Global Garden Products Lawn Mower 92 92 Hydro Instructions Manual

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




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3/2006
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 leads for the carburettor solenoid
valve opening control (if provided) or check
the fuel stopcock and filter.
6. The starter motor contin-
ues to turn after engine
has started, and does not
stop when the key is
removedMechanical difficulties with the con-
tact 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
signalling 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 lamp becomes
weak 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 inThe safety devices have cut in or are
faultyCheck the microswitch’s operation and the
relevant wiring [see 7.3 and 7.7]
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 7.8]
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 7.8] 
						

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92
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




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3/2006
11. The 6.3 A fuse blowsShort circuit or overload on the power
side of the electronic card (start-up
unit, starter relay) lights and recharger
connectorFind and replace the defective user [see 7.4
and 7.5 – 7.6]
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-
dition Malfunctioning or faulty blades
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 7.8] 
						

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92
7.2.1- SUMMARY TABLE FOR THE CUTTING IN OF
THE SAFETY DEVICES




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4/2005
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 BLADES 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 BLADES 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
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)
92
7.3.2
SAFETY MICROSWITCHES OPERATION CHECK





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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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92
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 )
the wiring connectors 
(1).
–The key in the «ON» position.
The reading shows the battery voltage, which
should never go below 11 Volts.
3/2006
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
1
432154321
1 
						

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92
7.6.2
STARTER RELAY OPERATION CHECK





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7.6 STARTER RELAY OPERATION CHECK
WARNING! – Remove the cap of the sparking
plug (or plugs), since the safety systems that
normally prevent accidental starting of the
engine are cut out when the checking procedure
is carried out.
To do this requires:
–engaging the parking brake;
–disengaging the blade;
–the key in the «ON» position.
Disconnect the connector CN3.
In making a bridge between the terminals 2 and 4
(CN3) of the wiring connector 
(1), the click of the
relay bobbin should be heard and the starter motor
should come into action.
➤Only with B&S and Tecumseh engines:
If the relay clicks but the starter motor does not
go, make a bridge 
(2)with a large section cable (5
mm2) between the power contacts of the relay.
If the starter motor comes into operation, look for
the fault within the relay or replace it. Otherwise,
check the starter motor together with its wiring.
3/2006
2
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
1
54321 
						

							7.7 ELECTRONIC CARD OPERATION CHECK
A) Card supply
To make this test it is necessary to have:
–The key in the «ON» position
–Connector CN2 
(1)disconnected from the card,
with all the other connectors attached.
In this situation the pilot lamp should come on.
If the indicator light goes out when connector 
(1)is
inserted, the earth connections of the microswitch-
es must be checked.
B) Safety and service supply check
This check is done with the tester in the Voltmeter
function (Volt DC 0 ÷ 20), with the black ferrule to
earth and the red one on terminal 3 (CN2) of the
card’s connector 
(2).
–The key in the «ON» position.
The reading on the tester shows the battery’s volt-
age.
C) Checking the operation of the self-setting
protection
For this test, put everything in the same situation as
in point “
A”.
By connecting terminal 3 of the CN2 connector of
the 
electronic card (3)to the frame’s earth, the
pilot lamp should go out due to the protection cut-
ting in. Eliminating the connection to earth, the pilot
lamp should come on again.
NOTE
During this test, the self-setting protection reaches
very high temperatures (around 160 °C) which are to
be considered normal. Similarly, there might be
some smoke inside the transparent box which is
due to the overheating of the powder inside.
WARNING! Do not touch this component of the
card until it has cooled down.
3/2006
CN 5
43212
CN 1
CN 2
CN 3
1321 654
54321
3
321
654
CN 5
43212
CN 1
CN 2
CN 3
1321654
54321
2
321
654
CN 5
43212
CN 1
CN 2
CN 3
1321 654
54321
1321
654
92
7.7.2
ELECTRONIC CARD OPERATION CHECK





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© by GLOBAL GARDEN PRODUCTS 
						

							3/2006
7.8 RECHARGE CIRCUIT CHECK
The job of the voltage regulator is to supply a flow of current to the battery at a constant voltage of about 14 -
15 Volts, cutting in every time that the output voltage from the generator exceeds this threshold.
A faulty regulator may recharge the battery insufficiently (therefore needing frequent recharging) or, otherwise,
may supply overloading that causes the self-resetting protection to cut in.
Before checking the recharge circuit, make sure that:
– all connections are correct;
– the earth connections are firmly connected, especially the earth connections to the regulator;
– the battery is charged and not sulphated [see 7.9];
– the charger fuse is not blown.
A) Checking the lower charging limit
Start the engine and keep running at minimum (with the headligts on - ➤if fitted).
With the voltmeter tester, measure the voltage at the battery terminals. If the value does not rise but tends to
fall, even slowly, it means that the regulator is not charging sufficiently and must be replaced.
If the voltmeter shows no value it means that the charger fuse is blown.
➤Only with a Honda engine:check the recharge relay. On moving the key from «OFF» to «ON» and vice
versa, the ticking of the relay contacts should be heard; otherwise it should be replaced.
B) Checking the upper charging limit
Start the engine and take it to maximum speed. With the tester in the voltmeter function, measure the voltage
at the battery terminals. The amount should rise and settle at 14-15 Volts after about 10-15 minutes.
If this level is exceeded to a point where the engine stops due to the self-resetting protection device cutting in
(at about 16 Volts), it means that the regulator is charging too much and must be replaced.
92
7.8.2
RECHARGE CIRCUIT CHECK





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© by GLOBAL GARDEN PRODUCTS 
						

							4/2005
7.9 CARE AND MAINTENANCE OF THE SEALED BATTERY
A) General information
In a sealed “dual” battery, the electrolyte for each element is carefully measured out during manufacture and
sealed at source, in order to ensure maximum performance during the battery’s entire life.
With a battery of this type, it is not necessary to add water or acid, and the cover must never be opened or
removed.
B) Recommendations for correct use
To keep the battery performing at optimum levels and to increase its life, various precautions should be taken:
–always keep the battery fully charged;
–always recharge a flat battery within 1 month, otherwise the elements could be damaged and no longer able
to take the charge (sulphated);
–always recharge the battery before and after periods of prolonged inactivity or storage.
C) Rules for recharging the battery
Recharging is a particularly important operation for the life of the battery and must be carried out according to
these instructions:
–do not recharge the battery when its case is broken or damaged;
–carefully read the instructions for using the battery charger and the battery;
–use the appropriate battery charger;
–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 recharging
immediately and dispose of the battery since it will be unusable.
With the battery disconnected (and at rest for at least 12 hours) and the tester in voltmeter function, measure
the voltage between the terminals. The amount given (open circuit voltage) gives an indication of the opera-
tions to be carried out, as per the following table:
Check the battery voltage at least 12-24 hours after recharging.
92
7.9.1
CARE AND MAINTENANCE OF THE SEALED BATTERY





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© by GLOBAL GARDEN PRODUCTS
Battery voltage
with open circuitBattery stateOperation to be carried
out
> 12.6 VoltsFully chargedNone
< 12.4 VoltsLow chargeRecharge 
						

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92
7.10.1
FITTING SAFETY MICROSWITCHES





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3/2003
7.10 FITTING SAFETY MICROSWITCHES
IMPORTANT
If the microswitches are to function correctly, it is important to follow the exact assembly positions by
referring to the drawings that indicate the various usages of each type.
A 
= Free
B= Activated
15 mm
AB
2 ÷ 6 mm
min. 1 mm
AB
1
2
Adjust the seat safety microswitch (1)only by
changing the position of the cam 
(2), after loosening
the two fixing screws 
(3).
This adjustment is correct when you have checked
the following:
A =  seat free: the lower edge of the cam (2)should
be touching the microswitch button without activat-
ing it.
B= seat with the driver in position: the lateral edge
of the cam 
(2)should press the push-button, leav-
ing at least 2-3 mm more travel.1
1
22
3
3
AB