REPAIR MANUAL XRU09
P 2/ 19 Repair CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”. Index 1 NECESSARY REPAIRING TOOL............................. 2 2 ROTOR, STATOR ASS’Y 2-1 Disassembling ......................................................... 3 2-2 Assembling .............................................................. 8 3 LOOP HANDLE SET, PIPE COMPLETE, GRIP SET, SWITCH LEVER, LOCK OFF LEVER 3-1 Disassembling .........................................................
P 3/ 19 2 ROTOR, STATOR ASS’Y 2-1 Disassembling (1) Remove Cutter blade / Tipped saw blade / Nylon cutting head / Plastic blade. (Figs. 2-1-1, 2-1-2 and 2-1-3) Fig. 2-1-1 < Cutter blade/ Tipped saw blade> 1. Hold Rotor by inserting Hex wrench into the side hole of Motor housing. Remove M10-17 Hex nut by turning it clockwise. 2. Remove Cup, Clamp washer, Cutter blade and Receive washer A (48).
P 4/ 19 (2) Remove Protector. (Fig. 2-1-4) And then, disassemble Motor housing section. (Fig. 2-1-5 as below and Fig. 2-1-6 in page 5, Figs 2-1-7/ 2-1-8 in page 6, and Fig. 2-1-9 in page 7) Fig. 2-1-4 < Protector> 1. Disassemble Protector by loosening two M5x20 Hex socket head bolts. 2. Disassemble Protector clamp by unscrewing two M5x16 Hex socket head bolts with WR*. Note: No need to remove Hex socket head bolts completely. M5x16 Hex socket head bolts with WR* (2 pcs.
P 5/ 19 Fig. 2-1-6 1. Cut the tip of plastic portion. 4. Remove Plastic cover. 2. Cut the skirt portion. 5. Pull Lead wires slowly while forming the sleeve to cylindrical figure with water pump pliers. F 3. Cut the drum portion.
P 6/ 19 Fig. 2-1-7 1. Remove Strain relief by unscrewing M4x16 Pan head screw. M4x16 Pan head screw 2. Pull out Motor housing. Motor housing Strain relief Fig. 2-1-8 1. Loosely tighten with Receive washer A and Hex nut M10-17/ Hex nut M10-14 to prevent Rotor from falling out. Loosely tighten Nylon cutting head instead of the hex nut if Nylon cutting head is used. Receive washer A Hex nut M10-17/ Hex nut M10-14 Rotor 2.
P 7/ 19 Fig. 2-1-9 1. Remove Rotor and Ring 14 from Motor housing with 1R045. Note: Hook the jaws of 1R045 to Motor housing and set the center shaft of 1R045 to the shaft of Rotor. The jaws must not be touched to Rotor. Rotor Ring 14 1R045 Rotor Motor housing 2. Remove Retaining ring R-28 with 1R291. 3. Remove Ball bearing 6001DDW by pressing down 1R028.
P 8/ 19 2 ROTOR, STATOR ASS’Y 2-2 Assembling (1) If Stator lead wires are cut as shown in Fig. 2-1-5, strip the ends. (Fig. 2-2-1) Fig. 2-2-1 1. Remove sheathes by 13mm from the tip. 2. Remove enamel with abrasive paper #100 by 11mm from the tip. Note: It is necessary to remove enamel to conduct electricity. (2) Mount Ball bearings to Stator ass’y and Motor housing. (Fig. 2-2-2) Fig. 2-2-2 1. Mount Ball bearing 607ZZ to Stator ass’y by hand. 2. Set Motor housing on 1R023 while avoiding its pin.
P 9/ 19 (5) Mount Stator ass’y to Motor housing. (Fig. 2-2-4) Fig. 2-2-4 1. Place Stator ass’y on the shaft of Rotor. Note: * Be careful not to pinch your fingers between Stator and Rotor by strong magnet power. * Mount Stator ass’y while aligning its hole to the locating pin on Motor housing. Hole of Stator ass’y Stator ass’y Locating pin on Motor housing Shaft of Rotor Motor housing 2. Set Motor housing on 1R033. Apply 1R026 on Stator ass’y and press down 1R026.
P 10/ 19 3 Loop handle set, Pipe complete, Grip set, Switch lever, Lock off lever 3-1 Disassembling See Figs. 3-1-1, 3-1-2, 3-1-3 as follows and Figs. 3-1-4, 3-1-2, 3-1-3 in the next page. Note: No need to remove Nylon cutting head / Plastic blade from Motor housing. Fig. 3-1-1 Fig. 3-1-2 1. Disassemble Roop handle set. Roop handle M5x25 Hex socket head screw (2 pcs.) Roop handle set 2. Remove Battery guard by unscrewing three M4x12 + Screws. M4x12 + Screw (3 pcs.
P 11/ 19 Repair Fig. 3-1-4 1. Remove six 4x18 Tapping screws and M5x18 Hex socket head bolt, and then remove Grip R. 4x18 Tapping screw (6 pcs.) Grip R M5x18 Hex socket head bolt 2. Remove Lock off lever together with Torsion spring 9 by lifting them up. 3. Remove Switch lever together with Torsion spring 10 by lifting them up. Switch lever Torsion spring 10 Torsion spring 9 Lock off lever Fig.
P 12/ 19 3 Loop handle set, Pipe complete, Grip set, Switch lever, Lock off lever 3-2 Assembling Assemble by reversing the disassembly procedure. Also, refer to the point shown in Fig. 3-2-1 as follows and Figs. 3-2-2 in next page. Fig. 3-2-1 1. Install Hanger from two holes side of Pipe complete. Housing and Grip set side Hanger Motor housing side 34mm 14mm Pipe complete Two holes One hole 2.
P 13/ 19 Fig. 3-2-2 1. Insert Lock off lever halfway over the boss of Grip L while pressing Torsion spring 9. Lock off lever 2. Push Lock off lever to the bottom of Grip L after holding the Torsion spring’s arm with the rib of Grip L. Boss of Grip L Lock off lever Torsion spring 9 Rib of Grip L 3. Assemble Lock off lever by fitting its projection to the groove in Grip L as shown in the following four pictures.
P 14/ 19 4 CIRCUIT DIAGRAM Fig. 4-1 Color index of lead wires' sheath Blue Brown Orange Purple White Yellow Black Gray Red Sub controller complete ON / OFF, High / Low speed Reversing switch LED Indicator High speed R/L change Low speed Switch unit for Trigger Symbol Electrical Parts Connector Insulated connector 5.5 -SD 22 AWG* 28 AWG* Stator 28 AWG* Flag receptacle Straight receptacle with polyolefin tube Controller B Polyolefin tube Insulated connector 5.
P 15/ 19 5 CIRCUIT DIAGRAM Fig. 5-1 Wiring in Motor housing Connectors Strain relief A Power supply cord unit (long) Motor housing A Section A-A Put Connectors to the space between the bottom of Motor housing and Power supply cord unit (long). Connectors Mount Strain relief while facing its looped side to the bottom of Motor housing. Looped side of Strain relief Power supply cord unit (long) Looped side of Strain relief The bottom of Motor housing Strain relief Insulated connector 5.
P 16/ 19 Fig. 5-2 Wiring in Grip set Note: Be careful not to pinch Corrugated tube of Power supply cord unit (short) with Strain relief . Corrugated tube with Power supply cord unit (short) Lead wires of Power supply cord unit (short) to Sub controller First, set lead wires of Switch unit to Grip set. Strain relief Set the connector on blue lead wires and black lead wires to the connector for Switch unit as drawn. Switch unit Do not put the sag of any Lead wires on Connectors.
P 17/ 19 Fig. 5-3 Wiring in Housing set Flag receptacles of Terminal A and Terminal B have to be connected so that their wire connecting portions are located over the marks of + - poles. Wire connecting portions Flag receptacles Put Power supply cord (long) between Rib D and Rib E. 10 pin Connector Housing L side Rib A Put Lead wires for 10 pin Connector between Rib B and Rib C. Rib C Terminal A Rib D Put lead wires of Terminals between Rib A and Rib B, and Rib B and Rib C.
P 18/ 19 6 TROUBLE SHOOTING 6-1 Check List for Trouble Shooting Check items from the top. (For description of the item, refer to Circuit diagram in Fig. 4-1). After corrective action, return to the start of Trouble shooting and check again. Symptom Cause Does Tester indicate 0.9V ~ 1.3V? When tester cannot be prepared, go to “Yes”. No Corrective action Controller is broken. Replace Controller. Sub controller is broken. Replace Sub controller.
P 19/ 19 Repair 6-2 Note in Repairing Fig. 6-2-1 (1) Make sure to use full charged battery with Star mark (Fig. 6-2-1). (2) When Housing is disassembled, check the conditions of electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc. (3) Do the running test 10 times in every work mode. Star mark 6-3 Test for recognizing the short-circuit of FET (Field Effect Transistor) on controller Trouble on Controller can be checked with Tester as follows. Fig.
