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1

 

INDEX 

 

1

 

INDEX .......................................................................................................................................................................................... 2

 

2

 

CAUTION .................................................................................................................................................................................... 3

 

3

 

NECESSARY REPAIRING TOOLS ........................................................................................................................................... 3

 

4

 

REPAIR ........................................................................................................................................................................................ 4

 

4-1

 

Lower pipe, Upper pipe complete, Switch lever .................................................................................................................. 4

 

4-1-1

 

Disassembling ............................................................................................................................................................. 4

 

4-1-2

 

Assembling .................................................................................................................................................................. 6

 

4-2

 

DC motor ............................................................................................................................................................................. 7

 

4-2-1

 

Disassembling ............................................................................................................................................................. 7

 

4-2-2

 

Assembling .................................................................................................................................................................. 8

 

4-3

 

Change lever, Adjust plate .................................................................................................................................................... 9

 

4-3-1

 

Disassembling ............................................................................................................................................................. 9

 

4-3-2

 

Assembling ................................................................................................................................................................ 10

 

4-4

 

Front wheel, Rear wheel .................................................................................................................................................... 11

 

4-4-1

 

Disassembling ........................................................................................................................................................... 11

 

4-4-2

 

Assembling ................................................................................................................................................................ 12

 

4-5

 

Connecting rod, Front shaft, Rear shaft .............................................................................................................................. 13

 

4-5-1

 

Disassembling ........................................................................................................................................................... 13

 

4-5-2

 

Assembling ................................................................................................................................................................ 14

 

4-6

 

Protective shield (For Canada only) ................................................................................................................................... 15

 

4-6-1

 

Disassembling ........................................................................................................................................................... 15

 

4-6-2

 

Assembling ................................................................................................................................................................ 15

 

4-7

 

Rear flap complete ............................................................................................................................................................. 16

 

4-7-1

 

Disassembling ........................................................................................................................................................... 16

 

4-7-2

 

Assembling ................................................................................................................................................................ 16

 

5

 

Circuit diagram ........................................................................................................................................................................... 17

 

6

 

Wiring diagram ........................................................................................................................................................................... 18

 

7

 

TIGHTENING TORQUE SPECIFICATIONS .......................................................................................................................... 21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Summary of Contents for DLM431

Page 1: ...450 57 490 19 1 4 Max 1 490 58 3 4 Width W 460 18 1 8 Height H Min 950 37 1 2 910 35 3 4 Max 1 020 40 1 4 H W L Socket wrench 17 Battery 5 Battery cover 6 Charger 5 5 Battery and charger are not suppl...

Page 2: ...te 9 4 3 1 Disassembling 9 4 3 2 Assembling 10 4 4 Front wheel Rear wheel 11 4 4 1 Disassembling 11 4 4 2 Assembling 12 4 5 Connecting rod Front shaft Rear shaft 13 4 5 1 Disassembling 13 4 5 2 Assemb...

Page 3: ...eady to keep disassembled parts by group Handle the disassembled parts carefully Clean and wash them properly If some bolts and screws are too tight use Impact driver Tighten the bolts and the screws...

Page 4: ...Remove Lower pipe M8x35 Thumb screw 2 pcs Fig 4 1 1 2 3 Pull out two Holders 4 Loosen two M6x50 Cup hex square neck bolts until the second thread is disengaged from M6 Thumb nut Note The first thread...

Page 5: ...lever and Upper pipe complete Fig 4 1 1 3 7 Loosen 4x18 Tapping screw and remove Switch lever case cover and Switch lever case 8 Loosen M4x20 Pan head screw and remove Arm Switch cover Switch lever ca...

Page 6: ...and tighten M4x20 Pan head screw while holding Hex nut 2 Mount Tension spring 9 Fig 4 1 1 5 Switch lever M4x20 Pan head screw Hex nut Lever The tip of Lever faces upward Fig 4 1 2 2 3 Route Power sup...

Page 7: ...inges Lock lever Battery cover complete Battery cover complete Hinge Fig 4 2 1 3 5 Loosen two 5x25 Tapping screws and remove Grip A Fig 4 2 1 4 6 Loosen seven 4x18 Tapping screws 5x25 Tapping screw 2...

Page 8: ...sen three M6x30 Pan head screws using a No 3 Phillips screwdriver and remove DC motor M6x30 Pan head screw 3 pcs DC motor Fig 4 2 2 1 Assemble DC motor by aligning its notch with Boss of Deck U shaped...

Page 9: ...ate Connecting rod Change lever 4x18 Tapping screw 2 pcs DC motor side Fig 4 3 1 4 6 The components of Change lever and Adjust plate are as follows Change lever cover Compression spring 9 Flat washer...

Page 10: ...Change lever to the position of Cutting height at 75mm 4 Hook Tension spring 16 with the hook with long nose pliers Hook Tension spring 16 Long nose pliers Change lever Fig 4 3 2 4 5 Shift Change leve...

Page 11: ...el cap Front wheel M8 Collared hex nut Fig 4 4 1 3 3 Tap the edge of each wheel with a plastic hammer Ball bearings 6200ZZ in the wheels are removed Fig 4 4 1 4 4 Remove each Plane bearing 10 with 1R2...

Page 12: ...fit Plane bearings 10 to Front Rear wheels with 1R243 and an arbor press Fig 4 4 2 2 2 Press fit Ball bearings 6200ZZ to Front Rear wheels with 1R252 and an arbor press Plane bearing 10 1R243 Front w...

Page 13: ...rt of Change lever and Adjust plate 4 3 1 Disassembling 4 Remove Front wheel and Rear wheel 4 4 1 Disassembling Fig 4 5 1 1 5 Loosen two 4x18 Tapping screws and remove Protective shield For Canada onl...

Page 14: ...Front cover Fig 4 5 1 4 8 Loosen two 4x18 Tapping screws and remove two Plates Front shaft and Rear shaft Fig 4 5 2 1 To distinguish between Front shaft and Rear shaft check the white marking on Fron...

Page 15: ...ollows 4x18 Tapping screw 2 pcs Protective shield Fig 4 6 2 1 1 Mount Protective shield into the grooves of Protective shield holder Fig 4 6 2 2 2 Insert Rod 8 into Protective shield Protective shield...

Page 16: ...omponents of Rear flap complete section are as follows Fig 4 7 2 1 Assemble Torsion spring 8 as shown below Top side of Deck Top side of Rear flap complete Stop ring E 5 Stop ring E 5 Stop ring E 5 St...

Page 17: ...WG22 Yellow AWG22 2 1 Closed end splice Red AWG16 Closed end splice Line filter A P N 688164 6 If used Red AWG16 Blue AWG16 Line filter B P N 688131 1 If used Black AWG16 White AWG16 Red AWG16 Closed...

Page 18: ...to the rib B Put the lead wires into any of these Lead wire holders Put the lead wires in this Lead wire holder Put the lead wires into any of these Lead wire holders Do not put lead wires on the rib...

Page 19: ...filter one time and then put the line filter in the position shown below Put the lead wire red of Motor and the lead wires white black into any of these Lead wire holders Controller Put the lead wire...

Page 20: ...gauge Put the lead wires from Battery fuel gauge Between the rib F and Boss Boss and the rib G Switch Rib F Boss Rib G Put the lead wires from Switch Between the rib G and Boss Put Closed end splices...

Page 21: ...1 3 1 5 2 4 Deck Cowling M 4x18 Tapping screw 0 9 1 1 4 5 Terminal housing set Terminal housing set 4x18 Tapping screw 1 3 1 8 3 6 Grip A Cowling M 5x25 Tapping screw 1 3 1 8 2 7 Lever Switch lever M4...

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