REPAIR MANUAL XML02
1 INDEX INDEX.......................................................................................................................................................................................... 2 CAUTION .................................................................................................................................................................................... 3 NECESSARY REPAIRING TOOLS ...........................................................................................
2 CAUTION Repair the machine in accordance with “Instruction manual” or “Safety instructions”. Follow the instructions described below in advance before repairing: · Wear gloves. · In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what are the parts. It is also recommended to have boxes ready to keep disassembled parts by group. · Handle the disassembled parts carefully. Clean and wash them properly.
REPAIR 4-1 Lower pipe, Upper pipe complete, Switch lever 4-1-1 Disassembling Fig. 4-1-1-1 [1] Remove Rear bag ass’y from Deck by lifting it up. [2] While holding Lower pipe or Upper pipe complete, loosen two M8x35 Thumb screws and remove the assembled part of Lower pipe and Upper pipe complete from Deck. Upper pipe complete M8x35 Thumb screw (2 pcs.) Upper pipe complete Remove Lower pipe M8x35 Thumb screw (2 pcs.) Lower pipe Remove Rear bag ass'y Deck Fig. 4-1-1-2 [3] Pull out two Holders.
Fig. 4-1-1-3 [7] Loosen 4x18 Tapping screw, and remove Switch lever case cover and Switch lever case. [8] Loosen M4x20 Pan head screw, and remove Arm. Switch cover Switch lever case Switch lever case cover M4x20 Pan head screw Arm 4x18 Tapping screw Fig. 4-1-1-4 Fig. 4-1-1-5 [9] Loosen four 4x18 Tapping screws, and remove Switch box cover complete and Switch box. [10] Remove Tension spring 9, and loosen M4x20 Pan head screw, and then remove Lever. [11] Remove Switch lever and Upper pipe complete.
4-1-2 Assembling Fig. 4-1-2-1 [1] Mount Lever to Switch lever, and tighten M4x20 Pan head screw while holding Hex nut. [2] Mount Tension spring 9. (Fig. 4-1-1-5) Switch lever M4x20 Pan head screw Hex nut Lever The tip of Lever faces upward. Fig. 4-1-2-2 [3] Route Power supply cord over Lower pipe.
4-2 DC motor 4-2-1 Disassembling Fig. 4-2-1-1 Fig. 4-2-1-2 [1] Remove Blade 430. [2] Pull Lock lever. [3] Turn Battery cover complete. [4] Remove Battery cover complete by releasing Battery cover complete from the hinges. Battery cover complete Hinge Battery cover complete Lock lever Fig. 4-2-1-3 Fig. 4-2-1-4 [5] Loosen two 5x25 Tapping screws, and remove Grip A. [6] Loosen seven 4x18 Tapping screws. Cowling 4x18 Tapping screw (7 pcs.) Terminal housing set Grip A 5x25 Tapping screw (2 pcs.
Fig. 4-2-1-7 [9] Loosen three M6x30 + Pan head screws using a No.3 Phillips screwdriver, and remove DC motor. M6x30 + Pan head screw (3 pcs.) DC motor 4-2-2 Assembling Fig. 4-2-2-1 Assemble DC motor by aligning its notch with Boss of Deck.
4-3 Change lever, Adjust plate 4-3-1 Disassembling [1] Remove Cowling. (4-2-1 Disassembling) Fig. 4-3-1-1 [2] Shift Change lever to the position of Cutting height at 75mm. [3] Release Tension spring 16 from the hook with long nose pliers. Tension spring 16 Hook Change lever Long nose pliers Fig. 4-3-1-2 Fig. 4-3-1-3 [4] Put a wood under Deck to raise Wheels from the ground.
4-3-2 Assembling Fig. 4-3-2-1 Fig. 4-3-2-2 [1] Put a wood under Deck to raise Wheels from the ground. [2] Lift up Connecting rod and insert the pin into the hole of Connecting rod. Hole of Change lever Connecting rod Pin of Connecting rod Wood Fig. 4-3-2-3 [3] Shift Change lever to the position of Cutting height at 75mm. [4] Hook Tension spring 16 with the hook with long nose pliers. Hook Tension spring 16 Change lever Long nose pliers Fig.
4-4 Front wheel, Rear wheel 4-4-1 Disassembling Fig. 4-4-1-1 Fig. 4-4-1-2 [1] Pull out Front wheel caps from Front wheels. Remove Rear wheel caps in the same way. [2] Remove M8 Collared hex nuts and Front wheels from Front shaft. Remove Rear wheels in the same way. Pull out Front wheel M8 Collared hex nut Front wheel cap Fig. 4-4-1-3 Fig. 4-4-1-4 [3] Tap the edge of each wheel with a plastic hammer. Ball bearings 6200ZZ in the wheels are removed.
4-4-2 Assembling Fig. 4-4-2-1 Fig. 4-4-2-2 [1] Press-fit Plane bearings 10 to Front/Rear wheels with 1R243 and an arbor press. [2] Press-fit Ball bearings 6200ZZ to Front/Rear wheels with 1R252 and an arbor press.
4-5 Connecting rod, Front shaft, Rear shaft 4-5-1 Disassembling [1] [2] [3] [4] Remove the assembled part of Lower pipe and Upper pipe complete. (4-1-1 Disassembling) Remove Cowling. (4-2-1 Disassembling) Remove the assembled part of Change lever and Adjust plate. (4-3-1 Disassembling) Remove Front wheel and Rear wheel. (4-4-1 Disassembling) Fig. 4-5-1-1 [5] Loosen two 4x18 Tapping screws, and remove Protective shield. Protective shield 4x18 Tapping screw (2 pcs.) Fig.
Fig. 4-5-1-3 [7] Loosen five 4x18 Tapping screws, and remove Front cover. 4x18 Tapping screw (5 pcs.) Front cover Fig. 4-5-1-4 [8] Loosen two 4x18 Tapping screws, and remove two Plates, Front shaft and Rear shaft. 4x18 Tapping screw (2 pcs.) Plate Plate Front shaft 4-5-2 Rear shaft Assembling Fig. 4-5-2-1 To distinguish between Front shaft and Rear shaft, check the white marking on Front shaft.
4-6 Protective shield 4-6-1 Disassembling Fig. 4-6-1-1 Fig. 4-6-1-2 [1] Loosen two 4x18 Tapping screws, and remove Protective shield section. [2] The component parts of Protective shield section are as follows: Protective shield Protective shield holder Rod 8 4x18 Tapping screw (2 pcs.) 4-6-2 Protective shield Stop ring E-7 Stop ring E-7 Assembling Fig. 4-6-2-1 Fig. 4-6-2-2 [2] Insert Rod 8 into Protective shield. [1] Mount Protective shield into the grooves of Protective shield holder.
4-7 Rear flap complete 4-7-1 Disassembling Fig. 4-7-1-1 The components of Rear flap complete section are as follows: Stop ring E-5 Stop ring E-5 Torsion spring 8 Rod 6 Stop ring E-5 Rear flap complete Stop ring E-5 4-7-2 Assembling Fig. 4-7-2-1 Assemble Torsion spring 8 as shown below.
Circuit diagram Fig.
6 Wiring diagram Fig. 6-1 Set the sheath of Power supply cord inside A as shown below. Route the lead wires of Controller as shown in the figure. Face the longer part of lead wires of Power supply cord to Deck. Strain relief Strain relief Power supply cord A 3mm 10mm Do not put lead wires on the rib E and Lead unit. Route the lead wires of Power supply cord through Line filters C (if used), and set the Line filters in the position shown below.
Fig. 6-2 Pass Lead wires (blue and red) of Motor through Line filter B (if used), and wind it around Line filter one time, and then put the line filter in the position shown below. Put the lead wire (red) of Motor and the lead wires (white, black) into any of these Lead wire holders. Controller Put the lead wire (red) of Motor into this Lead wire holder. Put the lead wire (red) of Motor into this Lead wire holder. Put the lead wire (blue) of Motor into this Lead wire holder.
Fig. 6-3 Flag receptacle Connect Flag terminal as shown in the figure on the right. Terminal Put the lead wires from Switch Between the rib G and Boss. Battery fuel gauge Switch Put Closed end splices in this space. Rib F Put the lead wires from Battery fuel gauge Between the rib F and Boss, Boss and the rib G. Boss Rib G Set the sheath of Power supply cord inside A as shown below.
7 TIGHTENING TORQUE SPECIFICATIONS No. 1 2 3 4 5 6 7 8 9 Parts to fasten Except No. 4 and 5 Switch box Deck Deck Terminal housing set Grip A Lever Arm Blade 430 set Strain relief Strain relief Cowling M Terminal housing set Cowling M Switch lever Switch lever DC motor *W: Spring washer R: Flat washer Tightening torque Fastener Q’ty (N･m) 4x18 Tapping screw 1.0 – 1.3 4x25 Tapping screw 1.3 – 1.5 2 4x25 Tapping screw 1.3 – 1.5 2 4x18 Tapping screw 0.9 – 1.1 4 4x18 Tapping screw 1.3 – 1.
