Service Manual

Carefree Mower Service Manual 6 - 1
DISASSEMBLY & REASSEMBLY
Disassembly — Battery Models
All the electrical components are located under the
hood. The on/off switch is controlled by a cable that
runs alon
g
side the handle. With the hood removed,
there is access to the test points of all electrical
components.
To access the motor, wirin
g
, switch, and batteries,
char
g
er and solenoid (on battery models), remove the
four screws retainin
g
the hood and lift the hood off.
To remove the motor, on battery powered models,
remove the hood and disconnect the battery terminals
and remove the solenoid. Turn the mower over and
remove the blade, bushin
g
fan, washer, and the four
screws holdin
g
the motor in place.
NOTE: On battery models, the solenoid must be
removed first as it uses one of the motor mountin
g
screws.
Transformer Replacement — Battery
Models
Remove the hood and disconnect the battery cables.
Lift the char
g
er assembly from its slot. Below the
char
g
er are four wires which plu
g
into the char
g
er
terminals throu
g
h slots in the body. Unplu
g
these four
wires, note that the wires are in pairs; ta
g
them if
necessary to remember which wires
g
o where.
Remove the nut holdin
g
the solenoid mountin
g
bracket
to the motor mountin
g
screw. Turn the mower on its
side and remove the blade, bushin
g
, fan, and spacer.
Remove the four screws holdin
g
the motor to the
chassis. Be ready to catch the motor and set it aside.
Remove the 11 screws holdin
g
the liner to the chassis.
Lift the liner off. The transformer is between the rear
wheels inside a plastic housin
g
. Note the orientation of
the transformer when it is removed. Replace the
transformer in the housin
g
and replace the housin
g
in
the chassis. Make sure the transformer terminals are
in the correct slots. Reinstall the liner, blade, fan, etc.
See the specifications for the proper torque on all
hardware.
Battery Replacement
The batteries are held in place by a strap. To remove
the strap, remove either of the screws securing the
ends of the strap. However, the batteries are resting
on double sided tape. It will be necessary to slide a
putty knife or similar object under the batteries to break
the tape loose. The battery pack can then be removed.
Note the way the battery terminals are positioned so
the new batteries can be installed property.
Blade Replacement — 120 Volt Models
The blade is attached to a spindle shaft. Tip the mower
on its side. Remove the blade retaining nut and
washer.
NOTE: You may find it helpful to remove the motor
cover and hold the lar
ge drive pulley to tighten or
loosen the blade nut.
6