Global Garden Products Lawn Mower 98S 98S Hydro Instructions Manual

							© by GLOBAL GARDEN PRODUCTS
98S
6.6.0
REPLACEMENT OF THE BLADES BELT





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two screws (11)and the left-hand guide pulley (12),
by unscrewing the two fixing nuts 
(13)and (14).
You can now take out and replace the belt.
On reassembling, take care to put the new belt in its
exact position with respect to the guide pulleys [see
8.2.5].
When assembly is complete, it is a good idea to  ...

Adjust the blade engagement  [see 4.1]. 
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							6.7 REPLACEMENT OF THE LIFTING CABLE

Remove the rear cover [see 5.2.A].
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 ...

Refit the rear cover [see 5.2.A]

Adjust the alignment of the deck [see 4.6.A].
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98S
6.7.0
REPLACEMENT OF THE LIFTING CABLE





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© by GLOBAL GARDEN PRODUCTS 
						

							© by GLOBAL GARDEN PRODUCTS
98S
6.8.0
REPLACEMENT OF THE BLADES ENGAGEMENT CABLE





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6.8 REPLACEMENT OF THE BLADES ENGAGE-
MENT 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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							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.
Disengage the blades to loosen the belt.
Take off both the right-hand protective cover 
(1)and
left-hand one 
(2)fastened by the screws (3).
Push the right-hand brake lever 
(4)to the left to free
the belt 
(5)from the right-hand blade pulley.
Remove the left-hand guide pulley 
(6)by unscrew-
ing the two fixing nuts 
(7)and (8)and free the belt
from the two pulleys 
(10).
You can now undo the central screws 
(9)and to
take out the pulleys 
(10).
Dismantle the flanged support 
(11)by unscrewing
the three fixing nuts 
(12).
The entire support (11), including shafts and
bearings, is a spare part available as single
assembly unit.
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98S
6.9.0- REPLACEMENT OF THE SUPPORTS AND
SHAFTS OF THE BLADES




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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
# Code 60800030/0 
(20) which works on the inner
ring
, hit it squarely with a mallet until the bearing is
fully driven home.
Fit the flange supports onto the deck, 
fully tighten-
ing the nuts (12)
.  
When reassembling, take care to put the new belt in
its exact position with respect to the guide pulleys
[see 8.2.5].
Tightening torques
9Screws for pulleys fastening  ............ 20 ÷ 25 Nm
12Nuts for flanged support  ................ 25 ÷ 30 Nm
11
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98S
6.9.0- REPLACEMENT OF THE SUPPORTS AND
SHAFTS OF THE BLADES




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							6.10 REPLACEMENT OF THE ACCELERATOR

Remove the fuel tank [see 5.3].
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 5.3].
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98S
6.10.0
REPLACEMENT OF THE ACCELERATOR





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							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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98S
6.11.0
REPLACEMENT OF THE BRAKE PADS AND DISC 





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							© by GLOBAL GARDEN PRODUCTS
98S
7.1.2- GUIDE TO THE IDENTIFICATION OF 
PROBLEMS IN THE ELECTRICAL SYSTEM




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3/2006
7.1 GUIDE TO THE IDENTIFICATION OF PROBLEMS IN THE ELECTRICAL
SYSTEM
In the following some of the problems connected to the malfunctioning of the electri-
cal 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. 
						

							© by GLOBAL GARDEN PRODUCTS
98S
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 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
removed
Mechanical 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 goes out or
becomes weak after sev-
eral 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
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
connector Find 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
Charger fuse blownReplace fuse (25 A) and check the recharge
circuit [see 7.8]
12. The 25 A fuse blowsFaults in the battery charging circuitReplace fuse (25 A) and check the recharge
circuit [see 7.8] 
						

							© by GLOBAL GARDEN PRODUCTS
98S
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 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 BLADES DRIVE PARKING ENGINE PILOT LAMP
Absent–/– Engaged –/– Stops ON
Absent Engaged–/– –/– Stops ON
–/–Engaged–/–EngagedStops ON
Absent–/– –/–DisengagedStops ON