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REPAIR PROCEDURES

Switch box assembly

The switch box assembly is located on the upper han-
dle bar. The switch and circuit breaker are housed
inside of it. To service the switch box assembly:

NOTE:

Opening the switch box assembly will

void the warranty on this mower. For warranty
repairs, replace the switch box and harness as
an assembly.

Remove the safety key.

Slide the safety bail out of the switch box assem-
bly.

Remove the two mounting screws using a T-27
Torx driver. See Figure 3.4.

Unhook the harness from the clips on the handle
bar.

Figure 3.4

Mounting screws

Remove the five screws holding the housing
together using a #2 phillips screwdriver. See Fig-
ure 3.5.

Separate the housing to reach the internal com-
ponents.

NOTE:

The test procedures for the components

of the switch box are in Chapter 2 Electrical sys-
tem.

Install the switch box by following the above
steps in reverse order.

Test run the mower before returning it to service.

Figure 3.5

Remove screws

Содержание CC 500 BAT

Страница 1: ...he contents of the product s Oper ators Manual supplied with the equipment No liability can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these ins...

Страница 2: ......

Страница 3: ...Equipment needed to diagnosis an electrical system 4 Equipment that may be useful 4 Digital volt ohm meter 5 Inductive amp meter 5 Wiring or a schematic diagram 5 Fused jumper wires 5 Types of circuits 5 Series 6 Parallel 6 Series parallel 6 Types of failures 6 Shorts 6 Opens 6 Increased resistance 6 Switches 7 Diodes 7 Fuses 8 Initial trouble shooting 9 Checking the motor 10 Testing the switch bo...

Страница 4: ...Chapter 3 Repair Procedures 21 General safety warning 21 Blades 21 Switch box assembly 23 To replace the switch box 24 Motor 25 Motor mount 26 ...

Страница 5: ...ss mower However the test procedures will vary between the different generations The service proce dures for the first two models of cordless mower can be found in the 1996 Service Update Seminar Book form number 770 8877L About the text format NOTE is used to point out information that is relevant to the procedure but does not fit as a step in the procedure CAUTION Indicates a potentially hazardo...

Страница 6: ...exity and of reassembly and by the potential for unsafe conditions to arise from mis takes made in assembly Some instructions may refer to other parts of the man ual for subsidiary procedures This avoids repeating the same procedure two or three times in the manual Understanding model and serial numbers The model number is 18A 188 710 The break down of what the number mean is as follows 18 indicat...

Страница 7: ...for short The capital letter I is used to represent Amps The third and final value is Resistance Resistance is the opposition to current flow It is a restriction that slows down the flow of current Resistance is measured in Ohm s The greek letter omega Ω is used to represent Ohm s Ohm s law Ohm s law state that voltage is the product of resis tance times current It is written as V IxR An example o...

Страница 8: ...rrosion in the wire the resistance will be too small to worry about The light bulb uses 12 volts 4 amps x 3 ohms 12 volts the battery has 12 volts that equals the 12 volts used by the light bulb How the system is wired together All circuits have some basic rules that must be fol lowed 1 All circuits must have at least one voltage source It is could be a battery an altenator or both 2 All circuits ...

Страница 9: ... meter usually beyond repair NOTE When measuring resistance and there is no continuity the meter will read infinity This is represented in a few different ways like OL open line or 1 0 displayed to the far left Check the operator s manual for the DVOM to see how it is represented on your meter Figure 2 3 Inductive amp meter An inductive amp meter sometimes referred to as an amp clamp or clamp mete...

Страница 10: ... was not designed to take bypassing a component in the circuit An common example of a short is the wire that chafed through The bare copper will short the circuit when it touches a ground source Opens An open is when current can not complete its path back to the power source A common example of this is a blown fuse Increased resistance Increased resistance is as the name implies an increase in res...

Страница 11: ...y one direction There will be a band on one end of the diode This indicates the negative side of the diode Most DVOMs have the ability to test a diode See Figure 2 8 Figure 2 8 Silver band electrons flow from the negative to the positive Testing a diode 1 Isolate the diode in the circuit 2 Set the DVOM to the diode scale See Figure 2 9 NOTE A diode requires and uses a small amount of voltage befor...

Страница 12: ...ses Fuses can be visually inspected to indicate they are bad blown a dark spot or the element inside will be in two pieces Some times a fuse can be bad and not show signs of this visually Any time a fuse is removed from a circuit it should be tested for continuity with an ohm meter before reinstalling See Figure 2 12 Figure 2 10 Continuity Silver band Figure 2 11 No continuity Silver band Figure 2...

Страница 13: ...um for the switch With out it the switch can not operate See Figure 2 14 Figure 2 13 Breaker Safety key Figure 2 14 Safety key After assuring the breaker is set and the safety key is in place remove the motor cover by following the steps outlined in Chapter 3 Repair Procedures and check the fuse If the fuse is ok then troubleshoot the electri cal system of this mower by looking at three compo nent...

Страница 14: ... in the harness connector See Figure 2 16 5 The reading on the meter should be within 1 volts of the battery voltage If it is the switch box is working properly and by process of elimina tion the motor is the problem NOTE The motor is not serviceable NOTE If the reading is between 1 volt to 5 volts look for lose or corroded connections NOTE If there is no voltage reading check the fuse at the moto...

Страница 15: ... screws Figure 2 19 Remove these screws Handle bar grove 1c Carefully separate the halves of the switch box Remove the side that fits against the handle bar See Figure 2 20 2 Test the switch NOTE The switch is a double pole single throw switch That means that it controls two separate circuits at the same time 2a Mark and disconnect all four wires NOTE Mark the wires to ensure they go back on the p...

Страница 16: ... a normally open circuit That means there should not be continuity through that circuit when the switch is at rest 2g To test that part of the switch attach a DVOM to the circuit Set the meter to the Ohms or Ω scale The meter should read infinity See Figure 2 24 2h With the DVOM still attached press in the switch The meter should read zero or near zero resistance See Figure 2 25 2i If the switch h...

Страница 17: ...here is a diode between the charger jack and the circuit breaker It has two jobs First it protects the batteries from a short in the charger jack like a child inserting something into the charger jack Secondly it helps to protect the charger from a back feed when the mower is operated with the charger plugged in See Figure 2 28 CAUTION Do not operate the mower with the charger plugged in NOTE An o...

Страница 18: ...ing diode using the Ω scale it will read continuity in both direc tions One direction will be high resistance and the other direction will be a relatively low resis tance These readings will not tell you if the diode is leaking 4d Set the DVOM to the diode test scale See Figure 2 31 4e Insert the positive probe of the DVOM into the port of the charger jack that has the green wire 4f Insert the neg...

Страница 19: ...This will prevent weaker batteries overworking the strong batteries and prolong the life of all of them IMPORTANT The voltage of the battery bank is over 48 volts for a fully charged battery bank To ensure that the batteries in the battery bank are evenly charged only use the charger that came with the mower To test the battery pack CAUTION The mower must run in order to test the battery pack move...

Страница 20: ...testing the battery pack The measurements are meant to be take with the blade as the only load on the motor Interpreting the results Figure 2 34 Figure 2 35 Table 1 Voltage Current Possible reasons 47 0 9 5 Normal readings 47 0 9 5 High load on motor a short in the harness or motor worn out Check for grass build up under neath the deck 44 0 47 0 9 5 Battery pack low or one battery going bad charge...

Страница 21: ...s equipped with a battery level indicator The indicator has five LEDs the number of LEDs that are lit is an indication of the voltage level of the battery It will only light up when the mower is in operation To test the battery indicator a cheap tester can be made from parts around the shop or buying the parts from an electronic supply store The components needed are 10K Ω variable resistor NOTE A...

Страница 22: ...rocedures 3 Unplug the wires from the battery indicator NOTE The wire connectors are two different sizes to help prevent getting them crossed when plugging them in See Figure 2 39 4 Disconnect the battery pack 5 Attach the spade end of the tester to the positive tab of the indicator 6 Attach the other end of the tester to the positive post of the battery pack 7 Attach one end of the jumper wire to...

Страница 23: ...ts do not match the above table replace the indicator If they do match the above results check the harness Returning to service After diagnosing and repairing any fault in an electrical circuit and any other repairs needed the following steps should be taken 1 Test run the machine to verify that the condition has been fix 2 Cycle the circuit at least ten times 3 Allow the machine to cool down for ...

Страница 24: ...ELECTRICAL SYSTEM 20 System schematic drawing Circuit Breaker ...

Страница 25: ... 3 8 lower than the rear of the deck This is very important to get the proper air flow in the deck so that the blades can make the grass blades stand up to get cut The air flow in the cutting deck is generated by the spinning blades If the blades are mounted upside down the air flow will be reversed pushing the grass down instead of standing up NOTE Blades that are mounted upside down increase the...

Страница 26: ...causing personal injury 5 Place the cutting blade locking plate and blade bolt on the motor shaft NOTE Make certain to replace the parts in the exact order in which they were removed When installing the cutting blade be sure it is installed with the curved ends pointing towards the mower deck and not towards the ground See Figure 3 3 6 Tighten the blade bolt to a torque of 170 220 in lbs 19 25Nm W...

Страница 27: ...t of the switch box assem bly 3 Remove the two mounting screws using a T 27 Torx driver See Figure 3 4 4 Unhook the harness from the clips on the handle bar Figure 3 4 Mounting screws 5 Remove the five screws holding the housing together using a 2 phillips screwdriver See Fig ure 3 5 6 Separate the housing to reach the internal com ponents NOTE The test procedures for the components of the switch ...

Страница 28: ...od idea to remove the fuse whenever the motor cover is removed 4 Disconnect the battery pack and the motor See Figure 3 7 5 Remove the two mounting screws using a T 27 Torx driver See Figure 3 8 6 Unhook the harness from the clips on the handle bar 7 Install the switch box assembly by following the above steps in reverse order 8 Test run the mower before returning to service Figure 3 7 Motor conne...

Страница 29: ...er See Figure 3 9 2b Press in the tab while lifting on the cover Repeat steps 2a and 2b on the other slots NOTE For safety reasons it is a good idea to remove the fuse when ever the motor cover is removed See Figure 3 10 Figure 3 9 Push in tab with a flat head screwdriver Figure 3 10 3 Remove the blade by following the steps described in the blade section of this chapter 4 Remove the fan and blade...

Страница 30: ... the motor by following the steps described in the previous section of this manual 3 Remove the three mounting screws using T 40 torx driver See Figure 3 14 4 Remove the motor mount from the deck of the mower 5 Install the motor mount by following the above steps in reverse order NOTE tighten the motor mount screws to a torque of 170 200 in lbs 19 22 5 Nm 6 Test run the mower before returning to s...

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