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REPAIR GUIDELINE
Lawn Mower_LM2000E
Version: 1
Date: 03/12/2015

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Summary of Contents for EGO LM2000E

  • Page 1 REPAIR GUIDELINE Lawn Mower_LM2000E Version: 1 Date: 03/12/2015...

  • Page 2: Table Of Contents

    Table of Contents Part# Contents Slides Troubleshooting Tool list Part 1 Blade Removal & Installation 8-14 Part 2.1 Housing Cover Assembly 15-35 Part 2.2 Battery Cover Assembly 36-39 Part 2.3 LED Light Assembly 40-48 Part 2.4 Rear Cover 49-55 Part 2.5 PCB Assembly 56-73 Part 2.6...

  • Page 3: Troubleshooting

    Troubleshooting LM2000-S  Following the following steps below to test the ON/OFF function before any other tests. 1) Fully extend the side rails and lock the two green clamps. 2) Turn the handle and lock it into one of the operating positions. 3) Insert a full charged battery pack, push the battery pack until you hear a “click”.
  • Page 4 Troubleshooting Indicator/ Headlight Display Problem Possible Cause Fault Position Test & Solution LED on Power battery indicator Headlight pack on mower The side rails are not fully extended and Fully extend the side rails and Side Rails locked by the green lock the clamps, then test again.
  • Page 5 Troubleshooting Indicator/ Headlight Display Problem Possible Cause Fault Position Test & Solution LED on Power battery indicator Headlight pack on mower Pull the switch lever, if there is no activating sound of the switch, The main switch in the means the switch actuator had switch box cover slide to the underside of the doesn’t work.
  • Page 6 Troubleshooting Indicator/ Headlight Display Problem Possible Cause Fault Position Test & Solution LED on Power battery indicator Headlight pack on mower Main PCB damaged Open the housing cover, replace (Hall component is PCBA the PCB Assembly. broken on PCB) Open the housing cover, replace Magnet ring damaged PCBA the motor Assembly.

  • Page 7: Tool List

    Tool List For Repair Tool List SPEC Remark #1 phillips Magnetic bits #2 phillips Remove the deep screw in the deck 13mm For front/rear wheel bolt Socket 14mm For blade bolt Loosen/tighten the terminal screws for Flat head screwdriver head width: 3mm motor cables Torque Wrench 14mm...

  • Page 8: Blade Removal & Installation

    PART 1: BLADE REMOVAL & INSTALLATION...
  • Page 9 Blade Removal 1. Stop the motor and remove the safety key and battery pack from the mower. 2. Turn the mower on its side. 3. While wearing protective gloves, place a metal rod (e.g., a manual screwdriver) into the fixing hole to act as a stabilizer.
  • Page 10 Blade Removal 5. If the bolt rotates with the motor shaft when loosing the bolt, turn the fan by hand to align the through holes in the fan with the holes in the blade, place another metal rod (e.g., a long bit) into the aligned holes to act as another stabilizer.
  • Page 11 Blade Removal 7. Remove the bolt, the outer flange and the blade. Replace any parts of them if they are broken or worn. 8. Take off the inner flange and fan from the motor shaft if any parts of them are broken or worn. Motor shaft Description Part Number...
  • Page 12 Blade Installation 1. Fix the inner flange into the fan. 2. Mount the fan and the inner flange onto the motor shaft with the fan blade towards the deck. Fan blades towards deck Inner flange Motor shaft Wrong assembly of the fan...
  • Page 13 Blade Installation 3. Mount the blade onto the inner flange with the recess toward the mower. 4. Mount the outer flange to the motor shaft; Mount the bolt into the shaft and pre-tighten it clockwise by hand. Outer flange bolt Bulge towards outside...
  • Page 14 Blade Installation 5. Turn the fan by hand to align the holes in the blade with the through holes in the fan. 6. Place a metal rod (e.g., a long bit) into the aligned holes to act as a stabilizer. Place another metal rod (e.g., a manual screwdriver) into the fixing hole on the deck to act as another stabilizer.

  • Page 15: Housing Cover Assembly

    PART 2.1: HOUSING COVER ASSEMBLY...
  • Page 16 PART 2.1: Disassemble/Assemble the Housing Cover Assembly Description Part Number SPEC Housing Cover 2823666000 Assembly...
  • Page 17 PART 2.1: Disassemble/Assemble the Housing Cover Assembly The following parts can be replaced only when the housing cover is removed from the mower. Description Part Number SPEC DC Motor ASSY 2823675000 PCB Assembly 2830052000 Rear Cover 3126689000 Resistor 4970295000 Handle Assembly 2824112000 LED Light Assembly 2823665000...
  • Page 18 Housing Cover Assembly Replacement Disassembly 1. Move the height adjustment lever to setting 3 (Fig. 1); remove the two screws in the lever and pull the lever from the shaft (Fig. 2&3). Description Part Number SPEC Height adjustment lever 2823707000 (Including screws)
  • Page 19 Housing Cover Assembly Replacement Disassembly 2. Remove the battery case a) Loosen and remove the six tapping screws (Fig. 4) b) Take out the battery compartment carefully from the mower (Fig. 5). Unclip the wires from mower housing (Fig. 6). c) Unplug the three connectors from the battery case by depressing the lever on the connector (Fig.
  • Page 20 Housing Cover Assembly Replacement Disassembly Depress the lever Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H Battery Compartment 2823667000 Assembly...
  • Page 21 Housing Cover Assembly Replacement Disassembly 3. Disconnect the flat flexible cable (FFC) a) The FFC and the plug is located at back of the power indicator, it can be unplugged from the opening of the battery compartment (Fig. 9). b) Press the sides of the connector and remove the plug from the socket (Fig. 10).
  • Page 22 Housing Cover Assembly Replacement Disassembly 4. Loosen and remove the screws a) Fold the handle (Fig. 11); Remove the 2 screws in the back of the mower housing (Fig. 12). Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H...
  • Page 23 Housing Cover Assembly Replacement Disassembly 4. Loosen and remove the screws b) Turn the mower on its side (Fig. 13). c) Remove the 22 screws (separated in the three areas in the mower deck (Fig.14) Area: A Area: B Area: C Description Part Number SPEC...
  • Page 24 Housing Cover Assembly Replacement Disassembly Screws in area A (8 pcs):...
  • Page 25 Housing Cover Assembly Replacement Disassembly Screws in area B (9 pcs):...
  • Page 26 Housing Cover Assembly Replacement Disassembly Screws in area C (5 pcs):...
  • Page 27 Housing Cover Assembly Replacement Disassembly 5. Take away the housing cover assembly from the mower deck a) Turn the mower back and fold the handle to the grass bag removal position (Fig. 15) b) Lift the housing cover assembly and separate it from the mower deck (Fig. 16). c) Turn the housing cover assembly and take it forward away from handle (Fig.
  • Page 28 Housing Cover Assembly Replacement Assembly 1. Mount the housing cover assembly to the mower deck Fold the handle to the grass bag removal position (Fig. 18) Hold the housing cover assembly, turn it and pass it through the handle (Fig. 19) Pull the cutting height adjusting bar and make it come through the depth stop plate(Fig.
  • Page 29 Housing Cover Assembly Replacement Assembly 2. Lock the housing cover assembly to the deck with screws a) Lock the back of the housing cover assembly with 2 screws (see slide 7) b) Fold the handle, turn the mower on its side. Lock the housing cover assembly to the deck with 22 screws (see slides 9 to 11).
  • Page 30 Housing Cover Assembly Replacement Assembly 3. Connect the FFC to socket in the housing cover assembly.
  • Page 31 Housing Cover Assembly Replacement Assembly 4. Position the LED light assembly (if it came out from the housing cover) Put the LED light assembly to the mounting location Align the cables to the wiring groove Wiring groove LED light assembly...
  • Page 32 Housing Cover Assembly Replacement Assembly 5. Install the battery compartment Plug the three connectors to the electric contacts on the battery compartment.
  • Page 33 Housing Cover Assembly Replacement Assembly 5. Install the battery compartment Align the cables to the wiring groove .
  • Page 34 Housing Cover Assembly Replacement Assembly 5. Install the battery compartment c) Insert the battery compartment into the housing cover. d) Lock it with six tapping screws. Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H...
  • Page 35 Housing Cover Assembly Replacement Assembly 6. Fix the height adjustment lever and lock with 2 tapping screws.

  • Page 36: Battery Cover Assembly

    PART 2.2: BATTERY COVER ASSEMBLY...
  • Page 37 PART 2.2: Disassemble/Assemble the Battery Cover Assembly Description Part Number SPEC Battery Cover Assembly 2823661000...
  • Page 38 Battery Cover Assembly Replacement 1. Detach the housing cover assembly from the mower (see Part 2.1) 2. Turn over the housing cover assembly, loosen and remove the four screws and clamps. Description Part Number SPEC Tapping 5610032000 ST4x16 Screw Clamp 3122798000...
  • Page 39 Battery Cover Assembly Replacement 3. Take out the battery cover from the opening of the battery compartment (Fig. 1) 4. Draw the shaft out from the battery cover assembly (Fig. 2) 5. Replace with a new battery cover assembly; Fix the new one to the housing cover in reverse order.

  • Page 40: Led Light Assembly

    PART 2.3: LED LIGHT ASSEMBLY...
  • Page 41 PART 2.3: Disassemble/Assemble the LED Light Assembly Description Part Number SPEC LED Light Assembly 2823665000...
  • Page 42 LED Light Assembly Replacement 1. Detach the housing cover assembly from the mower. (see Part 2.1) 2. Move the LED light aside; loose and remove the two screws in the front of the housing cover. Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H...
  • Page 43 LED Light Assembly Replacement 3. Loose and remove the five screws in the back of the housing cover. Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H...
  • Page 44 LED Light Assembly Replacement 4. Remove the battery cover, battery cover frame and LED light assembly together from the housing cover.
  • Page 45 LED Light Assembly Replacement 5. Remove the two screws to detach the PCB from battery cover frame (red circle indication). Description Part Number SPEC Tapping Screw 5610032000 ST4x16...
  • Page 46 LED Light Assembly Replacement 6. Pull the socket from the plug on PCB. (Fig. 1) 7. Remove the LED light assembly from the battery cover frame. (Fig. 2) Description Part Number SPEC LED Light Assembly 2823665000...
  • Page 47 LED Light Assembly Replacement 8. Replace with a new LED light assembly. 9. Mount the new LED light assembly to the battery cover frame in reverse order. Note to align the cables in the grooves of the frame, see the figure shown below. 10.
  • Page 48 LED Film Switch Replacement • The LED Film switch button can be replaced during this process following the figures shown below. Description Part Number SPEC Film Switch 4870499000...

  • Page 49: Rear Cover

    PART 2.4: REAR COVER...
  • Page 50 PART 2.4: Disassemble/Assemble the Rear Cover Rear Cover Description Part Number SPEC Rear Cover 3126689000...
  • Page 51 Rear Cover Replacement 1. Detach the housing cover assembly from the mower (see Part 2.1) 2. Pull out the shaft from right side (Fig. 1) 3. Take down the rear cover and shaft (Fig. 2) Shaft Description Part Number SPEC Shaft 5670345000 Φ7x 345...
  • Page 52 Rear Cover Replacement 4. Remove the spring from the rear cover. 5. Replace with a new rear cover or torsion spring. Description Part Number SPEC Torsion Spring 3660559000 15.2x22.4 Rear Cover 3126689000...
  • Page 53 Rear Cover Replacement 6. Insert the short foot of the torsion spring in the groove of rear cover.
  • Page 54 Rear Cover Replacement 7. Position the rear cover and torsion spring to the deck, pull the foot of the torsion spring and make it resting on the groove of the deck. Rested on the groove...
  • Page 55 Rear Cover Replacement 8. Insert the shaft through the hole and push it in position. Align the shaft to the fixing hole and push in position.

  • Page 56: Pcb Assembly

    PART 2.5: PCB ASSEMBLY...
  • Page 57 PART 2.5: Disassemble/Assemble the PCB Assembly • The following relevant parts can be replaced when replacing the PCB Assembly: Description Part Number SPEC PCB Assembly 2830052000 10-pin cable 4930490000 0.5ohm ±10% Resistor 4970295000 25A 50VDC 1E4 TUV/CE ,25A Push switch 4870501000 60VDC 1E4 UL/CUL...
  • Page 58 PCB Assembly Replacement 1. Detach the housing cover assembly from the mower (see Part 2.1) 2. Loose the locking screws in the terminal to disconnect the two motor cables.
  • Page 59 PCB Assembly Replacement 3. Remove the four screws in PCB, then take the PCB apart from the motor. 4. Turn over the PCB and disconnect the 3-pin plug and 10-pin plug from PCB. 3-pin plug 10-pin plug Description Part Number SPEC Tapping screw 5610024000...
  • Page 60 PCB Assembly Replacement 5. Cut off the zip ties with diagonal pliers to remove the big resistor from the motor body. Resister...
  • Page 61 PCB Assembly Replacement 6. Cut off the zip ties on the cables with diagonal pliers to release the cables.
  • Page 62 PCB Assembly Replacement Numbering the cables: 2&7 (green)
  • Page 63 PCB Assembly Replacement Connection Figure To the main switch Big Resistor (white) in the handle Position A White Black Black Long red cable Short red cable Position C Blue Position B To the electric contacts on the Black battery compartment Green To the electric contacts on the...
  • Page 64 PCB Assembly Replacement 7. Remove the heat-shrinkable sleeves on the cables at position A, Position B and Position C; 8. Disconnect the cable connection with soldering iron. 9. Replace with a new main PCBA if it is broken. 10. Place a new heat-shrinkable sleeve through the green cable and solder the green cable(6) to the short red cable of new PCB (3), use a hot air gun to shrink the sleeve.
  • Page 65 PCB Assembly Replacement 11. Place the previous red cable (7#, with terminal connector) and the long red cable (2) of the new PCB together through the two black magnetic rings; put a heat-shrinkable sleeve through the two cables, then solder them to the switch foot (2). Use a hot air gun to shrink the sleeve. Terminal connector Position C Make sure the 2#...
  • Page 66 PCB Assembly Replacement 12. Place a new heat-shrinkable sleeve through the short black cable (1) of new PCB and solder the cable to the big resistor, use a hot air gun to shrink the sleeve. Position A...
  • Page 67 PCB Assembly Replacement 13. Fix the big resistor to the motor body and fix it with two zip ties ; cut the excess.
  • Page 68 PCB Assembly Replacement 14. Mount the 3-pin plug and 10-pin plug on the terminals of the new PCB 15. Apply some silicon glue around the plug. 3-Pin plug 10-Pin plug...
  • Page 69 PCB Assembly Replacement 16. Mount the PCB onto the motor and lock it with four screws, fix the cables with three zip ties, cut the excess. 17. Pass the two motor cables through the magnet rings and fix them in the terminal (red cable to red cable, black cable to black cable);...
  • Page 70 PCB Assembly Replacement 18. Align the cables in the grooves. 2#, 6#, 7#, 9# and 3-pin cable in this groove 4#, 5#, 7# cable in this groove...
  • Page 71 PCB Assembly Replacement 19. Test the new PCBA Plug the three connectors to the electric contacts on the battery case. Insert a full charged battery pack in to the battery case. Adjust the handle to the operating position and fully extend the side rails and lock with the side clamps.
  • Page 72 To Replace the Resistor • The resistor can be replaced during the PCB assembly replacement. When the mower stops slowly without a brake. The cables may be disconnected from the feet of resistor or the resistor may be broken. Re-solder the cables or replace the resistor. •...
  • Page 73 To Replace the Position Switch • To replace the switch, solder the white cable (8#), red cables (2#, 7#) from the broken switch and replace with a new one. White Description Part Number SPEC 25A 50VDC 1E4 TUV/CE ,25A Push switch 4870501000 60VDC 1E4 UL/CUL...
  • Page 74 PART 2.6: DC MOTOR ASSEMBLY...
  • Page 75 PART 2.6: Disassemble/Assemble the Motor Assembly DC Motor Assembly Description Part Number SPEC DC Motor Assembly 2823675000...

  • Page 76: Motor Assembly

    Motor Assembly Replacement 1. Detach the housing cover assembly from the mower (see Part 2.1) 2. Loose the locking screws in the terminal to disconnect the two motor cables. 3. Test the motor by connecting the motor cables to a DC supplier (43VDC). If the motor doesn’t run, replace the motor.
  • Page 77 Motor Assembly Replacement 3. Remove the four screws in PCB, then take the PCB apart from the motor, take off the two magnet rings on the red and black cables. Magnet ring Description Part Number Magnet Ring 3680152000...
  • Page 78 Motor Assembly Replacement 4. Cut off the Zip Ties with diagonal pliers to remove the big resistor from the motor body. Resister...
  • Page 79 Motor Assembly Replacement 5. Turn the mower on its side. 6. See Part 1_Blade Remove & Installation to remove the bolt, the outer flange and the blade. 7. Take off the inner flange and fan from the motor shaft. Description Part Number SPEC Bolt...
  • Page 80 Motor Assembly Replacement 8. Place a Use a 10mm socket to loose the three bolts in the deck; grasp the motor when loosing the last bolt and prevent the motor from dropping. 9. Take the motor away from the deck. 10.
  • Page 81 Motor Assembly Replacement 11. Align the hole in the motor base with the knob on the deck, then position the motor on the deck . Knob on the deck Hole in the motor base...
  • Page 82 Motor Assembly Replacement 12. Put the spring washer, flat washer on the bolt in turn. 13. With one hand grasping and holding the motor, using a 10mm socket to lock the motor to the deck with these bolts.
  • Page 83 Motor Assembly Replacement 14. Mount the 3-pin plug on the terminals of the PCB and apply some silicon glue around the plug. 15. Fix the PCB on the motor with four screws. 3-Pin plug...
  • Page 84 Motor Assembly Replacement 16. Place the two magnet rings through the red and black motor cables, connect the motor cables in the terminal and lock them by tightening the screws.(red cable to red cable, black cable to black cable) 17. Align the motor cables to the wiring groove. Magnet ring...
  • Page 85 Motor Assembly Replacement 18. Test the new motor Plug the three connectors to the electric contacts on the battery case. Insert a full charged battery pack in to the battery case. Adjust the handle to the operating position and fully extend the side rails and lock with the side clamps.
  • Page 86 Motor Assembly Replacement 19. Fix the big resistor to the motor body with two Zip Ties, and cut the excess. 20. Turn the mower on its side. 21. Install the blade, following Part 1_Blade Remove & Installation .The recommended torque for the blade bolt is 49-59Nm.
  • Page 87 PART 3: BATTERY COMPARTMENT...

  • Page 88: Battery Compartment Assembly

    PART 3: Disassemble/Assemble the Battery Compartment Assembly Description Part Number SPEC Battery Compartment 2823667000 Assembly...
  • Page 89 Battery Compartment Assembly Replacement 1. Loosen and remove the six tapping screws (Fig. 1) 2. Take out the battery compartment carefully from the mower and unplug the three connectors from the battery case. (Fig. 2) 3. The battery case assembly is detached as Fig. 3. Description Part Number SPEC...
  • Page 90 Battery Compartment Assembly Replacement 4. Replace with a new battery compartment assembly. 5. Position the LED light assembly (if it came out from the housing cover) Put the LED light assembly to the mounting location Align the cables to the wiring groove Wiring groove LED light assembly...
  • Page 91 Battery Compartment Assembly Replacement 6. Install the battery compartment a) Plug the three connectors to the electric contacts on the battery compartment.
  • Page 92 Battery Compartment Assembly Replacement b) Align the cables to the wiring groove .
  • Page 93 Battery Compartment Assembly Replacement c) Insert the battery compartment into the housing cover. d) Insert an EGO battery pack and test if the mower can operate properly. e) Lock it with six tapping screws. Description Part Number SPEC Tapping Screw 5610042000 ST4.2x19-F-H...

  • Page 94: Top Handle& Switch Box Cover

    PART 4: TOP HANDLE & SWITCH BOX COVER...
  • Page 95 PART 4: TOP HANDLE & SWITCH BOX COVER • When open the switch box covers, the following relevant parts can be replaced: Description Part Number SPEC 25A 50VDC 1E4 TUV/CE ,25A Main switch 4870501000 60VDC 1E4 UL/CUL Switch lever 3705372000 Top handle 2823782000 Top &...
  • Page 96 Open the Switch Box Cover 1. Fold the handle to the grass bag removal position. 2. Remove the tapping screws (13 pcs) and hexagon socket screws (4 pcs) from the housing. Description Part Number SPEC Tapping Screw 5610032000 ST4x16 Hexagon Socket Screw 5610064000 M5x55...
  • Page 97 Open the Switch Box Cover 3. Remove bottom switch box cover gently from the top switch box cover to open them. Top switch box cover Bottom switch box Main switch Switch lever cover...
  • Page 98 Open the Switch Box Cover 4. Take down the spring and switch actuator from the top switch box cover. Spring Switch actuator Description Part Number SPEC Spring 3660599000 Switch Actuator 3127848000...
  • Page 99 Close the Switch Box Cover 1. Align the groove in the switch actuator with the raised rib on the pole, mount the switch actuator to the top switch box cover. 2. Put the spring through the pole and mount it on the switch actuator. Rib on the pole Switch actuator Spring...
  • Page 100 Close the Switch Box Cover 3. Mount the top switch box cover to the handle, make sure the ribs on the handle locating between the ribs on the switch box cover.
  • Page 101 Close the Switch Box Cover 4. Check the cables and make sure they are aligned in the wiring grooves, then close the bottom cover. 5. Grasp the top and bottom cover with one hand, lock them with screws. Description Part Number SPEC Tapping Screw 5610032000...
  • Page 102 To Replace the Main Switch a) Take out the main switch from the top switch box cover. b) Replace with a new switch if it is broken. Red- 2 White- 1 Black- 3 Red &Green- 4 Description Part Number SPEC Switch 4870501000...
  • Page 103 To Replace the Main Switch Test the switch : • Insert a full charged battery pack in to the battery case. • Adjust the handle to the operating position and fully extend the side rails and lock with the side clamps. •...
  • Page 104 To Replace the Switch Lever a) Loose the two screws in the clamp and remove the clamp, spring and switch lever from the top switch box cover. Replace with a new switch lever if it appears any distortion or malfunction. Spring Switch lever Clamp...
  • Page 105 To Replace the Switch Lever b) Put the spring in the hole, then mount the switch lever on the spring. Press the end of the switch lever with one hand, lock it with the clamp and screws. Description Part Number SPEC Switch lever 3705372000...
  • Page 106 To Replace the Top Handle a) Pull the top handle and remove the handle from the plastic bushings in the two side aluminum tubes. b) Replace with a new one if it appears worn or broken. Insert the two sides into the plastic bushings and press them in place. Description Part Number SPEC...
  • Page 107 To Replace the Top & bottom switch box cover a) Remove the main switch and cables from the top switch box cover. b) Remove the switch lever from the top switch box cover. Replace with a new set of covers. d) Refer to the previous slides to fix the main switch, switch levers in the top switch box cover.

  • Page 108: Handle Locking Clamp

    PART 5: HANDLE LOCKING CLAMP...
  • Page 109 PART 5: Disassemble/Assemble the Handle Locking Clamp Description Part Number Spec Handle Locking Clamp Set 2823714000...
  • Page 110 Handle Locking Clamp Replacement 1. Use a metal pole and a hammer to knock the shaft carefully and remove the clamp, shaft and spring from the tube. Clamp Shaft Spring...
  • Page 111 Handle Locking Clamp Replacement 2. Move the handle downward to take out the rubber pad and rubber base. 3. Replace the broken or worn parts. Rubber base Rubber pad...
  • Page 112 Handle Locking Clamp Replacement 4. Put the rubber pad and rubber base into the cave, pay attention the rubber pad towards inside and the rubber base towards outside.
  • Page 113 Handle Locking Clamp Replacement 5. Insert the short foot of the spring into the hole in the clamp, then mount the clamp to the joint.
  • Page 114 Handle Locking Clamp Replacement 6. Insert the shaft and knock it with a hammer until the lower side is flush with the housing surface. 7. Test the clamp. The side rails should be locked stably by the two clamps. They shall not retract when applying pushing force on the handle.
  • Page 115 Handle Locking Clamp Replacement Description Part Number Picture Handle Locking Clamp Set 2823714000...

  • Page 116: Left/Right Beam Housing

    PART 6: LEFT/RIGHT BEAM HOUSING...
  • Page 117 PART 6: Left/Right Beam Housing • When open the left/right beam housing, the following relevant parts can be replaced: Right beam Right inner housing set tube ASSY Description Part Number Micro switch 4870500000 Beam tube Left beam housing set 2823783000 Right beam housing set 2823784000 Switch actuator...
  • Page 118 Open the Right Beam Housing 1. Remove the 8 tapping screws to open the right beam housing NOTE: The micro switch is located in the right beam housing. Right beam housing Description Part Number SPEC Tapping Screw 5610032000 ST4x16...
  • Page 119 Open the Right Beam Housing 2. Take way the top housing, rubber pad and rubber base, switch actuator, spring(fixed on the switch actuator) Switch actuator spring Micro switch Top housing Rubber base Description Part Number SPEC Rubber pad Switch actuator 3126768000 Spring 3660287000...
  • Page 120 Open the Right Beam Housing 3. Take out the micro switch and cable from the bottom housing. 4. Replace with a new switch if it shows malfunction. 5. Test the micro switch. • Leave the trigger of the micro switch unpressed. Turn on the mower, the mower should be turned on properly.
  • Page 121 Close the Right Beam Housing 1. Align the cable in the bottom housing; press the cable in place. 2. Align the locating hole with the locating pin on bottom housing, position the switch in position. Locating hole Locating pin...
  • Page 122 Close the Right Beam Housing 3. Mount the bottom housing onto the side rail and beam tube. 4. Fully extend the side rail to make sure the dent on the rail appears in the opening of the outer tube. Dent in the opening Outer tube...
  • Page 123 Close the Right Beam Housing 5. Fix the switch actuator into the bottom housing. Description Part Number Switch Actuator 3126768000 Spring 3660287000 Locating pin into the This corner into the locating hole in housing outer tube Switch lever in the groove of the actuator Position the spring in locating...
  • Page 124 Close the Right Beam Housing 6. Attach the rubber pad and base on the rectangle groove in the outer tube. 7. Close the top housing and locked with 8 pcs tapping screws Rectangle groove Rubber pad and base Description Part Number SPEC Tapping Screw 5610032000...
  • Page 125 Open the Left Beam Housing 1. Remove the 8 tapping screws to open the left beam housing Left beam housing Description Part Number SPEC Tapping Screw 5610032000 ST4x16...
  • Page 126 Open the Left Beam Housing 2. Separate the top and bottom housing, remove the bottom housing from the side rail and beam tube. 3. Replace the left beam housing set if they appear any worn (Following Part 5 to fix the clamp to the new housings).
  • Page 127 Close the Left Beam Housing 1. Mount the top housing onto the side rail and beam tube. 2. Turn the handle to let the handle be locked at any of the operating position.
  • Page 128 Close the Left Beam Housing 3. Position the rubber pad and rubber base into the groove of bottom housing. Make sure the rubber pad pointing outside. 4. Close the bottom housing and locked with screws. Rubber pad pointing outside...
  • Page 129 To Replace the Left/Right Inner Tube ASSY/Beam Tube 1. Remove the switch box covers (see Part 4) 2. Pull the top handle and remove the handle from the plastic bushings in the two side aluminum tubes (see Part 4) 3. Remove the left/right beam housing (see previous steps in this PPT)
  • Page 130 To Replace the Left/Right Inner Tube ASSY/Beam Tube 4. Pull the left/right inner tube assembly from the outer tube. 5. Replace the bent, broken tubes. Right inner tube ASSY Left inner tube ASSY Description Part Number Beam Tube Left Inner Tube ASSY 2823082000 Right Inner Tube ASSY 2823781000...
  • Page 131 To Replace the Left/Right Inner Tube ASSY/Beam Tube 6. Insert the left/right tube assembly into the outer tube. Pay attention left and right inner tubes are not interchangeable, left inner tube should be fixed in the left outer tube, and right inner tube should be in the right outer tube.
  • Page 132 To Replace the Left/Right Inner Tube ASSY/Beam Tube 7. Insert the left/right tube assembly into the outer tube. Pay attention left and right inner tubes are not interchangeable, left inner tube should be fixed in the left outer tube, and right inner tube should be in the right outer tube.
  • Page 133 To Replace the Left/Right Inner Tube ASSY 8. Close the left/right beam housing (see previous steps in this PPT).

  • Page 134: Quick Adjust Lever

    PART 7: QUICK ADJUST LEVER...
  • Page 135 PART 7: Disassemble/Assemble the Quick Adjust Lever Description Part Number SPEC Handle Lever Set 2824092000...
  • Page 136 Quick Adjust Lever Replacement 1. Remove the two tapping screws (one in the decoration cover, another in the inner side of the side tube. Description Part Number SPEC Tapping Screw 5610032000 ST4x16...
  • Page 137 Quick Adjust Lever Replacement 2. Remove the clamp ring; 3. Use your palm to press the lever and draw out the pin out of the lever. Clamp ring...
  • Page 138 Quick Adjust Lever Replacement 4. Remove the spring, adjust lever and decoration cover from the side tube. 5. Replace the damaged parts accordingly. Description Part Number SPEC Including Quick adjust lever, decoration Handle Lever Set 2824092000 cover, spring, pin, clamp ring...
  • Page 139 Quick Adjust Lever Replacement 6. Align the locking pin with the bushing and fix it through the bushing. 7. Adjust the handle to “Grass bag removal position”; fully force the pin into the bushing and let the pin extend out of the side tube and lock the handle at the position. Extend the pin out of the side pole and lock at the grass bag removal position...
  • Page 140 Quick Adjust Lever Replacement 8. Pass the adjust lever through the decoration cover; 9. Align the screw dome with the hole in side tube and mount the decoration cover to the side tube. Screw dome...
  • Page 141 Quick Adjust Lever Replacement 10. Fix the spring between the adjust lever and the side tube. 11. Hold the tube and lever, depress the lever to align the hole in the lever with the hold in the plastic part. 12. Fully insert the pin and lock the pin with the clamp ring from the backside. Clamp ring...
  • Page 142 Quick Adjust Lever Replacement 13. Lock the decoration cover with two tapping screws. 14. Test the lever function to check if it can lock the handle at different positions.

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