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

							© by GLOBAL GARDEN PRODUCTS
98S
7.3.1
SAFETY MICROSWITCHES OPERATION CHECK





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
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 connector of the wiring
(1)and
should give this result:
N° Contacts Tester reading and condition
SEAT MICROSWITCH
3 - 5 (CN2)∞(absent) O (seated)
PARKING MICROSWITCH
3 (CN2) - 2 (CN2) O (free)∞(engaged)
BLADES MICROSWITCH
3 - 4 (CN2)∞(engaged) O (disengaged)
“IN NEUTRAL” SIGNAL
3 - 1 (CN2)∞(drive) O (neutral)
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)
3/2006
2
54321
CN 5
2
CN 1
CN 2
CN 3
1321 654
54321
CN 5
2
CN 1
CN 2
CN 3
1321654
54321
11
321
65454321 
						

							© by GLOBAL GARDEN PRODUCTS
98S
7.4.1
TERMINAL BOARD SUPPLY CHECK





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
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 6 (CN2) 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
2
CN 1
CN 2
CN 3
1321654
54321
1
321
65454321 
						

							© by GLOBAL GARDEN PRODUCTS
98S
7.6.2
STARTER RELAY OPERATION CHECK





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
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 blades;
–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.
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
2
CN 1
CN 2
CN 3
1321654
54321
54321
1 
						

							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 disconnected from the card, with
all the other connectors attached.
By making a bridge between the contacts 6 (CN2)
of the wiring 
(1)and the contact of the card (2), the
light should come on.
If the indicator light go 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 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 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
2
CN 1
CN 2
CN 3
1321 654
54321
321
654
3
CN 5
2
CN 1
CN 2
CN 3
1321654
54321
1
321
654
2
CN 5
2
CN 1
CN 2
CN 3
1321 654
54321
1
321
654
2
98S
7.7.1
ELECTRONIC CARD OPERATION CHECK





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
© 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.
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.
98S
7.8.1
RECHARGE CIRCUIT CHECK





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
© 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.
WARNING!
Only recharge with a battery charger at a constant voltage; other battery chargers could damage the battery. 
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.
98S
7.9.1
CARE AND MAINTENANCE OF THE SEALED BATTERY





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
© by GLOBAL GARDEN PRODUCTS
Battery voltage
with open circuit Battery stateOperation to be carried
out
> 12.6 VoltFully chargedNone
< 12,4 VoltLow chargeRecharge 
						

							© by GLOBAL GARDEN PRODUCTS
98S
7.10.1
FITTING SAFETY MICROSWITCHES





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
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 
						

							© by GLOBAL GARDEN PRODUCTS
98S
7.11.2
ELECTRICAL DIAGRAMS





1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
CN3
5
CN5 CN1CN2
WH
BL
RE
RE BK
BK
BKRE
RERE
REBR BKBRBL
REBL
RE
YERE
RE RE
BKRE RE
GY GY
VIVIWH
BL
BR10 1
6
7
8
9
2
34 11BL
BL
12
13
RE
NC - 3
NO - 2C
BK
BK
YE
NC - 3
NO - 2C
NC - 3
NO - 2C
RERE
AVV +Bt Mot. Avv
GND
GND BL
BK BK
BK
a
bcd
25722417/1
14a14b
1Electronic card2Engine2aGenerator2bStarter motor2cEngine stop2dCarburettor3Battery4Starter relay5Key ignition switch6Blades microswitch7Brake microswitch8Seat microswitch9aNeutral microswitch (➤In mechanical drive models)9bNeutral microswitch (➤In hydrostatic drive models)10Pilot lamp11Recharge connector12Headlight switch13Headlight14a6.3 A  fuse (delayed)14b25 A fuse
CABLE COLOURS
BKBlackBLBlueBRBrownGYGreyOROrangeRERedVIVioletWHWhiteYEYellow
9a9b687 
						

							8.1 SUMMARY OF TIGHTENING TORQUES
Below are the specified tightening torques for the
fixing bolts on the main parts.: 
1Screws for engine fastening  ........... 25 ÷ 30 Nm
2Screw for pulley .............................. 45 ÷ 50 Nm
3Rear axle locknut ............................ 25 ÷ 30 Nm
4Screws for pulleys fastening  .......... 20 ÷ 25 Nm
5Nuts for flanged support  ................ 25 ÷ 30 Nm
6Screw for blade  .............................. 45 ÷ 50 Nm
Every section in this manual gives values for all the
components involved in each operation.
3/2003
14
6523
98S
8.1.1
SUMMARY OF TIGHTENING TORQUES





1 / 1
WORKSHOP MANUAL
page from 
2002to  ••••
© by GLOBAL GARDEN PRODUCTS 
						

							© by GLOBAL GARDEN PRODUCTS
98S
8.2.1- SUMMARY OF MAIN ASSEMBLY AMOUNTS
AND CHECKS




1 / 4
WORKSHOP MANUAL
page from 
2002to  ••••
4/2005
8.2 SUMMARY OF MAIN ASSEMBLY AMOUNTS AND CHECKS
1
Frame
2Cutting deck
3Steering geometry
4Drive belt development
5Blades belt development
6Fitting the gearchange control tie-rod (➤ in mechanical drive models)
7Fitting the drive control tie-rod  (➤ in mechanical drive models)
8Fitting the pedal tie-rod  (➤ in hydrostatic drive models)
9Fitting the deck lifting tie-rod
10Fitting the blades brake tie-rod
1