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

							The Manufacture reserves the right to make any improvements to the product of a technical or commercial
nature that may be necessary. There may be, therefore, differences between the various series of machines
and that described here, though the basic features and various repair methods will remain the same.
© by GLOBAL GARDEN PRODUCTS - No use of the illustrations or duplication, reproduction or translation,
even partial, of the texts in this document may be made without explicit authorization.
WORKSHOP
MANUAL
Rel. 4.0YEAR OF MANUFACTURE 2006
9 9 9 9
8 8 8 8
S S S S
9 9 9 9
8 8 8 8
S S S S
       
h h h h
y y y y
d d d d
r r r r
o o o o 
						

							3/2006
CONTENTS
1. Rules and procedures for Service Centres 
This chapter covers all the main aspects of the
relationship between the manufacturer and the
service centres.
A close collaboration between the manufacturer
and the service centres is conclusive for solving
problems in the most effective way as well as
maintaining an image of efficiency and reliability.
Compliance with these brief and simple guide-
lines will facilitate this task and prevent general
misunderstandings and time-wasting for both
the manufacturer and the service centre.
2. General and safety regulations
This chapter covers the main aspects of a servic-
ing procedure and the general rules for guaran-
teeing a successful service which protects the
environment and respects the safety of both the
serviceman and the user of the apparatus.
3. Maintenance
This chapter deals with the criteria for routine
maintenance.
4. Adjustments and tuning
This chapter deals with the adjustments to be
made to remedy the more frequent performance
failures and are usually resolved by quick checks
and tunings.
5. Removal of external parts and main assem-
blies
For doing more difficult jobs, greater accessibili-
ty may be required. This can be done by taking
the unit concerned off and working at the bench,
or by removing the cover or other external parts.
Whether or not this will be useful is at the discre-
tion of the mechanic’s experience.
6. Repairs
This chapter deals with all the more complex
work connected with the replacement or repair
of malfunctioning or worn parts.
The descriptions must follow a logical sequence-
and can include operations not specifically con-
nected to a particular type of repair.
In this case, careful reading of the entire proce-
dure can help you omit all those operations not
connected with the case in hand without, how-
ever, overlooking anything that may be neces-
sary.
7. Electrical system
This chapter deals with the problems and checks
connected with the electrical system.
All work can be done using a tester without hav-
ing to use special equipment.
The electrical diagrams can be useful to you for
understanding how the system functions and to
facilitate the pinpointing of any problems.
8. Technical specifications
This chapter summarises all the main information
regarding the machine.
98S
i.2
INDEX





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GENERAL INDEX
1.1
1Identification and procedures
2.11Safety regulations
2.21Tools
2.31Lifting
2.41Practical hints
3.11Criteria for maintenance
4.10Blade engagement adjustment
4.20Blades brake adjustment
4.30Brake adjustment
4.40Drive belt adjustment 
						

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4.51Drive pedal adjustment   (➤hydrostatic drive models)
4.60Aligning the cutting deck
4.70Steering allowance adjustment
4.80Steering geometry adjustment
4.90Checking blades alignment 
4.100Sharpening and balancing of the blades
5.10Removal of front hood
5.20Removal of the wheel cover
5.30Removal of the fuel tank
5.41Removal of the engine
5.50Removal of the rear axle
5.6 0Removal of the cutting deck
6.10Replacement of tyres and wheels
6.20Replacement of front wheel bearings
6.31Dismantling of the steering components
6.41Replacement of the drive belt
6.50Replacement of the small wheels for the drive belt
6.60Replacement of the blades belt
6.70Replacement of the lifting cable
6.80Replacement of the blades engagement cable
6.90Replacement of the supports and shafts of the blades
6.100Replacement of the accelerator
6.110Replacement of the brake pads and disc  
7.12Guide to the identification of problems in the electrical   system
7.21Summary table for the cutting in of the safety devices
7.31Safety microswitches operation check
7.41Terminal board supply check
7.5–---
7.62Starter relay operation check
7.71Electronic card operation check
7.81Recharge circuit check
7.91Care and maintenance of the sealed battery
7.101Fitting safety microswitches
7.112Electrical diagrams
8.11Summary of tightening torques
8.21Summary of main assembly amounts and checks
8.30Special tools
98S
i.2
INDEX





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INTRODUCTION
This manual has been compiled to help Service
Centres with the maintenance, dismantling and
repair of the following versions of the J98 lawn-trac-
tor:
– mechanical drive with gear box;
– hydrostatic drive (hydro).
Each page of this manual states the following infor-
mation:
A)Machine or machine series to which the page
applies.
B)Page number, specifically: 
–the first two figures separated by a point indi-
cate the section and the chapter
–the third figure indicates the modification
index.
C)Temporary validity of the page, with reference to
the year of manufacture or serial numbers.
D)Date of release.
E)Page number and total number of pages dedi-
cated to the subject.
F)Any previous or ensuing pages dedicated to the
subject.
G)Any chapters before or after the current one.The manual refers to the following symbols:
Warns of operations that should be carried
out with utmost care to avoid impairing the func-
tionality and safety of the lawnmower.
Warns of operations that should be carried
out with utmost care to avoid injury to the oper-
ator. 
Reference to another procedure or part of
the manual.
#Indicates that a special tool should be used
[see 2.2].
➤This symbol highlights all those operations
that require different working methods depend-
ing on the type of machine, subsequent modifi-
cations or accessories fitted.
NOTE
Whenever a reference is made to a position on the
machine “front”, “back”, “left” or “right” hand side,
this is determined by facing the direction of forward
travel. 
The manual has left out the simplest and quickest
operations that can be handled by a good mechan-
ic, while concentrating more on specific aspects
and the best servicing procedures.
You are asked to read through this manual to
acquire a basic understanding of the machine,
which is necessary for working rationally without
making errors or wasting time.
All problems related to use are fully covered in the
user manual.


98S
ii.1
INTRODUCTION





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The unit is supported by two brackets (13)with
their screws (14)and (15)and is attached to the
frame by four screws (16).
Loosen the two screws (14)to give a minimum of
movement to the brackets (13)and undo the two
screws (15). Then carefully loosen the four lower
screws (16), holding up the unit so that it does
not fall.
➤In the hydrostatic drive models:
Dismantle the pin of the brake control rod (17)
and the pin of the drive engagement control rod
(18). 
Loosen the nut (19)of the release lever to detach
the rod (20)from the lever (21).
The unit is held up by a support (22)and fastened
to it by a screw with a nut (23), and it is attached
to the frame by four screws (24).
Undo the nut (23)and then carefully undo the
four lower screws (24), holding up the unit so that
it does not fall.
To reassemble, reverse the order of the previous
operations, taking particular care with the two self-
tapping screws (15)which, if not screwed in cor-
rectly, could damage the threads inside so prevent-
ing it from being fastened properly.
When refitting the blade engagement cable, make
sure that the washer (25)is correctly positioned
between the bracket(26)and the cable sheath(3).
Reattach all the connections, and then …

Check the brake [see 4.3]
24
20
21
19
2322
15
13
316
14
1724
10
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98S5.5.0REMOVAL OF THE REAR AXLE 




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98S
1.1.1
IDENTIFICATION AND PROCEDURES





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1.1 IDENTIFICATION AND PROCEDURES
A) Identification
1) Machine
Each machine has a label attached (1)under the
driver’s seat which shows the technical specifica-
tions, the model and the serial number.
The model and serial number must be shown on
each repair sheet when requests are made
under guarantee, and are indispensable for
spare part orders.
2) Transmission (Rear axle)
The transmission unit (both mechanical and hydro-
static) is made up of an engine block including the
rear axle. This unit is made by another manufactur-
er to our precise technical specifications which dif-
ferentiate it from similar items by this same Manu-
facturer.
The serial number on the label (2) clearly identi-
fies the product and its specifications. This num-
ber must always be quoted when requesting
spare parts or any information from the Manu-
facturer.
3) Engine
The engine is made to precise technical specifica-
tions which differentiate it from similar items by this
same Manufacturer.
The serial number on the label clearly identifies
the product and its specifications. This number
must always be quoted when requesting spare
parts or any information from the Manufactur-
er.A) Guarantee validity
B) Guarantee validity
The guarantee is supplied under the terms and the
limits of the contractual relations in being. As far as
the engine and the transmission unit are concerned,
the conditions given by their respective manufac-
turers apply.
C) Service repairs after guarantee period
The Service Centre has to make out a report con-
taining the machine’s serial number, a summary ofthe problem, the repairs carried out and any spare
parts used for each repair done on the machine.
A copy of this report must be retained to be made
available to the Manufacturer together with the parts in
case of any subsequent disputes with Customers.
D) Fault notification
The Manufacturer welcomes any notifications of faults
that recur with particular frequency. It gives the oppor-
tunity for a careful inspection of the problem and the
implementation of corrective action at production
level.
Similarly, the Manufacturer will notify of any faults dis-
covered on the machines produced, with recommen-
dations for the most suitable procedures for their rem-
edy.
E) Spare parts request
When requesting spare parts, the code number must
be given, referring to the exploded charts for the year
of manufacture, shown on the identification label [


point A].
PEERLESS
TECUMSEH
2
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							4/2005
2.1 SAFETY REGULATIONS
A) Qualification of operators
All maintenance, disassembly and repairs must be
carried out by expert mechanics who are familiar
with all the accident prevention and safety regula-
tions after reading through the procedures in this
manual.
B) Safety measures
All the machines are manufactured in accordance
with the strict European safety regulations in force.
To maintain these levels of safety in the longer term,
the Service Centres should work to this end by
making appropriate checks every time there is the
chance to do so.
Particularly, every time there is work done on the
machine the Service Centre should:
1) check:
–that safety microswitches are working cor-
rectly  [see 7.3];
–that the casings and protection covers have
not been removed;
–that the labels with instructions or provisions
have not been removed or have become illegi-
ble (these form an integral part of the safety
system).
2) they should also:
–restore to proper working order any safety
devices which have been manipulated or
removed;
–reattach inefficient, damaged or missing cas-
ings and protection covers;
–replace illegible labels;
–not endorse any repair or modification on the
machine or the engine which results in a
change in performance or use that is incorrect
or different from the purpose for which it was
designed and approved;
–warn the Customer that the failure to comply
with the above points results in the automatic
annulment of the Guarantee and the Manufac-
turer declines all responsibility, as also shown
in chapter 1 of the Instruction Booklet.
C) Precautions during servicing
The operations described in this manual do not
entail particularly hazardous situations besides thenormal hazard related to mechanical operations
and that can be avoided by taking the necessary
care and attention normally required for this type of
work.
As well as following the usual accident prevention
regulations that apply to most repair shops, we rec-
ommend you: 
–taking out the ignition key before beginning
any repair work.
–protect hands with suitable working gloves,
especially when working near the cutting unit; 
–check that you do not cause accidental petrol
leaks or other losses;
–do not smoke when working on the tank or
when handling petrol; 
–do not inhale oil or petrol fumes; 
–clean up all traces of spilt petrol immediately; 
–test the engine in a well-ventilated environ-
ment or where there are adequate exhaust
fume extraction systems;
–do not pollute the environment with oil, petrol
or other waste and dispose of all waste in
accordance with the laws in force;
–ensure that other persons cannot accidentally
carry out actions that may physically endan-
ger those working on the machine.
D) Necessary equipment
All the operations can be carried out with the tools
normally used in a good garage.
Some operations require special equipment and
tools [

2.2].
E) Symbols and terms used for safety purposes
Some paragraphs in this manual are preceded by
symbols which indicate the following:
Operations that should be carried out with
utmost care to avoid impairing the functionality
and safety of the lawnmower.
Operations that should be carried out with
utmost care to avoid injury to operators. 
“WARNING” stresses the risk of injury to oneself
and others if instructions and regulations are not
observed 
98S
2.1.1
SAFETY REGULATIONS





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98S
2.2.1
TOOLS





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2.2 TOOLS
All work can be carried out using the tools normally
available in a good workshop. However, it is advis-
able to have a kit of special tools 
(1 ÷ 5)which are
already part of a set (Code no. 82180040/2) or
which can be made following the instructions given
in chapter 8.3.
These tools 
(1 ÷ 5)are to be used where there is the
symbol «#» in this text.
1.Blocks H = 26 mm for adjusting the cutting deck
2.Blocks H = 32 mm for adjusting the cutting deck
3.Bush for assembly of blades bearings
4.Stopper for assembly of wheel bearings
5.Pulley extractor
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23
4
5 
						

							2.3 LIFTING
The machine must never be lifted using a hoist
or other lifting equipment which uses cables.
WARNING! - This machine IS NOT DESIGNED to
be positioned vertically with it resting on the rear
plate.
If you need to have easier access to the lower part
of the machine, you can lift the front.
A) Front
Once the parking brake has been engaged, the
lawn-tractor can be lifted using a jack which pushes
on the underside of the frame, placing a wood block
(1) between the base of the jack and the frame and
checking to see that the free movement of the front
spring equaliser has not been obstructed.
Place the machine on firm and flat ground.
At least two competent people should be
involved in this operation to assure necessary
safety.
Position a support block(2)in wood (or other mate-
rial) that can bear the weight of the machine; it
should be 30-35 cm high with a base of at least 100
x 25 cm. 
To prevent the machine from moving accidentally,
engage the parking brake and put the gear lever in
1st gear 
(➤in mechanical transmission models), or
check that the transmission release lever is
engaged  
(➤ in hydrostatic trasmission models).
Position a wedge 
(3)behind each of the two rear
wheels and raise the front of the machine by hold-
ing parts with a secure grip. Then push the support
block 
(1)underneath the front wheels and lower the
machine until the wheels rest on the block.
B) Rear
Position a support (4)in wood (or other material)
that can bear the weight of the machine; it should
be 28 cm high on the left, 26 cm high on the right
and 45 cm wide. Place it under the lower edge of
the plate.
Position an appropriately sized wedge 
(5)in front of
the front wheels to stop the machine from acciden-
tally moving forwards.
Before carrying out any type of work, make
sure that the machine is completely stable and
avoid operations that could cause it to fall over. 
5
4
4/2005
4
26 cm
28 cm
45 cm
2
30-35
cm
3
1
98S
2.3.1
LIFTING





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							2.4 PRACTICAL HINTS
A) Fitting snap rings
One side of the “Benzing” snap rings (1)has a
rounded edge and the other a sharp edge.
For maximum grip the rounded part needs to be
facing towards the element to be held 
(2), with the
sharp edges on the outside.
B) Joint pivot pins
There are a large number of pivot pins, usually con-
nected to rods, that need to be able to move in var-
ious directions.
A typical situation has the pin 
(3) fixed by a self-
locking nut 
(4) with two anti-friction washers (5)in
between the pin 
(3)and the support element, and
between this and the nut (
4).
Since these are joints, the nut must never be tight-
ened completely but only so much that it can
ensure the free rotational movement of the pin on its
axis without, however, creating excessive free play
which could result in the parts concerned becoming
misaligned and failing to work correctly.
C) Crown fasteners
Some pin ends (6)are secured by crown fasteners
(7). During dismantling, these fasteners are always
damaged and lose their hold, 
so they should never
be reused
.
On assembly, make sure it is inserted in the right
direction and push the fastener 
(7)onto the pin
using a pipe or socket spanner 
(8)with the right
diameter, so that it can be fitted without deforming
the fastener “crown”.
A deformed fastener should always be replaced.
7
6
7
6
8
3
55
4
3
45
1
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98S
2.4.1
PRACTICAL HINTS





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3.1 CRITERIA FOR MAINTENANCE
The Instruction Handbook has a number of operations to be carried out by the Customer for a minimum of
basic maintenance, and other operations not always within his capacity.
For this reason the Service Centre should undertake to keep the machine in perfect working order in two
ways:
a)Tuning the machine whenever possible.
b)Proposing a regular maintenance programme to the Customer to be carried out at prearranged intervals
(for example, at the end of the summer or prior to a long period of inactivity).
a) Occasional tuning
–Check working order of safety devices and renew illegible or missing labels
–Check type pressures
–Clean air filter
–Check engine oil level
–Check for fuel leaks
–Align cutting deck
–Sharpen and balance the blades and check the condition of the hubs
–Check for wear in the belts
–Check the blade brake engagement
–Grease front wheels lever joint pins and bushes
–Grease the bush of the drive pedal  
(➤hydrostatic drive models)
–Check tightness of engine screws
–Check all those items indicated in the engine manual
b) Regular maintenance
–All work carried out in section a), plus:
–Check battery charge
–Check tension of belts
–Adjust drive engagement 
(➤mechanical drive models)
–Adjust brake
–Adjust blade engagement
–Adjust blades brake
–Check steering allowance
–Check front bearings
–Check cutting deck lifting cables
–General lubrication
–Clean away grass cuttings and wash exterior
–Clean and wash inside cutting deck 
–ETouching up of any damaged paint
98S
3.1.1
CRITERIA FOR MAINTENANCE





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