background image

W

iring diagram

P 12/ 14

Fig. D-2

Switch

Controller

Connect Lead wire (white) and Lead wire (orange) to 

Switch with Insulated terminal.

Be careful about the directions of the insulated terminals.

Insulated terminals

Battery

terminal

Stator complete

Rib B

Rib D

Rib F

Projection on

Flag terminal

Rib E

Rib C Connector 2-SD

Resistor unit

Line 

filter

Rib A

When Line filter is used, insert it

between Rib E and Rib F.

Important: 

Three Flag teminals and two straight teminals (

circled by red

have a lock structure, that enables you to remove the flag/ straight

terminals from the tab of Battery terminal with ease.

While pushing the projection of the flag/ straight teminal with 

a slotted screwdriver to release the lock, pry off the flag/ straight

terminal from the tab of Battery terminal as shown left. 

Note

: Check whether flag/ straight terminals have a lock structure

          before disassembly as follows:

           • Find the projection on flag/ straight terminals.

           • Swing flag/ straight terminals slightly and gently to 

              feel a little backlash due to the lock structure.

Never force to pull any flag/ straight terminals ! 

Connect flag/ straight terminals onto the tabs of Battery terminals

until you can hear a tiny click sound.

Lead wires from Terminal must be

routed between Rib C and Rib D.

Thick Lead wire from Stator complete must be bent

to prevent pinching between Housing L and R.

Lead wires covered with a tube from Stator complete

must be placed under Thick lead wire.

Lead wires covered with a tube from Stator complete

must be routed between Rib A and Rib B.

Do not put any

Lead wires on 

this boss.

Place Resistor unit and Connector 2-SD in the area

circled by a blue broken line. Connector 2-SD must

not be placed on/ under Noise suppressor (if used).

Be sure to use

Resistor unit.

Lead wire (white) 

between Terminal 1 

and Terminal 2

Lead wire (orange) from Controller

Battery terminal

Slotted screwdriver

Summary of Contents for DGA404

Page 1: ...ion Cell Energy capacity W 27 36 54 72 90 Charging time approx min 15 18 22 36 45 with DC18RC Wheel size mm Hole diameter 6 1 4 Max thickness Diameter 100 4 16 5 8 22 23 7 8 8 500 No Yes Yes Yes Yes...

Page 2: ...gear 37 1R291 Retaining ring S and R pliers removing Retaining ring R 32 Round bar for arbor 12 50 removing Ball bearing 629LLB 1R286 Round bar for arbor 6 50 removing Spiral bevel gear 37 1R280 Beari...

Page 3: ...embled part of Gear housing and Bearing box from Gear housing cover While holding Rotor by a gloved hand turn M6 Hex nut counter clockwise with a Wrench 10 Wrench 10 M6 Hex nut Rotor Rotor Gear housin...

Page 4: ...cover and Rotor section Figs 6 and 7 1R286 Arbor press Ball bearing 629LLB Ball bearing 607LLB 1R269 Rotor When handling or storing multiple Rotors be sure to keep a proper distance between Rotors as...

Page 5: ...groove of Gear housing cover and Spindle toward the opposite of Switch knob Fig 12 Assemble by reversing the disassembly procedure Note Be careful about the points shown in Figs 10 11 and 12 Gear hous...

Page 6: ...ng Note When Spindle is removed from Spiral bevel gear 37 Ball bearing 6201DDW has a damage during the removal process Therefore replace Ball bearing 6201DDW with a new one Spindle Labyrinth ring M4x1...

Page 7: ...DISASSEMBLY ASSEMBLY 3 2 Spiral bevel gear 37 Ball bearing 696ZZ and Ball bearing 6201DDW cont 3 3 Shaft lock section 1R029 Bearing box Spiral bevel gear 37 Spindle 1R034 Arbor press Apply 1R268 to S...

Page 8: ...ating cavity in Stator complete Mating cavity on the left side and the right side Two each Projection in Housing on the left side and the right side Two each Stator complete Be sure to align the cente...

Page 9: ...ns on the triangle corners of Switch lever 3 DISASSEMBLY ASSEMBLY 3 5 Assembling of Switch knob and Switch lever Switch lever Switch knob The ends of Torsion spring 2 must be placed on these positions...

Page 10: ...one end of Torsion spring 2 on the rib of Housing L See below for the detail The other end of Pin 2 should be inserted into the hole of Housing R Place the top projection on the reverse side of Switch...

Page 11: ...WG Tape Controller The orange lead wire end from Controller can be connected to either or The one white lead wire end must be connected to either or together with the orange lead wire end and then the...

Page 12: ...ve a lock structure before disassembly as follows Find the projection on flag straight terminals Swing flag straight terminals slightly and gently to feel a little backlash due to the lock structure N...

Page 13: ...nical problem happens Identify the mechanical problem and repair or replace the part s Locate the incomplete connection and repair or replace them Controller is broken Replace Stator complete Switch i...

Page 14: ...to Minus terminal of Battery terminal Fig D 7 Note Be careful not to revere them The reverse attachment could spoil the test 4 Wait until the Tester shows the value without fluctuation There is no fau...

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