BATTERY POWERED WHEELBARROW XUC01 REPAIR MANUAL March 2018 Ver.
1 CONTENTS CONTENTS ................................................................................................................................................................................. 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 the parts are. It is also recommended to have boxes ready to keep disassembled parts by group. ・ Handle the disassembled parts carefully. Clean and wash them properly. 3 NECESSARY REPAIRING TOOLS Code No.
FASTENING TORQUE Parts to fasten Cover (LED light) Wheel 5 Fastener Frame Frame M5x16 Hex socket head bolt M16x1.5 Hex nut Tightening torque (N･m) 3.5 – 4.5 40 – 50 LUBRICANT AND ADHESIVE APPLICATION Apply the following lubricants and adhesives. Lubricant Makita grease FA. No.2 Bead cream (commercial product) Amount a little a little Fig.
6 REPAIR 6-1 Battery 6-1-1 Disassembling 1 Remove Battery from the machine before repair. 6-2 Frame 6-2-1 Disassembling Fig. 1 1 2 [1] Release Rock lever [1]. Loosen M8x25 Thumb screw [3] (4pcs) and remove Spring washer 8 [4], Flat washer 8 [5], M8x50 Hex bolt [6], M8x75 Hex bolt [7] (2pcs) and then remove Frame [2]. [2] [7] [5] [6] [4] [3] Fig. 2 3 [3] [3] [2] 4 [5] [9] [8] [7] [1] [4] [6] [5] [3] 5 Upper frame [3] can be disassembled from Lower frame [5] as follows.
-3 Battery box 6-3-1 Disassembling (Repair can be done with Upper frame) Fig. 3 1 [2] [2] Remove four M5x14 H.S.H.Bolt WR [1] with 1R015-A and Impact driver and take out Battery box assembly [2]. Tips Prepare a workbench [3] to put Battery box assembly [2]. [3] [1] 1R015-A Fig. 4 2 [1] [2] Fig. 5 3 4 [2] 5 [3] Remove Binding PT3x16 Tapping screws (8 pcs) [1] and remove Front cover [2]. Repair Controllers and other electric parts according to Circuit diagram and Wiring diagram.
6-3-2 Assembling Fig. 7 1 [1] 2 Insert claw portion of Terminal [2] into the groove of Ceter case [1]. Put Terminal holder[4] onto Center case [1] so as not to pinch Lead wires and then fasten them with PT 3x16Tapping screws [3] (2 pcs). [2] [3] [4] Fig. 8 3 4 [2] 5 [1] Insert Leaf springs [1] (2 pcs) to Battery box and assemble it to Center case[3]. Assemble Battery box[2] fastening with Tapping screws bind PT 3x16 [4] (5 pcs).
6-4 Switch box 6-4-1 Disassembling Fig. 9 1 Remove M8x20 Hex bolt [1] and M8x40 Collar bolt [2]. Then pull off Handle R [4] from Sub frame [3]. [4] Tips Prepare a workbench or a box to put Handle R [4]. [1] [2] [3] Fig. 10 [3] 2 Remove Binding PT 3x16 Tapping screw [1] (5 pcs) and open Switch box L [2]. Electric parts can be removed without disassembling Switch box R [3]. [2] [1] Fig. 11 3 Remove Switch [1] pushing lock of receptacle [2] with a slotted screwdriver. This Receptacle is with lock.
6-4-2 Assembling Fig. 12 1 [2] Assemble Switch lever [1] and Torsion spring 11 [2] as shown in the left Fig. [1] Fig. 13 2 [1] Assemble Switch plate [1] by connecting Connector to Switch box through the bottom of pipe of Handle R. [2] Fig. 14 3 Assemble Pipe clamp 28 [1] if they are disassembled. Pipe clamp is non-directional in spite of the different shape of the ends of Pipe clamp. [1] Fig.
6-5 LED light 6-5-1 Disassembling Fig. 16 1 [1] [2] Remove only inside Bind PT 3x16 Tapping screws [2] (2 pcs). Then LED light assembly [1] can be disassembled. [2] Fig. 17 [3] [4] [5] 2 [2] [1] Remove CT 4x16 Tapping screws [1] (4pcs) and remove Light case cover [2] (Left/ right both Lights) Tips Put some board on the center Lower frame to make a workbench. [6] [7] [4] (In case of replacing only LED lights) [2] 3 Fig.
* Fig. 20 [1] [2] [3] 6 Loosening engagement of Clamp A [1] and Clamp B [2] remove LED light assembly [4]section from Lower frame [3]. [4] 6-5-2 Assembling Fig. 21 1 Assemble Reflector [1] by engaging four protrusions with four holes on LED circuit [1]. Though bottom shape of Reflector is rectangular, it is non-directional. [1] [2] Fig. 22 2 Insert the protrusion of Clamp A [1] into the hole of Lower frame. In this way LED light assembly position is fixed.
6-6 Brake 6-6-1 Disassembling Fig. 23 [2] 1 [1] Loosening M6x18 H.S.H bolt W/WR [1] (2 pcs) of Brake caliper assembly, pull off Brake cable through Adjust screw section [2]. [3] Fig. 24 2 [3] Removing M6x18 H.S.H bolt W/WR [1] (2 pcs) remove Brake caliper assembly [3] from Lower frame [2]. [2] [1] Fig. 25 [4] [3] [1] 3 Remove two screws [1] and Connector [2] and then disassemble Brake pad [3] and Pad spring [4] (2 pcs). The components of Brake caliper assembly are as shown left.
Fig. 26 4 [2] 5 Pull off Brake cable [3] by adjusting slit of Adjust screw of Brake assembly [1]. Pulling up Brake lever [4], remove nipple of Brake cable [3] from Brake lever [4]. [1] [3] [4] [3] Fig. 27 6 Remove Hex socket bolts (2 pcs) [1] and Brake assembly [3] from Handle complete. [2] [1] [3] 6-6-2 Assembling Fig. 28 1 Assemble by reversing the disassembly procedure. Assemble Brake assembly and Brake cable.
Fig. 30 [4] 3 [1] 1R36 4 [5] [3] [2] 5 Temporary fasten Brake caliper with M6x18 H.S.H bolts W/ WR [1]. Inserting 1R366 (0.1mm) between Brake disc [2] and Brake pad [3] support Lever [3] to apply Brake effectively. Eliminating the sagging of Brake cable, fasten Hex socket bolts [1] (2 pcs) and then a Hex socket bolt [5] to fix Brake cable. After adjusting the Brake switch on the motor to check the following parts for proper function.
Fig. 33 [4] 6 [1] [3] Remove Front tire 430 [1] by lifting it up from Lower frame [2]. Note Two Washer [3] are attached at both left and right side of axle. Two Coned disc spring 16 [4] are attached at opposite side of Brake. [2] Fig. 34 [2] 7 [3] Remove six Hex socket head Button bolt [1] and remove Brake disc [2]. [1] Note Six Flat washers are attached opposite side of Brake disc. Be careful not to lose them. Fig.
Fig. 37 [2] [1] 10 Remove Wheel [3] with a Lever for replacing tire [1] from [3] Fig. 38 Front tire 430 [2]. 11 Pull off Snap in valve [1] from Wheel [2] by pushing it with Arbor press and 1R283 etc.
Fig. 39 12 Grasp Snap in valve [1] with a plier and pull off from Wheel [2]. [2] [1] 6-7-2 Assembling Fig. 33 1 [4] 2 [1] [3] [2] 3 Lid of Bead cream Apply Bead cream [3] to insert surface of Snap in valve [1] and a mounting hole [2] of Wheel all around. Insert Snap in valve [1] into the hole [2] of Wheel by picking up screw side of Valve [1] to pass through the hole.
Fig. 42 6 [1] [3] Tips Be careful not to make a damage to Wiring of Motor [3] and Snap in valve [4] and assemble Front tire 430 [1]. If the opposite side of Snap in valve is inserted first it can be smoothly assembled. [2] Yellow line Insert the Yellow line side of Front tire 430 [1] into Brake disc side of Wheel and engage lower side of Beads with a Lever [2] for replacing tire. [4] Fig. 43 7 Fig. 44 8 Apply Bead cream to the opposite side of Bead.
Fig. 46 11 Prepare some wood stand to put Wheel.( only Wheel to turn Front tire) Put the wiring side of Wheel upward. 12 Engage bead of Front tire 430 and Wheel by pushing down the tire. And then pump up to be engaged completely. Wood stand Fig. 347 [1] 13 Insert Valve core with Valve clip [1] to prevent from air leakage out of Front tire. [2] Note Adjust air pressure to designated 0.23Mpa with Air gauge [2] . Fig.
Fig. 35 17 When Band to connect each wiring is cut with a nipper all Bands must be replaced with a new one. After fastened with a new one extra Band must be cut down. 6-8 1 Puncture repair of Front tire 430 Puncture repair of Front tire is to be consigned to outside Repair agency such as Auto-repair shops. In that case designated air pressure 0.23Mpa must be noticed to them.
7 CIRCUIT DIAGRAM Motor section Battery Insertion section Motor Power supply cord Grommet Closed end splice AWG 14 Green 1.5mm2 Green AWG 14 Blue 1.5mm2 Blue 1.5mm2Yellow AWG 14Yellow Wire diameter is 0.2mm2 AWG 28 Connector Line filter Grommet Brake operation section Line filter Connector AWG 26 Controller 0.2mm2 0.
Connector Battery Insertion section Buzzer circuit Switch for illumination Switch for Fuel gauge Line filter AWG 26 AWG 26 AWG 26 AWG 26 Connector AWG 28 (7 pcs) LED circuit board AWG 28 LED circuit board AWG 28 (4 pcs) Main switch Connector Lead unit AWG 26 AWG 28 (9 pcs) Connector (9 pcs) AWG 26 (9 pcs) Connector SubAWG 28 Controller AWG 28 (4 pcs) Main B1 switch AWG 28 (4 pcs) AWG 14 Orange AWG 14 Orange Closed end splice AWG 14 Orange AWG 26 B2 Connector Connector AWG14 Blac
8 WIRING DIAGRAM 8-1 Center case section 8-1-1 Assembling of Controller Fix Controller with these Hooks. Line filter (if it is used) Put Line filter Controller lead wire (orange, white, blue) connected to Terminal (Key side) in this space. (If it is used) Pass Controller lead wire connected to Terminal through the Opening. Opening 8-1-2 Rib A Pass Controller lead wire connected to Terminal between two Rib A. Assembling of Terminal Do not put any Lead wires on Ribs.
8-1-3 Assembling of other than Power supply cord Fig.：Drawing after repair Put Lead wires in the below area to avoid pinching. ・between Cover and Lead unit (for connecting Key) ・between Cover and Center case Lead unit (for connecting to Key) Cover Put Electrolytic capacitor in this space. Electrolytic capacitor Put Closed end splice connected to Lead unit (for connecting to Key) in this space. Don’t put any Lead wires on this Rib.
Assemble Buzzer circuit as shown below. Buzzer circuit Route Controller lead wire connected to Sub controller complete through this space. The cross section between A – A’ Put Lead wires of Buzzer circuit in this Lead holder. Don’t make a slack between Buzzer circuit and Lead holder. Line filter A (with Controller, without Tube) A A’ Buzzer circuit Put Connector of Buzzer circuit as shown above. Pass Lead wire of Buzzer circuit in this space.
・Tape A , Tape B: Sub controller complete (without Switch) for bundling Lead wire Put Tape B in left or right groove as shown below. Don’t put any Lead wires on this Rib. Lead wires of Sub controller complete (without Switch) must be tight. Don’t make a slack between Tape A and Tape B. Lead wire connected to Sub controller complete (without Switch) between Boss and Rib A. Sub controller complete (with Switch) Put Tape A in this space.
Put Line filter A as shown below (left side of Hook) Avoid pinching of Lead wires between Line filter A and Center case, Controller case.
8-1-4 Assembling of Power supply cord Fig.：Drawing after repair Cord for Motor Cord for LED light Relay cord for Switch box Cord for Brake < Assembling of Relay cord for Switch box and Cord for LED light > Put Connector of Relay cord for Switch box in this space as shown below. 4 pins Put Closed end splice of which Lead wires are connected to Relay cord for Switch box in the below dot area. 10 pins Route Lead wires connected to Relay cord for Switch box between Ribs.
Put Connector of Cord for LED light in the space as shown below. Put Sheath of Cord for LED light in this space. Cord for LED light Line filter of Cord for LED light Relay cord for Switch box Put Line filter of Cord for LED light in this space. Don’t put any Lead wires on Ribs.
< Assembling of Cord for Motor and Cord for Brake > Tip of Sheath of Cord for Motor should not be jumped out from root of Controller lead wire (Signal wire connecting to Motor and Brake) Assemble Front cover while Battery changeover switch is come out of Center case. Route Lead wire of Cord for Motor (with Connector) between Boss and inner wall. Battery changeover switch Don’t route Lead wire of Cord for Motor (with Connector) in the area as shown below.
Lead wires should not be jumped out from Opening toward Terminal. Opening 8-1-5 Assembling of Battery changeover switch Assemble Battery changeover switch after Front cover is assembled to Center case. Battery changeover switch Assemble Battery changeover switch as shown above.
8-2 Switch box section Switch plate complete Don’t put Connector so that Lead wire of Switch plate complete faces to Switch terminal side. NG Connector of Switch plate complete Switch terminal Switch Switch plate complete Rib Assemble Flag receptacle as shown above. Assemble area A to touched to Rib. Don’t put any Lead wires on these Ribs. A Put Connector under Relay cord for Switch box. 【Note for assembling Switch】 Before start to repair, set Lever <1> or <2>.
8-3 LED Light case section < Right side > Assemble the tip of Sheath of Power supply cord (with two Connectors) in this zone. Route Lead wire of LED circuit through this groove. Assemble Power supply cord unit (with two Connectors) at this side. Don’t make a slack in this space. Assemble Power supply cord unit (with a Connector) at this side. Assemble the tip of Sheath of Power supply cord (with a Connector) in this zone. LED circuit Don’t put any Lead wires on this Rib.
8-4 Fixing of Band Band assortment Band A（687849*1） ： Band B（687410*4） ： Band A, B Pull the Band until the gap with Cord and Pipe will be eliminated. Max 3mm Cut off unnecessary Band. *The cut end must be Max 3mm. Sec. A-A Band B Fix Band B as shown below. Pipe A Upper Band B Lower A Cord Connect Cord and Lead wires without making slacks.
8-5 Wiring 8-5-1 Position 1 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case Battery box Light case (left side) Wheel section Switch box Position 1 Light case (right side) Assemble Wheel so that the Cord between Wheel and Battery box comes out as shown below Fig. Fix Cord between Wheel and Battery box under the lower side of Pipe.
8-5-2 Position 2 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case (left side) Light case Battery box Position 2 Switch box Wheel section Light case (right side) Fix Cord between Wheel and Battery box with Band B. Don’t wind Cord around Pipe.
8-5-3 Position 3 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case Battery box Light case (left side) Position 3 Switch box Wheel section Light case (right side) Fix two Cords with Band B. 1. Cord between Wheel and Battery box 2.
8-5-4 Position 4 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case Battery box Light case (left side) Wheel section Switch box Position 4 Light case (right side) Fix the Wire between Wheel and Brake with Band B. Fix three Cords with Band B. 1. Cord between lights 2. Cord between light case and Battery box 3.
8-5-5 Position 5 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case Battery box Light case (left side) Wheel section Switch box Position 5 Light case (right side) Pass the below two Cords through the Cord clip preventing them from falling down. 1. Wire between Wheel and Brake section 2.
8-5-6 Position 6 Battery box section Color index of cords' sheath Wheel Battery box Brake section Position 6 Brake Battery box Switch box Battery box Wheel Brake wires Light case Light case Battery box Light case (left side) Wheel section Switch box Light case (right side) Pass the Cord between Switch box and Battery box, Light case (right) and Battery box over the Pipe (Wheel side). Fix the Cord between Light case (right) and Battery box with Wire clamp.
8-5-7 Position 7 Color index of cords' sheath Battery box section Wheel Battery box Brake section Brake Battery box Switch box Battery box Position 7 Wheel Brake wires Light case Light case Battery box Light case (left side) Wheel section Switch box Light case (right side) Pass the Cord between Wheel and Battery box, Brake and Battery box through the Wheel side of Lock lever. Pass the Cord between Wheel and Battery box, Brake and Battery box over the Pipe (Wheel side).
