21
MAINTENANCE SECTION
5.
Mount the Switch Plate with the Pilot Rod onto the
Start Switch by depressing the Start Switch lever with
the Pilot Rod. Insert the Pilot Rod into the slot in the
Microswitch Circuit Board and align the Switch Plate
on top of the Start Switch. Insert the two Switch Base
Screws (63) from the bottom of the Microswitch
Circuit Board into the Switch Plate. Tighten the
Screws to 1.6 KG–cm.
6,
Mount the Shut–off Switch (60) onto the Switch Plate
with the two Switch Screws (62). Tighten the screws
to 1.6 KG–cm.
7.
Position the Insulating Film (66) onto the back of the
Brush Light Circuit Board. Insert the two Switch Base
Spacers (65) through the Insulating Film and into the
holes of the Circuit Board.
8.
Install the Brush Light Circuit Board onto the back of
the Microswitch Circuit Board by inserting the Two
Switch Base Spacers into the holes in the Circuit
Board.
Be sure that the Brush Light LED is toward the
motor side of the circuit board.
9.
Using needle nose pliers, install the three connectors
from the Controller Assembly (68) onto the
Shut–off Switch.
Make sure to connect the correct color wire to the
proper terminal. Refer to the wiring diagram to
insure that all wires are installed properly.
Refer to Dwg. TPD1821.
10. Install the two–pin connector from the Controller
Assembly onto the Microswitch Circuit Board.
11. Install the three–pin connector from the Controller
Assembly onto the Reverse Switch Circuit Board.
12. Run the ground wire around the Switch Base Spacers
and between the Microswitch Circuit Board and the
Brush Light Circuit Board.
(Dwg. TPD1818)
ROUTE OF GROUNDING WIRE
MICRO SWITCH
ASSEMBLY
GROUNDING WIRE
CIRCUIT BOARD FOR
BRUSH LIGHT
13. Bring the Motor Assembly and Microswitch Circuit
Board together by inserting the Motor Pilot Rod into
the hole in the Motor shaft and then setting both into
the Housing Package (75A or 76).
For Throttle Lever Start Models, lay the ground wire
between the Motor and the Housing Package.
14. Install the two Switch Base Screws and tighten to 1.6
KG–cm.
15. Install the Controller Assembly into its groove in the
Housing. Place the ground wire into the notch in the
Controller Assembly and align this notch with the tab
in the Housing.
16. Install the Reverse Switch Circuit Board into the two
grooves in the Housing.
17. Install the Receptacle Assembly (73) into the Housing,
making sure the ground wire is in the correct position.
The Receptacle can be installed in either position.
18. Place the black and white Receptacle wires into the
notch in the Controller Assembly.
19. Place the ceramic Fan Pilot Rod (40) into the Fan
Pinion Gear (39) and then fit the Gear into the Fan
(41). Now slide the Fan (41) onto the Motor shaft.
Assembly of the Gear Case and Clutch Housing
1.
Apply grease to the Planet Gears (34), the surfaces of
the Gear Heads (31) and the teeth of the Gear Head
Pinion Gear (35).
2.
Assemble the Spindle/Gear Heads, the Gear Head
Pinion Gear and the Gear Head.
3.
Apply grease to all the Gears.
4.
Place the Gear Head onto the Spindle/Gear Heads.
5.
Apply grease to the Spindle Washer (29).
6.
Place the Spindle Washer, then the Spindle Bearing
(30), onto the Cam (27).
7.
Apply grease to the inner teeth of the Gear Case (36).
8.
Insert the Cam into the Spindle Bearing.
9.
Hold the Cam with needle nose pliers and insert the
entire unit into the Gear Case while rotating the Cam
and the Gear Case.
10. Apply grease to the gear end of the Gear Case and
install the Gear Case Shield (37).
11. Apply grease to the notches of the Cam.
12. Place the Cam Rollers (28) into the notches on the
Cam.
13. Apply grease to the inner surface, the holes and the
grooves of the Cam guide (24).
14. Insert the Cam Guide Balls (25) into the holes in the
Cam Guide.
15. Install the Cam Guide over the Cam. Keep the Cam
Balls at a 90 degree angle to the Cam Rollers to
prevent the Balls from being pushed out.
16. Apply grease to the inner surface of the Bit Holder
Assembly (19 or 21). Using a rod, push the Pilot (20
or 22) into the Bit Holder.
