REPAIR MANUAL XHU02
P 2/ 12 Repair CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”. [1] NECESSARY REPAIRING TOOLS Code No. Description 1R035 Bearing Setting Plate Use for Supporting Spur gear 93, when removing Spindle with Arbor press [2] LUBRICATION Apply the following grease to the portions designated with the black triangle to protect parts and product from unusual abrasion. Item No.
P 3/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Shear blade complete DISASSEMBLING Disassemble Shear blade complete as drawn in Fig. 2. Fig. 2 1. Remove Under cover by unscrewing four M4x10 Pan head screws. Under cover M4x10 Pan head screw (4 pcs.) 2. Remove Shear blade complete by unscrewing four M5x14 Pan head screws. And remove two Nylon sleeves from Shear blade complete. Flat washer 8 M5x14 Pan head screw (4 pcs.) 3.
P 4/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. DC motor DISASSEMBLING (1) Disassemble Shear blade complete and Spur gear 93 as drawn in Fig. 2. (2) Remove Protector and Front grip section as drawn in Fig. 4. Fig. 4 1. Remove Protector by unscrewing two 4x18 Tapping screws. And loosen two M5x25 Pan head screws on the joints of Front grip. M5x25 Pan head screw (2 pcs.) 4x18 Tapping screw (2 pcs.) 2.
P 5/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. DC motor (cont.) DISASSEMBLING (4) Disassemble DC Motor from Motor housing as drawn in Fig. 6. Fig. 6 1. Remove one Rubber ring 6, two Rubber rings 8 and five 3x16 Tapping screws. 3. Separate DC Motor from Bearing box complete. 2. Remove DC motor together with Bearing retainer from Motor housing L.
P 6/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. DC motor (cont.) ASSEMBLING (2) Fix Motor housing R and Motor housing L with Rubber rings as drawn in Fig. 8. Fig. 8 Rubber ring 6 Motor housing R Motor housing L Rubber ring 8 (4 pcs.) (3) Setting Motor housing section to Housing L, set Housing R in place with six 3x16 Tapping screws and one M4x65 Pan head screw as drawn in Fig. 9. Fig. 9 Housing L Note: As this boss of Housing L is easy to be deformed, tighten M4x65 Pan head screw carefully.
P 7/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -3. Spur Gear 93 DISASSEMBLING (1) Disassemble Shear blade complete, and then, remove Spur gear section as drawn in Fig. 2. (2) Disassemble Spur gear 93 as drawn in Fig. 11. Fig. 11 1. Put Spur gear section on 1R035, remove Spindle with Arbor press. 2. Spindle is removed from Spur gear 93. Spur gear 93 Spindle Spindle 1R035 ASSEMBLING (1) Assemble Spindle to Spur gear 93 as drawn in Fig. 12. Fig.
P 8/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -4. Front grip DISASSEMBLING (1) Remove Front grip section without disassembling Under cover as drawn in Fig. 13. Fig. 13 Switch lever Front grip Slotted screwdriver 1. Insert a slotted screwdriver into the gap between Front handle and Switch lever B, and push Switch lever B toward the direction designated with black arrow. One of Boss of Switch lever B is removed from the hole of Front handle.
P 9/ 12 Repair [3] DISASSEMBLY/ASSEMBLY [3] -5. Switch arm DISASSEMBLING (1) Disassemble Front grip section as drawn in Fig. 4. (2) Remove Housing R as drawn in Fig. 5. (3) Switch arm is removed as drawn in Fig. 15. Fig. 15 Switch Switch arm ASSEMBLING Switch arm has to be assembled to Housing L so that it can push ON/OFF button of Switch to link with Switch lever B’s action. See Fig. 16. Fig.
P 10/ 12 Circuit diagram Fig. D-1 Model No. XHU03 XHU02 Color index of lead wires' sheath Orange White Black Purple Red Yellow LED (Warning lamp for battery) Tape for bundling Lead wires Line filter Line filter is not used for some countries. Red dot mark Switch lever B side COM Switch in rear grip Switch Switch in front grip White lead wire is used for some countries.
P 11/ 12 Wiring diagram Fig. D-2 Wiring to DC motor Connectors Face Lead wires (red, black) to Motor housing L side and connect their connectors with Terminals of DC motor. Controller side Red dot mark Connect Lead wire (red) to the connecting terminal near Red dot mark. Lead wire (black) Lead wire (red) Motor housing L side Bearing box Fig. D-3 Wiring in Motor housing L Face black Lead wire to Controller side and set DC motor to Motor housing L.
P 12/ 12 Wiring diagram (cont.) Fig. D-4 Wiring in Housing set Wiring of LED warning lamp for battery LED Lamp Rib A Face the projected portion of LED Lamp to Front grip side. Groove Rib B Put the following Lead wires between Rib A and Boss. Rib C Put LED Lamp’s Lead wires into groove. Put Lead wires between Rib B and Rib C. Boss Route the Lead wires (white, orange, purple) between the Rib and inner wall of Housing set.
REPAIR MANUAL XBU02
P 2/ 13 Repair CAUTION: Repair the machine in accordance with "Instruction manual" or "Safety instructions". [1] NECESSARY REPAIRING TOOLS Code No. 1R028 1R032 1R045 1R247 1R269 Description Bearing setting pipe 20-12.2 Bearing setting plate 8.
P 3/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -1. Fan 110, Rotor (cont.) DISASSEMBLING (2) Separate Motor housing from Housing set L. (Fig. 2) Fig. 2 While paying attention not to loosen Switch section in Handle portion, separate Motor housing section from Housing set L. Switch section Fan 110 is removed from this side in the next step. Housing set L Motor housing (3) Remove M5 Coned disc spring hex nut from the rotor shaft and remove Fan 110. (Fig. 3) Fig. 3 1.
P 4/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -1. Fan 110, Rotor (cont.) DISASSEMBLING (4) Remove Rotor from Motor housing. (Fig. 4) Fig. 4 1. Remove Flat washer 8 from the rotor shaft. 2. Loosen four 3x20 Tapping screws, and disassemble Cap from Motor housing so that Rotor can be removed from the cap side. Motor housing Cap Rotor Flat washer 8 Motor housing 3. Tap the rotor shaft with a plastic hammer. 4. Remove Rotor and Motor housing cover from Motor housing.
P 5/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -1. Fan 110, Rotor (cont.) Caution for Handling of Rotor When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 6 because Rotor has a strong magnetic force. Failure to follow this instruction could result in: • Finger injury caused by pinching between Rotors • Magnetic loss of Rotors or damage on the magnet portion of Rotor (Fig. 7) Fig. 6 Fig.
P 6/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -1. Fan 110, Rotor (cont.) ASSEMBLING (3) Assemble Fan 110 to the rotor shaft. (Fig. 9) Fig. 9 Motor housing 1. Fix Cap to Motor housing with four 3x20 Tapping screws. Cap Flat washer 8 Rotor 2. Assemble Flat washer 8 to the rotor shaft. 2. Assemble Fan 110 to the rotor shaft while aligning their flats on Fan110 and the rotor shaft. Awl or small screwdriver Fan 110 Flat 4. Lock Fan 110 with the grip of plastic hammer. 3.
P 7/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -2. Fan Lock ON button ASSEMBLING Assemble Lock ON button. (Fig. 10) Fig. 10 1. Join Lock ON buttons and Compression spring 5 together while aligning their protrusions on Lock ON buttons in the same direction. If not, Housing set R may not be fixed properly. Protrusions 2. Assemble Lock ON button to Housing set L while fitting one protrusion to the cut portion of boss.
P 8/ 13 Repair [3] DISASSEMBLY/ASSEEMBLY [3] -3. Sub Controller DISASSEMBLING Disassemble Sub controller. (Fig. 11) Fig. 11 1. Remove Dial 28. 2. Disconnect the connector. Dial 28 Connector 3. Remove Sub controller by prying it off with a slotted screwdriver. Note: When removing Sub controller, be sure not to grip or pick up the axis for Dial 28 or Lead wires of Sub controller.
P 9/ 13 Repair [4] TROUBLESHOOTING Whenever you find any trouble in your machine, refer to this chapter first. Note in Repairing (1) Use a full charged battery which has the star mark. (Fig. T-1) (2) When Housing is disassembled, check the conditions of the electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc. (3) Do a running test 10 times. Fig.
P 10/ 13 Repair [4] TROUBLESHOOTING Check List for Troubleshooting Check the items from top of the following list. (Description of the item is referred to Circuit diagram in Fig. D-1.) After corrective action, return to the start of Trouble shooting and check again. Symptom Cause Does it read 0.9V ~ 1.3V on the tester? When a tester cannot be prepared, go to “Yes”. No Corrective action Controller is broken. Replace Controller. Controller is broken. Replace Controller.
P 11/ 13 Circuit diagram Fig. D-1 Color index of lead wires' sheath Black Closed end splice Poly olefin tube Flag connector w/ lock Straight connector w/ poly olefin tube Blue Brown Gray Orange Purple Red White Yellow Stator Tape 28AWG Connector 14AWG 28AWG Terminal (on Housing set R side) Battery fuel gauge 14AWG #187, t=0.8mm #250, t=0.8mm 14AWG 22AWG AS 14AWG 26AWG #250, t=0.8mm Controller 14AWG 22AWG AS 14AWG #187, t=0.8mm #250, t=0.
P 12/ 13 Wiring diagram Fig. D-2 Wiring in Motor housing Route Lead wires of Startor through this groove. Motor housing Stator Fig. D-3 Wiring to Terminals Set Flag connectors to Terminals as shown below.
P 13/ 13 Wiring diagram Fig. D-4 Wiring in Housing set L Wiring to Sub controller Rib A Sub Controller Put Lead wires of Sub controller in this groove. Put Lead wires of Sub Controller under the top of rib A. Put connectors as shown in the figure. Note: Do not put the slacks of the lead wires on the connectors. Put Lead wires of Switch in this space. Route the tube covering the lead wires on the other lead wires.
