Global Garden Products Lawn Mower 92 92 Hydro Instructions Manual

							6.5 REPLACEMENT OF THE SMALL WHEELS
FOR THE DRIVE BELT

Remove the collector channel [see 5.3].
For better access to the parts concerned the drive
belt should also be slackened.
This is done by ...
➤In mechanical drive models:engaging the
parking brake 
➤In hydrostatic drive models:loosening the
stretcher nut 
(1)
The two wheels (2)are held onto the frame by two
nuts 
(3), with a spacer in between (4).
When reassembling, there should be kept in mind
that:
–thetall spacer
(4a)is to be fitted beneath the
right-hand wheel 
(2a - 2c);
–the short spacer 
(4b)is to be fitted beneath the
left-hand wheel 
(2b - 2d);
➤In mechanical drive models:
the left wheel (2b) must be fitted to the frontsup-
port of the frame [see 8.2.4];
➤In hydrostatic drive models:
The position of the right-hand wheels (2c)and
left-hand wheels 
(2d)is determined by the differ-
ent use of the hole in the plate 
(5)screwed onto
the frame [see 8.2.4].
When reassembly is completed, tighten the nuts 
(3)
to the amounts shown.
Always refit the dust covers 
(5)of the wheels (2).
4a
4b
2c
2d
5
hydro
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4b
2a
2b
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6.5.1- REPLACEMENT OF THE SMALL WHEELS
FOR THE DRIVE BELT




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							4/2005
Lastly ...

Adjust the drive engagement [see 4.4].

Refit the collector channel [see 5.3].
➤In hydrostatic drive models:reset the tension of the stretcher spring [see 4.4]. If only the front nut (1)
has been loosened without having touched the rear one, the right tension will be achieved by just tightening
up the nut 
(1).
Tightening torque
3Nuts for small wheels ...................... 25 ÷ 30 Nm
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6.5.1- REPLACEMENT OF THE SMALL WHEELS
FOR THE DRIVE BELT




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							6.6 REPLACEMENT OF THE BLADES BELT
Loosen the screw (1), unfasten the safety pin (2)
and move the fork (3)to the side.
Turn the belt shifter 
(4)forward by enough to free
the belt 
(5)from the pulley (6).
Set the cutting plate in the lowest position, to obtain
greater accessibility and disengage the blades to
slacken off the belt. 
Remove the right-hand protective cover 
(7)by
unscrewing the nut 
(8)and loosening the screws
(9).
Remove the left cover 
(10)fixed by two screws (11).
Release the left spring 
(12)and loosen the left guide
pulley 
(13).
Release the right spring 
(14)loosen the nut (15)of
the idle pulley and take off the guide pulley 
(16)
after having released the spring (17).
At this point the brake shoes can be manually
moved away from the pulley and the belt can be
taken off and renewed.
On reassembling, take care to exactly position the
new belt in the pulley rims [see 8.2.5].
Reset the belt shifter 
(4)into position, refit the fork
(3)with the relative safety pin (2)and fully tighten
the screw 
(1).
Once assembly is completed ...

Adjust the blade engagement [see 4.1].
Tightening torque
15Nut for idle pulley  ........................... 25 ÷ 30 Nm
16
17
12
13
715
14
978911
10
65423
1
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6.6.1
REPLACEMENT OF THE BLADES BELT





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							6.7 REPLACEMENT OF THE LIFTING CABLE

Remove the collector channel [see 5.3].
Put the deck at the minimum cutting height, loosen
and release the adjuster 
(1)and loosen the nut (2)
for the drive pulley (3)in order to be able to take off
the cable 
(4).
Put the deck at the maximum height so that the
toothed sector turns to the back. Pass the cable
along the groove and insert the end 
(5)in the hous-
ing.
Put the cable back in its path around the pulley,
hook on the adjuster 
(1)and tighten the pulley nut
(2).
When reassembled ...

Adjust the alignment of the deck [see 4.6.A].

Refit the collector channel [see 5.3].
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6.7.0
REPLACEMENT OF THE LIFTING CABLE





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							© by GLOBAL GARDEN PRODUCTS
92
6.8.0- REPLACEMENT OF THE BLADES 
ENGAGEMENT CABLE




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6.8 REPLACEMENT OF THE BLADES 
ENGAGEMENT CABLE

Remove the right-hand rear wheel [see 6.1].
With the cutting deck in the lowest position and the
lever in the disengaged position, loosen the
adjuster 
(1), remove it from its housing and unhook
the spring
(2).
Take off the barrel
(3)at the end of the fork (4)which
is near the joint for the lever, and take out the whole
cable 
(5). 
On reassembling, make sure that the washer
(6)is
positioned between the bracket 
(7)and the cable
sheath 
(5).
Once assembly is completed ...

Adjust the blade engagement [see 4.1].
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3
7
6
12 
						

							6.9 REPLACEMENT OF THE SUPPORTS AND
SHAFTS OF THE BLADES

Remove the cutting deck [see 5.7].
NOTE
This operation is not strictly necessary since, with a
little practice and experience, it is possible to dis-
mantle the deck supports without removing the
deck.

Remove the blades [see 4.10] and take off the
hubs.
Remove the right-hand cover 
(1)by unscrewing the
nut 
(2)and loosening the screws (3). Take off the
left-hand cover
(4)held by two screws (5).
Release the two springs
(7)and(8)of the right and
left brakes and take off the left guide pulley 
(6).
At this point it is possible to undo the central screws
(9)and to take off the pulleys(10).
Dismantle the flange support 
(11)by unscrewing
the three nuts
(12).
The entire support (11), including shafts and
bearings, is a spare part available as single
assembly unit.
11
12
8
69
10
7
910
5
4
12
3
3
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6.9.0- REPLACEMENT OF THE SUPPORTS AND
SHAFTS OF THE BLADES




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WORKSHOP MANUAL
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© by GLOBAL GARDEN PRODUCTS 
						

							If you should want to just replace the shaft or bear-
ings, remove the key 
(13)and hit the shaft with a
plastic mallet on the pulley side in order to remove
the shaft together with the lower bearing 
(14).
After having removed the snap ring 
(15), the dust
cover 
(16)and the spline(17), the bearing(14)
splined onto the shaft can be removed using a nor-
mal extractor, taking care to close up the threaded
hole 
(18)with a screw to prevent the point of the
extractor from damaging the thread.
The second bearing still in place must be removed
by hitting it from the inside of the flange using a 12
÷15 mm diameter round bar
(19).
On reassembling, first put the shaft into the hole of
the lower bearing and insert this into the support.
Fit on the upper bearing and, using the special bush
# Cod. 60800030/0
(20) which works on the inner
ring
, hit it squarely with a mallet until the bearing is
fully driven home.
The right and left shafts seem to be the same, but
can be differentiated as follows:
–
right shaft: red paint on the pulley side;
–
left shaft: green paint on the pulley side.
Before refitting the support assembly, check that
these positions are correct.
Fit the flange supports onto the deck,
fully tighten-
ing the nuts (12)
. 
Tightening torques
9Screws for pulleys fastening  ............ 20 ÷ 25 Nm
12Nuts for flanged support  ................ 25 ÷ 30 Nm
11
20
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19
11
1417
161518
13
11
14
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6.9.0- REPLACEMENT OF THE SUPPORTS AND
SHAFTS OF THE BLADES




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WORKSHOP MANUAL
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© by GLOBAL GARDEN PRODUCTS 
						

							6.10 REPLACEMENT OF THE ACCELERATOR

Remove the fuel tank [see 5.4].
Take off the steering wheel by taking out the pin
(1)
and remove the dashboard held on by three screws
(2)and by another two screws (3)on top of the
electronics card.
Take off the knob
(4)and disconnect the wire (5)
from the connection terminal(6)on the engine.
Undo the two screws 
(7)and take out the accelera-
tor together with the wire.
On reassembling, put the accelerator lever in the
«MINIMUM» position, connect the end of the wire
(5)to the terminal(6)on the engine after having
moved the cursor 
(8) in the same «MINIMUM» posi-
tion specific to each type of engine and shown in
the instruction booklet.
When assembly is completed …

Refit the fuel tank [see 5.4].
7
3
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2
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6.10.0
REPLACEMENT OF THE ACCELERATOR





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© by GLOBAL GARDEN PRODUCTS 
						

							6.11 REPLACEMENT OF THE BRAKE PADS
AND DISC (
➤In mechanical drive models)

Remove the left-hand rear wheel [see 6.1].
Disconnect the control rod 
(1)from the lever(2)and
undo the two screws
(3)which hold on the support
(4).
The support
(4)contains a pad (5a)separated from
the control pistons
(6)by a plate(7).
The other pad
(5b)can be reached by taking off the
disc 
(8). 
If there is oil on the pads, clean with solvent and go
over them with fine-grade abrasive paper.
Both pads should be replaced if the depth of either
of them is less than 5 mm.
Renew the disc if it is damaged, distorted or less
than 4 mm thick.
On reassembly, carefully reposition all the compo-
nents and refit the complete support. When con-
necting the rod 
(1)be sure to use the upper hole in
the lever
(2).
NOTE
During all these operations it is better to not
unscrew or loosen the central screw 
(9)to avoid
altering the calibration of the cam driving the pis-
tons.
If it has been moved, the lever’s free movement will
have to be checked [see 4.3].
When fully reassembled ...

Check the brake adjustment [see 4.3].
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6.11.1
REPLACEMENT OF THE BRAKE PADS AND DISC 





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							© by GLOBAL GARDEN PRODUCTS
92
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




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WORKSHOP MANUAL
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3/2006
7.1GUIDE TO THE IDENTIFICATION OF PROBLEMS IN THE ELECTRICAL
SYSTEM
In the following some of the problems connected to the malfunctioning of the
electrical system are shown, with their probable cause 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 contactCheck 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 7.9]
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 is activated [see
7.6]
Battery or card not earthed to frameCheck and put right
6.3 A fuse blownReplace fuse (6.3 A - delayed)
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 7.9]
Overvoltage from a malfunction in the
regulatorCheck the recharge circuit [see 7.8]
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.