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[4] TROUBLE SHOOTING

Symptom

Cause

Corrective action

The Tester designates between

0.79 and 0.81V by the steps 

shown in 

Fig. T-3 of page 9

.

In case the tester is not ready, 

go to “Yes”

Yes

Yes

Lamp (a) is ON.

See “Lamps on 

Housing set”.

Yes

Yes

No

No

Lamps on Housing set

The function does

not have trouble.

Scratch on the core of 

Rotor or mechanical 

trouble is recognized.

In spite of the above corrective actions,

the machine shows same symptom.

Yes

Yes

No

No

No

No

All of Lamps (b), (c),

(d) are ON.

See “Lamps on 

Housing set”.

Replace Controller.

Controller is broken.

Replace Stator complete*.

Controller is broken.

Replace Stator complete*.

Controller is broken.

Replace Stator complete.

Replace Stator complete*.

Replace Stator complete*.

Replace Rotor ass’y.

Controller is broken.

Replace Stator complete*.

Controller is broken.

Check the engagement of 

Gears and Rotor ass’y or

condition of mechanical

parts.

Mechanical trouble 

occurs.

Check Connectors, 

or replace them.

Check Connectors or

replace them.

Lead wires are 

disconnected.

Check Lead wires, or 

replace the broken wire(s).

Lead wires are broken.

Check Lead wires, or 

replace the broken wire(s).

Rotor ass’y is broken.

Stator complete is 

broken.

Switch is broken.

Replace Switch.

Terminal is broken.

(a): Mode lamp (green)

If Green lamp is ON, the machine is

automatically set in High Torque mode.

(b),(c), (d): Battery power remaining lamp

All 3 stages of Battery power

remaining lamp are on.

See “Lamps on Housing set”.

Controller is broken.

P 8/ 11

R

epair

Whenever you find any trouble in your machine, first, refer to this list to check the machine for solution.

(1) Use the 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.), Armature, Stator complete, Gear section, etc.

Note

Check List for Trouble Shooting

Motor runs when the machine

is switched on (in forward and 

reverse mode;10 times each)

In case of running inconstantly, 

go to “No”. 

Check the items from the top in 

Fig. T-2

. (Description of the item is referred to Circuit 

diagram in 

Fig. D-1 of page 10

.)

Repeat the check of the corrective action ten times.

Check Terminal,

or replace it.

Connectors are

disconnected.

Connectors are

disconnected.

Star mark

Fig. T-1

Fig. T-2

*It includes Controller.

Summary of Contents for DGA405

Page 1: ...ergy capacity Wh 27 36 54 72 90 Charging time approx min 15 24 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 Yes Paddle...

Page 2: ...bevel gear 37 to Spindle supporting Spindle when assembling Spiral bevel gear 37 to Spindle disassembling Rotor from Gear housing cover supporting Bearing box when removing Spindle from Spiral bevel...

Page 3: ...d hand turn M6 Hex nut counterclockwise with Wrench 10 Then remove Spiral bevel gear 10 4 Hook the jaws of 1R045 with Gear housing cover then push out Rotor ass y In this step Ball bearing 629LLB stil...

Page 4: ...cure the gear by turning M6 Hex nut clockwise with Wrench 10 Keep enough distance between Rotors so that they are out of their magnetic forces each other ASSEMBLING Spiral bevel gear 10 M6 Hex nut Fig...

Page 5: ...Spindle and Spiral bevel gear 37 are removed 4 Remove Retaining ring R 32 with 1R291 from the groove in Bearing box 5 Turn Bearing box upside down and press down Ball bearing 6201DDW from Bearing box...

Page 6: ...gear 37 Bearing box 1R029 1R036 Ball bearing 696ZZ Ring spring 11 3 Apply 1R268 to Shoulder pin 4 through the small hole on Pin cap and tap 1R268 with Metal hammer Shoulder pin 4 is removed from Gear...

Page 7: ...tor complete Assemble Stator complete as drawn in Fig 13 3 DISASSEMBLY ASSEMBLY 3 4 Stator complete ASSEMBLING Mating cavity on the left side and the right side tow each Terminal of Stator complete Ce...

Page 8: ...ace the broken wire s Lead wires are broken Check Lead wires or replace the broken wire s Rotor ass y is broken Stator complete is broken Switch is broken Replace Switch Terminal is broken a Mode lamp...

Page 9: ...everse attachment could spoil the test Wait until the display shows the value without fluctuation Terminal Terminal Insulating tape Switch lever complete black bar red bar P 9 11 1 Set Digital tester...

Page 10: ...and fasten the plate with the M3 5 screw of Switch Switch unit Tape Terminal Connector AWG24 AWG24 AWG28 AWG14 AWG28 AWG22 AWG14 AWG14 AWG14 Controller Line filter if used Stator P 10 11 Circuit diagr...

Page 11: ...Switch Route lead wires red yellow black of Terminal between Rib E and Rib F Put Line filter between Rib G and Rib H P 11 11 Wiring diagram Bend thick lead wires orange white blue of Controller here s...

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