

Adjust the lever’s return cable [see 4.5.D].
and, lastly …

Refit the collector channel [see 5.5].

Close up the wheels cover [see 2.5].
Tightening torques
11Drive lever support screws ............. 25 ÷ 30 Nm
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6.9.1
REPLACEMENT OF THE DRIVE LEVER UNIT





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							© by GLOBAL GARDEN PRODUCTS
72
6.10.0
REPLACEMENT OF THE LEVER RETURN CABLE





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3/2002
6.10 REPLACEMENT OF THE LEVER RETURN
CABLE
( ➤hydrostatic drive models)

Lift the wheels cover [see 2.5].

Remove the collector channel [see 5.5]
With the pedal released, unhook the barrel 
(1)from
the lever 
(2), take it off the lever (3), loosen the nut
(4)of the adjuster, release the spring (5)and remove
the cable 
(6).
Start fitting the spring 
(5)using the upper hole of the
lever 
(7)and then completing the operations
described before in reverse order.
When fitting is completed,

Adjust the cable [see 4.5.D].

Refit the collector channel [see 5.5].

Close up the wheels cover [see 2.5].
5
4
7
1
6
2
3 
						

							6.11 REPLACEMENT OF THE FRICTION DISCS
FOR CLUTCH DEVICE
( ➤hydrostatic drive
models)
The friction discs can lose efficiency if they get dirty
with oil or grease, or if they are accidentally lubricat-
ed by the user, in which case they must be
replaced.

Lift the wheels cover [see 2.5].
Unscrew the nut 
(1)and dismantle the pin (2)from
the lever 
(3). By unscrewing the nut(4), you can
take out the spring 
(5)and the lever (3).
Loosen the nut 
(6)so that the sector (7)can slide
along and be taken off the square shaft 
(8)together
with the two friction discs 
(9)and the two steel
discs 
(10).
When reassembling, carry out the operations
described above in reverse order, making sure that
the two tabs of the steel discs are correctly posi-
tioned in the recesses made in the lever 
(3)and on
the support bracket 
(11), and ensuring that the sec-
tor 
(7)is pushed down on the shaft (8) untill the rec-
ommended distance of 57 - 57.5 mm is achieved.
When fully assembled …

Adjust the release rod [see 4.5.B].

Adjust the spring [see 4.5.C].

Close up the wheels cover [see 2.5].
Tightening torque
6Drive lever sector nut  ....................... 10 ÷ 15 Nm
8
57 - 57,5 mm
7
11
10
9
9
10
6
78
9
10
1011
21
5
4
3
3/2002
72
6.11.0- REPLACEMENT OF THE FRICTION DISCS
FOR CLUTCH DEVICE




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WORKSHOP MANUAL
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							© by GLOBAL GARDEN PRODUCTS
72
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




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3/2006
7.1GUIDE TO THE IDENTIFICATION OF PROBLEMS IN THE ELECTRICAL
SYSTEM
Some of the problems connected to the malfunctioning of the electrical system are
shown in the following table, with their probable causes and the remedial action to
be taken. Should the problem continue after the appropriate checks, seek
assistance from your local Service Centre.
Faulty electronic cards must always be replaced without trying to repair them
or replace single components.
START
ON
OFF
PROBLEM CAUSE REMEDY
1) Activation of the self-resetting protection of the electronic card is signalled by the failure of the LED to light, by it
switching off during work, by the engine running erratically or stopping.
b) ... in position «START» or
after a few seconds’ use:Sulphated battery (it no longer
accepts recharging)Replace the battery
Faulty or wet electronic cardCheck and dry with low pressure tepid air
(hair-dryer)
Disconnected or missing batteryReconnect the battery, which must always
be connected
Battery terminals corroded or with
poor contact Check and clean the connections
c) ... after several minutes’
use:Poor or missing earth contact on the
charge regulatorCheck the earth connections and the screws
fastening the regulator
2. With the key in the «ON»
position the pilot lamp
remains offThe battery is not supplying the cardCheck the connection cables
3. The pilot lamp comes on
but, with the key in the
«START» position, the
starter motor does not
turn or lacks power (poor
starting)The battery is not supplying sufficient
currentRecharge the battery [see 7.8]
Badly earthed battery, or the starter
relay or motor not earthed
Defect in the starter relay
Check and put right
Check that the starter relay activates [see7.5]
Battery or card not earthed to frameCheck and put right
10 A fuse blownReplace fuse (10 A)
Battery terminal crossedCheck connections.WARNING! In this case, the card is irrepara-
bly damaged and you need to replace it
since it is no longer usable!
Check the battery’s condition [see 7.8]
Overvoltage from a malfunction in the
regulatorCheck the recharge circuit [see 7.7]
Battery disconnected or faulty during
useCheck the battery or wiring
1. Activation of the self-
resetting protection 1) ....
a) .... on inserting the key
in position «ON»:Battery terminal crossedCheck the battery connections
Short circuit to earthCheck the connectors and wiring of the
microswitches 
						

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7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




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PROBLEM CAUSE REMEDY
4. The pilot lamp is flashing
with the key in the
«START» position and the
starter motor does not
turnStarting not permitted [see summary
logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and the
relative wiring
5. The starter motor turns
but the engine does not
startNo fuel flowCheck the stop cock and the fuel filter
6. The starter motor contin-
ues to turn after engine
has started, and does not
stop when the key is
removedMechanical difficulties in the return of
the contact breakers of the starter relayReplace the starter relay.
7.The starter motor operates
as soon as the key is in the
«ON” position, and can be
turned off only by removing
the key (pilot lamp on)Fault in the cardReplace the card
Starter block operating faultsReplace the block
8. The pilot lamp does not
come on when the key is
in the «ON» position but
the machine worksFault in the electronic circuit or in the
LEDReplace the card (NOTE:You can finish the
work in any case, but you need to replace
the card or signalling LED as soon as possi-
ble)
9. The pilot light goes out
after several hours’ work Insufficient chargeCheck that the charging cable has not
detached
10. The engine stops while in
use for reasons not due
to the safety devices cut-
ting in continuedThe safety devices have cut in or are
faultyCheck the microswitch’s operation and the
relevant wiring [see 7.3 and 7.6]
Accidental detaching of an electrical
wireCheck all wiring
Starting of engine not permitted [see
summary logic table 7.2]After checking that the conditions are met,
check all the microswitches [see 7.3] and the
relative wiring
Check that there are no current leakages
caused by cables with damaged insulation
Check that the regulator is working properly
[see 7.7]
Starter works erratically for mechani-
cal or electrical reasons taking exces-
sive current and causing binding of
relay contactsCheck the starter motor
Impaired starter systemCheck that spark plug caps are positioned
correctly
Check that the spark plug electrodes are
clean and have the correct gap
Malfunction in the electronic cardTry replacing the card with one that is known
to work
Charger fuse blownReplace fuse (25 A) and check the recharge
circuit [see 7.7] 
						

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7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




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11. The 10 A fuse blowsShort circuit or overload on the power
side of the electronic card (start-up
unit, starter relay) and recharger con-
nector Find and replace the defective user [see 7.4
and 7.5]
Short circuit or damage to the elec-
tronic card protection (power side)Try changing the card with one that is known
to work. If the problem stops, replace the
faulty card
PROBLEM CAUSE REMEDY
13. No audible signal for the
“grass-catcher full” con-
ditionMalfunctioning or faulty blade
microswitches and grass-catcher sig-
nallingCheck the microswitches and wiring.
WARNING! – Check that the blade
microswitch stops the engine or prevents if
from being started if the acknowledgement
conditions are not met [see 7.2]
Malfunctioning or faulty electronic
cardTry changing the card with one that is known
to work. If the problem stops, replace the
faulty card
12. The 25 A fuse blowsFaults in the battery charging circuitReplace fuse (25 A) and check the recharge
circuit [see 7.7] 
						

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7.2.1- SUMMARY TABLE FOR THE CUTTING IN OF
THE SAFETY DEVICES




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7.2 SUMMARY TABLE FOR THE CUTTING IN
OF THE SAFETY DEVICES
This table shows the various situations in which the
safety devices intervene.
–/–    =    Uninfluential
A) STARTING («START» position)
OPERATOR GRASS-CATCHER BLADE DRIVE PARKING ENGINE PILOT LAMP
–/– –/– –/–Engaged–/– DOES NOT start Flashing
–/– –/–Engaged–/– –/– DOES NOT start Flashing
Absent–/– –/– –/–DisengagedDOES NOT start Flashing
B) WHILE CUTTING
OPERATOR GRASS-CATCHER BLADE DRIVE PARKING ENGINE PILOT LAMP
Absent–/– –/–Engaged–/– Stops ON
Absent–/–Engaged–/– –/– Stops ON
–/–Missing Engaged–/– –/– Stops ON
–/– –/–Engaged–/–EngagedStops ON
Absente–/– –/– –/–DisengagedStops ON 
						

							© by GLOBAL GARDEN PRODUCTS
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
2
54321
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
111
321
654543214321
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7.3.2
SAFETY MICROSWITCHES OPERATION CHECK





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7.3 SAFETY MICROSWITCHES OPERATION
CHECK
This check is made by detaching all the connectors
and by using the tester in the Ohm-meter function.
This operation should be done, without the driver
on board, by making contact with the ferrules on
the contacts of the female connector of the wiring
(1)and should give this result:
N° Contacts Tester reading and condition
GRASS-CATCHER ATTACHED MICROSWITCH
3 - 6 (CN2)∞(without g.catc.)O(with g.catcher)
SEAT MICROSWITCH
3 - 5 (CN2)∞(absent) O (seated)
PARKING MICROSWITCH
3 (CN2) - 1 (CN5) O (free)∞(engaged)
BLADE MICROSWITCH
3 - 4 (CN2)∞(engaged) O (disengaged)
“IN NEUTRAL” SIGNAL
3 - 1 (CN2)∞(drive) O (neutral)
GRASS-CATCHER FULL MICROSWITCH
2 (CN2) - Massa O (full)∞(empty)
STARTER UNIT
+ Battery - 2 (CN3)∞(OFF) O (ON) O (START)
+ Battery - 3 (CN3)∞(OFF)∞(ON) O (START)
ENGINE STOP
This operation must be done by making contact
between the ferrules of the electronic card
(2),
keeping all the connectors attached, and should
give this result:
N° Contacts Tester reading and condition
5 (CN3) - Earth O (Always) 
						

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7.4.2
TERMINAL BOARD SUPPLY CHECK





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7.4 TERMINAL BOARD SUPPLY CHECK
This check is done with the tester in voltmeter func-
tion (Volt DC 0 ÷ 20), with the black ferrule on termi-
nal 3 (CN5) and the red ferrule on terminal 2 (CN3)
of the wiring connectors
(1).
–The key in the «ON» position.
The reading shows the battery voltage, which
should never go below 11 Volts.
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
1
432154321
1