Global Garden Products Lawn Mower 102 - 122 102 - 122 Hydro Instructions Manual

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




1 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
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
1) The cutting in of the self-resetting protection of the electronic card is signalled by a beep, except in cases where the
battery is missing, flat or with the terminal crossed. The signal stops when the key is returned to position «OFF»; then
wait a few seconds before returning to position «ON».
PROBLEM CAUSE REMEDY
2. The dashboard remains off
with the key in position
«ON»The battery is not supplying the cardCheck the connection cables
Battery or card not earthed to frameCheck and put right
10 A fuse blownReplace fuse (10 A)
Battery terminal crossedCheck connections. 
Check the battery’s condition [see 7.10]
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. It 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
Overvoltage from a malfunction in the
regulatorCheck the recharge circuit [see 7.9]
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. 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




2 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
PROBLEM CAUSE REMEDY
Starting 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.
4. The starter 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.
5. The starter continues to
turn after engine has start-
ed, and does not stop
when the key is removedMechanical difficulties with the con-
tact breakers of the starter relayReplace the starter relay.
Starter works erratically for mechani-
cal or electrical reasons taking exces-
sive current and causing binding of
relay contactsCheck the starter
Impaired starter systemCheck that the spark plug cap is 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
Starter relay is faultyCheck that the starter relay is activated [see
7.6]
3. The dashboard switches
on but, with the key in
position «START», the
starter does not turn or
lacks power (poor starting)The battery is not supplying sufficient
currentRecharge the battery [see 7.10]
Badly earthed battery, or the starter
relay or engine not earthedCheck and put right
6. The starter operates as
soon as the key is in the
«ON» position, and can be
turned off only by remov-
ing the keyFault in the cardReplace the card
Starter block operating faultsReplace the block
7. The battery warning light
does not come on with the
key in position “ON”  but
the machine operatesFault 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)
8. The battery warning light
remains onInsufficient chargeCheck that the charging cable has not
detached
Check that there are no current leakages
caused by cables with damaged insulation
Check the recharge circuit [see 7.9]
9. Abnormal, uncontrolled
lighting up of the LEDs or
irregular card operation Faulty or wet electronic cardCheck and dry with low pressure tepid air
(hair-dryer)
Bad earthing of the electronic cardCheck and put right
Charger fuse blownReplace fuse (25 A) and check the recharge
circuit [see 7.9] 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
7.1.2- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




3 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
PROBLEM CAUSE REMEDY
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 operation of the microswitch opera-
tion and the relevant wiring [see 7.3 and 7,8]
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.
11. The 10 A fuse cuts inShort circuit or overload on the power
side of the card (ignition block, starter
relay, headlamps and recharger con-
nector)Find and replace the defective user [see 7.4
– 7.5 and 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.
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 blades
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 cuts inFaults in the battery charging circuitReplace fuse (25 A) and check the recharge
circuit [see 7.9] 
						

							102 - 122
7.1a.0- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




1 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006© by GLOBAL GARDEN PRODUCTS
TC•
TX
7.1a 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
1) The cutting in of the self-resetting protection of the electronic card is signalled by a beep, except in cases where the
battery is missing, flat or with the terminal crossed. The signal stops when the key is returned to position «OFF»; then
wait a few seconds before returning to position «ON».
NOTEThe self-setting protection reaches very high temperatures (around 180 °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
PROBLEM CAUSE REMEDY
2. The dashboard remains off
with the key in position
«ON»The battery is not supplying the cardCheck the connection cables
Battery or card not earthed to frameCheck and put right
10 A fuse blownReplace fuse (10 A)
Battery terminal crossedCheck connections. 
Check the battery’s condition [see 7.10]
b) ... in the «START» posi-
tion or after a few seconds
of use, following an
attempt at starting with
outside means:Sulphated battery (it no longer
accepts recharging)Replace the battery
Faulty or electronic cardCheck 
Disconnected or missing batteryReconnect the battery. It 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
Overvoltage from a malfunction in the
regulatorCheck the recharge circuit [see 7.9]
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 
						

							102 - 122
7.1a.0- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




2 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006© by GLOBAL GARDEN PRODUCTS
TC•
TX
PROBLEM CAUSE REMEDY
Starting 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.
4. The starter 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.
5. The starter continues to
turn after engine has start-
ed, and does not stop
when the key is removedMechanical difficulties with the con-
tact breakers of the starter relayReplace the starter relay.
Starter works erratically for mechani-
cal or electrical reasons taking exces-
sive current and causing binding of
relay contactsCheck the starter
Impaired starter systemCheck that the spark plug cap is 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
Starter relay is faultyCheck that the starter relay is activated [see
7.6]
3. The dashboard switches
on but, with the key in
position «START», the
starter does not turn or
lacks power (poor starting)The battery is not supplying sufficient
currentRecharge the battery [see 7.10]
Badly earthed battery, or the starter
relay or engine not earthedCheck and put right
6. The starter operates as
soon as the key is in the
«ON» position, and can be
turned off only by remov-
ing the keyFault in the cardReplace the panel/board group (NOTE:it is
possible to complete the work in any case,
but the panel/board group must be replaced
as soon as possible)
Starter block operating faultsReplace the block
7. The battery warning light
does not come on with the
key in position “ON”  but
the machine operatesFault in the electronic circuit or in the
signalling LEDReplace the panel/board group (NOTE:it is
possible to complete the work in any case,
but the panel/board group must be replaced
as soon as possible)
8. The battery warning light
remains onInsufficient chargeCheck that the charging cable has not
detached
Check that there are no current leakages
caused by cables with damaged insulation
Check the recharge circuit [see 7.9]
10. Abnormal, uncontrolled
lighting up of the LEDs or
irregular card operation Faulty electronic cardCheck 
Bad earthing of the electronic cardCheck and put right
Charger fuse blownReplace fuse (25 A) and check the recharge
circuit [see 7.9]
9. The battery indicator light
is blinkingRecharge overvoltageCheck the recharge circuit [see 7.9]
Battery insufficiently charged at start-
upRecharge the battery [see 7.10] 
						

							102 - 122
7.1a.0- GUIDE TO THE IDENTIFICATION OF
PROBLEMS IN THE ELECTRICAL SYSTEM




3 / 3
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006© by GLOBAL GARDEN PRODUCTS
TC•
TX
PROBLEM CAUSE REMEDY
11. 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 operation of the microswitch opera-
tion and the relevant wiring [see 7.3 and 7,8]
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.
12. The 10 A fuse cuts inShort circuit or overload on the power
side of the card (ignition block, starter
relay, headlamps and recharger con-
nector)Find and replace the defective user [see 7.4
– 7.5 and 7.6]
Short circuit or damage to the elec-
tronic card protection (power side)Replace the panel/board group with one that
is known to work; if the problem does not
reoccur replace the faulty group definitively.
14. 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 blades
microswitch stops the engine or prevents if
from being started if the acknowledgement
conditions are not met [see 7.2]
Malfunctioning or faulty electronic
cardReplace the panel/board group with one that
is known to work; if the problem does not
reoccur replace the faulty group definitively.
13. The 25 A fuse cuts inFaults in the battery charging circuitReplace fuse (25 A) and check the recharge
circuit [see 7.9]
15. The clock does not keep
time after the machine is
switched offBuffer battery flatReplace [see 7.14a]. 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
7.2.1- SUMMARY TABLE FOR THE CUTTING IN
OF THE SAFETY DEVICES




1 / 1
WORKSHOP MANUAL
page from 
2005to  ••••
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.
Note
●Pilot lamp on 
❍Pilot lamp off
❇Pilot lamp uninfluential
–/–    =    Uninfluential
A) STARTING («START» position)
OPERATOR GRASSCATCHER BLADES DRIVE PARKING ENGINE PILOT LAMPS
–/– –/– –/–Engaged–/– DOESN’T start❇ ❇ ❇ ❇ ❇ ❇ ❇ ❍
–/– –/–Engaged–/– –/– DOESN’T start● ❇ ❇ ❇ ❇ ❇ ❇ ❇
Absent–/– –/– –/–DisengagedDOESN’T start❇ ❍ ● ❇ ❇ ❇ ❇ ❇
B) WHILE CUTTING
OPERATOR GRASSCATCHER BLADES DRIVE PARKING ENGINE PILOT LAMPS
Absent–/– –/–Engaged–/– Stops❇ ❇ ● ❇ ❇ ❇ ❇ ❍
Absent–/–Engaged–/– –/– Stops● ❇ ● ❇ ❇ ❇ ❇ ❇
–/– MissingEngaged–/– –/– Stops● ❇ ❇ ❇ ❇ ● ❇ ❇
–/– –/–Engaged–/–EngagedStops● ● ❇ ❇ ❇ ❇ ❇ ❇
Absent–/– –/– –/–DisengagedStops❇ ❍ ● ❇ ❇ ❇ ❇ ❇ 
						

							102 - 122
7.2a.0- SUMMARY TABLE FOR THE CUTTING
IN OF THE SAFETY DEVICES




1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006© by GLOBAL GARDEN PRODUCTS
TC•
TX
7.2a SUMMARY TABLE FOR THE CUTTING IN
OF THE SAFETY DEVICES
This table shows the various situations in which the
safety devices intervene.
Note
●Pilot lamp on 
❍Pilot lamp off
❇Pilot lamp uninfluential
–/–    =    Uninfluential
A) STARTING («START» position)
OPERATOR GRASSCATCHER BLADES DRIVE PARKING ENGINE PILOT LAMPS
–/– –/– –/–Engaged–/– DOESN’T start❇ ❇ ❇ ❇ ❇❇ ❍ ❇
–/– –/–Engaged–/– –/– DOESN’T start❇ ❇ ● ❇ ❇❇ ❇ ❇
Absent–/– –/– –/–DisengagedDOESN’T start● ❇ ❇ ❇ ❇● ❇ ❇
B) WHILE CUTTING
OPERATOR GRASSCATCHER BLADES DRIVE PARKING ENGINE PILOT LAMPS
Absent–/– –/–Engaged–/– Stops❇ ❇ ❇ ❇ ❇● ❍ ❇
Absent–/–Engaged–/– –/– Stops❇ ❇ ● ❇ ❇● ❇ ❇
–/– MissingEngaged–/– –/– Stops❇ ● ● ❇ ❇❇ ❇ ❇
–/– –/–Engaged–/–EngagedStops● ❇ ● ❇ ❇❇ ❇ ❇
Absent–/– –/– –/–DisengagedStops❍ ❇❇ ❇ ❇● ❇ ❇ 
						

							TC•
TX
© by GLOBAL GARDEN PRODUCTS
102 - 122
7.3.1- SAFETY MICROSWITCHES AND SWITCHES
OPERATION CHECK




1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
3/2006
CN4
18
17
16
15
14
1
2
3
4
5
131211109876
CN3CN2CN1
1211131015 16 17
18
1422
CN4
18
17
16
15
14
1
2
3
4
5
131211109876
CN3CN2CN1
1
8796121113105
1
432
15 16 17
18
14
111
7.3 SAFETY MICROSWITCHES AND SWITCHES 
OPERATION CHECK
This check is made by detaching all the connectors
and by using the tester in the Ohm-meter function.
This operation must be performed without the oper-
ator aboard, making contact with the ferrules on the
contacts of the wiring connector 
(1)and must give
these results:
No. of Contacts Tester reading and condition
GRASS-CATCHER ATTACHED MICROSWITCH
6 - 7∞without g.catc.)O(with g.catcher)
OPERATOR PRESENCE
6 - 3∞(absent)O(seated)
PARKING MICROSWITCH
6 - 2 O(free)∞(engaged)
BLADES MICROSWITCH (OR PUSH-BUTTON)
6 - 1∞(engaged)O(disengaged)
“IN NEUTRAL” SIGNAL
17 - 8 O(drive)∞(neutral)
GRASS-CATCHER FULL MICROSWITCH
17 - 9∞(empty)Ofull)
FUEL WARNING LIGHT
6 - 4 O(reserve)∞(full)
OIL PRESSURE WARNING LIGHT
17 - 16 O(always)
IGNITION KEY
+ Battery - 18∞(OFF) O (ON) O (START)
+ Battery - 15∞(OFF)∞(ON) O (START)
ENGINE STOP
This operation must be done making contact with
the ferrules  on the contacts of connector CN3 and
CN4 
(2)of the card, keeping all other connectors
connected, and must give this result:
No. of Contacts Tester reading and condition
17 - 13 O(Always) 
						

							102 - 122
7.3a.0- SAFETY MICROSWITCHES AND SWITCHES
OPERATION CHECK




1 / 1
WORKSHOP MANUAL
page from 
2006to  ••••
7.3a SAFETY MICROSWITCHES AND SWITCH-
ES OPERATION CHECK
This check is done by disconnecting connector
CN1 and using the tester in Ohmmeter mode. This
operation must be performed without the operator
aboard, making contact with the ferrules on the
contacts of the wiring connector 
(1)and must give
these results:
No. of Contacts Tester reading and condition
GRASS-CATCHER ATTACHED MICROSWITCH
1 - 6∞without g.catc.)O(with g.catcher)
OPERATOR PRESENCE
1 - 14∞(absent)O(seated)
PARKING MICROSWITCH
1 - 17 O(free)∞(engaged)
BLADES MICROSWITCH (OR PUSH-BUTTON)
1 - 16∞(engaged)O(disengaged)
“IN NEUTRAL” SIGNAL
1 - 7 O(drive)∞(neutral)
GRASS-CATCHER FULL MICROSWITCH
1 - 13∞(empty)O(full)
FUEL LEVEL GAUGE (if present)
1 - 5 O(reserve)∞(from 1/2 to full)
1 - 8 O(full)∞(from reserve to 1/2)
OIL WARNING LIGHT  (if present)
1 - 15 O(always)
IGNITION KEY
+ Battery - 11∞(OFF) O (ON) O (START)
+ Battery - 12∞(OFF)∞(ON) O (START)
ENGINE STOP
Questa operazione deve essere eseguita facendo
contatto con i puntali sui contatti del connettore
CN1 della scheda e deve dare questo risultato:
No. of Contacts Tester reading and condition
1 - 3 O(Always)
CN4
18
17
16
15
14
1
2
3
4
5
131211109876
CN3CN2CN1
1211131015 16 17
18
1422
CN4
18
17
16
15
14
1
2
3
4
5
131211109876
CN3CN2CN1
1
8796121113105
1
432
15 16 17
18
14
111
© by GLOBAL GARDEN PRODUCTS
TC•
TX