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EGO LM2120E-SP Repair Manual Line

Blade removal & installation
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REPAIR GUIDELINE
PART 1: BLADE REMOVAL & INSTALLATION-LM2120E-SP Lawn Mower
1

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  • Page 1 REPAIR GUIDELINE PART 1: BLADE REMOVAL & INSTALLATION-LM2120E-SP Lawn Mower...
  • Page 2 Table of Contents LM2120E-SP Lawn Mower Contents Page Blade Removal Blade Installation...
  • Page 3 1. Blade Removal LM2120E-SP Lawn Mower 1. Release switches and remove the battery pack from the mower. 2. Wear protective gloves, turn the mower on its side (Fig. 1). 3. Place a metal rod (e.g., a screwdriver) with a diameter less than 9 mm into the fixing hole to act as a stabilizer and place another metal rod (e.g., a long bit) with a diameter between 5 - 6.35mm...
  • Page 4 1. Blade Removal LM2120E-SP Lawn Mower Use a 14mm wrench to turn the blade bolt counterclockwise to loosen it. Stabilizer Another Stabilizer Loosen...
  • Page 5 1. Blade Removal LM2120E-SP Lawn Mower 5. Remove the bolt, outer flange and blade. Replace any broken or worn parts. 6. Remove the inner flange and fan from the motor shaft, then replace any broken or worn parts. Description Part Number...
  • Page 6 2. Blade Installation LM2120E-SP Lawn Mower 1. Fix the inner flange to 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...
  • Page 7 2. Blade Installation LM2120E-SP Lawn Mower 3. Mount the blade onto the inner flange with the Flat position surface stating “THIS SIDE FACING GRASS” facing outwards (Fig. 1) . 4. Aligning the flat position of the outer flange with the corresponding flat position on the motor Outer Flange shaft, mount the outer flange in place(Fig.
  • Page 8 2. Blade Installation LM2120E-SP Lawn Mower 5. Fix the bolt into the shaft and pre-tighten it in a clockwise direction by hand. Outer flange Pre-tighten by hand Bolt...
  • Page 9 2. Blade Installation LM2120E-SP Lawn Mower 6. Turn the blade by hand to align the holes in the blade with the holes in the inner flange(Fig. 1). 7. Place a metal rod (e.g., a long bit) with a diameter between 5 - 6.35mm into the aligning hole to act as a stabilizer.
  • Page 10 REPAIR GUIDELINE PART 2.1: Parts in Power Unit Replacement_LM2120E-SP Lawn Mower...
  • Page 11 Table of Contents LM2120E-SP Lawn Mower Contents Page Power Unit Removal Motor Assembly Replacement 9-20 Main PCBA Replacement 21-35 Power Unit Assembly 36-42 Handle Position Switch Replacement...
  • Page 12 1. Power Unit Removal LM2120E-SP Lawn Mower 1. Before replacing or maintaining parts in power unit or self-propelled unit, fold the handle to the grass bag removal position to remove the service cover from the mower. Service Cover Description Part Number...
  • Page 13 1. Power Unit Removal LM2120E-SP Lawn Mower Service Cover 2. Turn the mower on its side and remove the blade, fan and inner flange from the motor shaft as shown in Part 1. Another Stabilizer Loosen Stabilizer...
  • Page 14 1. Power Unit Removal LM2120E-SP Lawn Mower The following parts can be replaced only when the service cover is removed from the mower. Description Part Number DC Motor ASSY 2730249001 Main PCB Assembly 2830176001 Self-propelled Motor 2824920002 Self-propelled PCBA 2830177001...
  • Page 15 1. Power Unit Removal LM2120E-SP Lawn Mower Loosen the 4 hexagon head bolts with a socket wrench (S=10mm). WARNING: During this process, there is a risk of the power unit dropping. The power unit must be supported. Loosen Plate Spring Washer...
  • Page 16 1. Power Unit Removal LM2120E-SP Lawn Mower Separate the power unit from the mower by disconnecting the wires linking with the main switch, microswitch, handle position switch, self-propelled PCB and switch. Linked with microswitch Linked with self- propelled switch Linked with main switch and...
  • Page 17 1. Power Unit Removal LM2120E-SP Lawn Mower Remove the power unit from the mower. Power Unit...
  • Page 18 2. Motor Assembly Replacement LM2120E-SP Lawn Mower Open the battery cover and stabilize it using a manual screwdriver. Then loosen the 5 screws to remove the inner cover(Picture see next slide). Battery cover Stabilizer Description Part Number SPEC Battery cover...
  • Page 19 2. Motor Assembly Replacement LM2120E-SP Lawn Mower...
  • Page 20 2. Motor Assembly Replacement LM2120E-SP Lawn Mower Remove the zip tie and disconnect the black connector. Black plug Test the motor Zip tie...
  • Page 21 2. Motor Assembly Replacement LM2120E-SP Lawn Mower 3. Test the motor resistance between the three wires by using a multimeter. a) Set the multimeter function to “Resistance measuring” . b) Measure the resistance between any of the two connectors.
  • Page 22 2. Motor Assembly Replacement LM2120E-SP Lawn Mower c) If any of the measurement are infinite, it means the circuit between the two connectors is an open circuit, the motor is damaged. Follow the next procedure to replace a new motor.
  • Page 23 2. Motor Assembly Replacement LM2120E-SP Lawn Mower Remove the 5 screws (2 deep in the battery box ) to separate the motor and base from the battery box. 2 screws deep in the battery box Description Part Number SPEC Battery box...
  • Page 24 2. Motor Assembly Replacement LM2120E-SP Lawn Mower Battery box Motor and its base...
  • Page 25 2. Motor Assembly Replacement LM2120E-SP Lawn Mower Remove the 3 hex bolts, spring washers and plates with a socket wrench (S=10mm) to separate the motor from its base. Front service cover Motor Motor base with front service cover Description Part Number...
  • Page 26 2. Motor Assembly Replacement LM2120E-SP Lawn Mower If the base or the front service cover is damaged, remove the 3 screws to separate them and replace the damaged one. Front service cover Motor base Description Part Number SPEC Tapping screw 5610042014 ST4.2x19...
  • Page 27 2. Motor Assembly Replacement LM2120E-SP Lawn Mower To fit a new motor, align the locating notch on the motor with the locating pin on motor base to position the motor into place. (Fig. 1). Turn the motor shaft upside to fix the motor onto the motor base by tightening the 3 hex bolts(Fig.
  • Page 28 2. Motor Assembly Replacement LM2120E-SP Lawn Mower 10. Insert the motor into the battery with motor shaft upside and reverse the whole set to lock them using the inside 5 screws (2 screws deep in the battery box). 2 screws deep in...
  • Page 29 2. Motor Assembly Replacement LM2120E-SP Lawn Mower 11. Connect the black plug and tighten it with a zip tie. Black plug...
  • Page 30 3. Main PCBA Replacement LM2120E-SP Lawn Mower 1. Remove the motor as shown in previous steps. 2. Release the two plugs linked with main PCBA. 3. Remove the screw and plain washer as shown in the figure below. Description Part Number...
  • Page 31 3. Main PCBA Replacement LM2120E-SP Lawn Mower 4. Measure the fuse with a multimeter. If it is open-circuit, meaning the fuse is broken. Yellow plug Fuse...
  • Page 32 3. Main PCBA Replacement LM2120E-SP Lawn Mower Following the steps shown, take the key holder apart from the battery box. Bend the wires as far as possible...
  • Page 33 3. Main PCBA Replacement LM2120E-SP Lawn Mower 6. Remove the fuse set from the groove by disconnecting the yellow plug. If the fuse is damaged, replace with a new one. Fuse...
  • Page 34 3. Main PCBA Replacement LM2120E-SP Lawn Mower 7. Reverse the battery box to cut off the zip tie and disconnect the long yellow plug (Fig.1). 8. Take the PCBA from the battery box and remove the 4 screws to separate the electric contact base from the battery box.(Fig.2).
  • Page 35 3. Main PCBA Replacement LM2120E-SP Lawn Mower 9. Separate the PCBA from the electric contact base. Description Part Number Electric contact 3126782001 base Electric contact base...
  • Page 36 3. Main PCBA Replacement LM2120E-SP Lawn Mower 10. PCB with key holder, main PCBA and the electric contact base set are as following pictures show. Main PCBA Sliding block Release button Spring PCB with key holder Electric contact base Description...
  • Page 37 3. Main PCBA Replacement LM2120E-SP Lawn Mower 11. Assemble the release button, sliding block and spring onto the electric contact base.
  • Page 38 3. Main PCBA Replacement LM2120E-SP Lawn Mower 12. Mount the electric contact of the PCBA onto the electric contact base . NOTICE: Hold the electrical contact base set tightly to stabilize the unit. Front view Electric contact of PCBA Rear view...
  • Page 39 3. Main PCBA Replacement LM2120E-SP Lawn Mower 13. Mount them into the battery box. Fix them by tightening the 4 screws(Fig. 1). 14. Pass the three wires and wire harness through the hook on the PCBA as Fig. 2 shown.
  • Page 40 3. Main PCBA Replacement LM2120E-SP Lawn Mower 15. Aligning the notch on the PCB board with the locating pin on the battery box, fix the PCB board by tightening the screw with the plain washer(Fig. 1). 16. Connect the two black plugs (Fig. 2).
  • Page 41 3. Main PCBA Replacement LM2120E-SP Lawn Mower 17. From the back side, pass the five wires through the corner and hook them into the groove in the corner.
  • Page 42 3. Main PCBA Replacement LM2120E-SP Lawn Mower 18. Use a zip tie to fix the wires. Cut the excess using diagonal pliers. 19. Insert the long yellow plug into its socket. Zip tie Long yellow plug...
  • Page 43 3. Main PCBA Replacement LM2120E-SP Lawn Mower 20. Reverse the battery box to align the fuse with its wire in the groove and insert the fuse plug. The fuse should be facing downwards. 21. Put the key holder in place.
  • Page 44 3. Main PCBA Replacement LM2120E-SP Lawn Mower 22. Mount the motor into the battery box as “Motor Assembly Replacement” part show. 23. Close the inner cover by locking the 5 screws. Inner cover...
  • Page 45 4. Power Unit Assembly LM2120E-SP Lawn Mower 1. Mount the front service cover onto service box. Fix it with 3 screws. Screwdriver Front service cover...
  • Page 46 4. Power Unit Assembly LM2120E-SP Lawn Mower 2. Mount the reassembled power unit onto the mower. 5 wires should be exposed. Power unit with front service cover Linked to microswitch Linked to self- propelled switch Lined to main switch and...
  • Page 47 4. Power Unit Assembly LM2120E-SP Lawn Mower 3. Insert the plugs into the corresponding sockets.
  • Page 48 4. Power Unit Assembly LM2120E-SP Lawn Mower 4. Align the wires into the grooves. Step 1 Step 2 Step 3...
  • Page 49 4. Power Unit Assembly LM2120E-SP Lawn Mower Step 5 Step 6...
  • Page 50 4. Power Unit Assembly LM2120E-SP Lawn Mower 5. Turn the mower on its back. In this way, the power unit can be located stably on the mower without dropping. 6. Tighten the 4 hexagon head bolts with a socket wrench(S=10mm) to fix the power unit.
  • Page 51 4. Power Unit Assembly LM2120E-SP Lawn Mower 7. Close the service cover. Service Cover...
  • Page 52 5. Handle Position Switch Replacement LM2120E-SP Lawn Mower 1. If the handle position switch is broken, during the process of assembling power unit onto the mower, replace it with a new one. 2. Reconnect the switch with wires by soldering.
  • Page 53 REPAIR GUIDELINE PART 2.2: LED LIGHT ASSEMBLY_LM2120E-SP Lawn Mower...
  • Page 54 Table of Contents LM2120E-SP Lawn Mower Contents Page LED Film Switch Replacement LED Headlights Replacement 4-12...
  • Page 55 1. LED Film Switch Replacement LM2120E-SP Lawn Mower The LED Film switch button can be replaced following the figures shown below. Film switch Remove the button from the cover Pull out from the groove Loosen the screw If you can’t loosen the screw smoothly, remove the service cover before this step.
  • Page 56 2. LED Headlights Replacement LM2120E-SP Lawn Mower 1. Remove the cover of the LED Film switch button as previous steps show. 2. Separate the wiring harness with LED from the cover by disconnect the plug (Fig. 1, Fig. 2). 3. Fold the handle to the operating position and remove the battery inner cover (Fig. 3).
  • Page 57 2. LED Headlights Replacement LM2120E-SP Lawn Mower 4. Remove the screw on the right (red circle indication) to separate the coupled decorative covers. 5. Remove the left and right decorative covers using two screwdrivers. If the decorative covers are damaged, replace them.
  • Page 58 2. LED Headlights Replacement LM2120E-SP Lawn Mower 6. If the harness or PCB is damaged, replace with a new one by disconnecting the plug inside the battery box . Decorative covers...
  • Page 59 2. LED Headlights Replacement LM2120E-SP Lawn Mower 7. Remove the 2 screws to separate the front decorative cover. Front decorative cover Screw on right Description Part Number SPEC Tapping screw 5610042014 ST4.2×19 Screw on left...
  • Page 60 2. LED Headlights Replacement LM2120E-SP Lawn Mower 8. Separate the plug to remove the LED headlights from the battery box. The LED headlights includes 2 small PCBs, two reflectors and two transparent caps. Linked with main PCB...
  • Page 61 2. LED Headlights Replacement LM2120E-SP Lawn Mower 9. Replace the broken parts of the LED headlights. If the front decorative cover or EGO logo is broken, replace them. Front decorative Description Part Number cover PCB assembly 2830182001 Right transparent cap...
  • Page 62 2. LED Headlights Replacement LM2120E-SP Lawn Mower 10. Assemble the new LED headlights onto the battery box. Right LED headlight Left LED headlight Wire alignments Wire alignments...
  • Page 63 2. LED Headlights Replacement LM2120E-SP Lawn Mower 11. Align the wires into the groove as well as the PCB and insert the plug into its socket.
  • Page 64 2. LED Headlights Replacement LM2120E-SP Lawn Mower 12. Plug the wire harness with LED into its groove in film cover (Fig. 1). 13. Mount the decorative covers onto the battery box and lock them with the screw (Fig. 2). Wire alignments Lock the covers with this screw.
  • Page 65 REPAIR GUIDELINE PART 2.3: BATTERY COVER ASSEMBLY_LM2120E-SP Lawn Mower...
  • Page 66 Battery Cover Assembly Replacement LM2120E-SP Lawn Mower The battery cover consists of the transparent guard and the battery cover itself. Shaft Description Part Number E-clip Battery cover 3127880001 E-ring Transparent guard 3127900001 Shaft 5670380001 E-clip 5660003003 Battery cover Transparent guard...
  • Page 67 Battery Cover Assembly Replacement LM2120E-SP Lawn Mower 1. Remove the screw to open the LED film switch button cover. 2. Remove the E-clip from the shaft. E-ring LED film switch cover...
  • Page 68 Battery Cover Assembly Replacement LM2120E-SP Lawn Mower 3. Draw the shaft out from the battery cover assembly by using a thin rod. 4. Replace with a new battery cover set; Fix the new one to the battery box in reverse order.
  • Page 69 REPAIR GUIDELINE PART 3: REAR COVER_LM2120E-SP Lawn Mower...
  • Page 70 Rear Cover Replacement LM2120E-SP Lawn Mower Rear Cover Description Part Number Rear Cover 3126689003...
  • Page 71 Rear Cover Replacement LM2120E-SP Lawn Mower 1. Detach the service cover from the mower by loosening the 6 screws.
  • Page 72 Rear Cover Replacement LM2120E-SP Lawn Mower 2. Pull out the shaft from right side by hand (Fig. 1). 3. Take down the rear cover and shaft (Fig. 2). Shaft Description Part Number SPEC Shaft 5670345001 Φ7x 345...
  • Page 73 Rear Cover Replacement LM2120E-SP Lawn Mower 4. Remove the spring from the rear cover. Replace with a new rear cover or torsion spring. Description Part Number SPEC Torsion Spring 3660559001 15.2x25...
  • Page 74 Rear Cover Replacement LM2120E-SP Lawn Mower 6. Insert the shorter foot of the torsion spring into the groove of the rear cover. Insert...
  • Page 75 Rear Cover Replacement LM2120E-SP Lawn Mower 7. Position the rear cover and torsion spring assembly in the deck. The foot of the spring should be in the deck groove. Rested on the groove...
  • Page 76 Rear Cover Replacement LM2120E-SP Lawn Mower 8. Insert the shaft through the hole on the mower and the torsion spring, and push it into position. Align the shaft to the fixing hole and push it into position. 9. Lift up the rear cover to check if it can rotate around the shaft smoothly. If it works well, mount the service cover onto the mower by tightening the 6 screws.
  • Page 77 REPAIR GUIDELINE PART 4: TOP HANDLE & SWITCH BOX COVER_LM2120E-SP Lawn Mower...
  • Page 78 Table of Contents LM2120E-SP Lawn Mower Contents Page Opening the Switch Box Cover The Safety Button Replacement 7-10 The Main Switch Set(Lever/Trigger) Replacement 11-13 The Top Handle Replacement The Top & Bottom Switch Box Cover Replacement The Main Switch/Self-propelled Switch/Speed-adjusting PCB...
  • Page 79 Top Handle & Parts in Switch Box Cover Replacement LM2120E-SP Lawn Mower When opening the switch box covers, the following relevant parts can be replaced: Description Part Number Main Switch 4870566001 Main Switch Trigger 3127908001 Main Switch Lever 2824118001 Self-propelled Switch...
  • Page 80 1. Opening the Switch Box Cover LM2120E-SP Lawn Mower 1. With the handle locked in the operating position, remove the 4 bolts. The 4 bolts are separately fixed by one hexagon nut on the reverse. Hexagon Description Part Number SPEC...
  • Page 81 1. Opening the Switch Box Cover LM2120E-SP Lawn Mower 2. Fold the handle to the grass bag removal position(Fig. 1). 3. Remove the 8 tapping screws from the housing(Fig. 2). NOTICE: During this process, keep holding the top switch box cover with one hand to prevent dropping.
  • Page 82 1. Opening the Switch Box Cover LM2120E-SP Lawn Mower 4. Hold the top switch box cover with one hand and remove bottom switch box cover gently with the other hand. Replace any damaged parts accordingly. Top Switch Box Cover Self-propelled...
  • Page 83 2. The Safety Button Replacement LM2120E-SP Lawn Mower 1. Remove the spring, screw, plain washer, switch actuator and safety button. Switch Actuator Screw Washer Spring Safe Button Description Part Number SPEC Description Part Number SPEC Spring 3660011002 12.7×16 Switch Actuator...
  • Page 84 2. The Safety Button Replacement LM2120E-SP Lawn Mower Place the new safety button into the mounting slot. Align the actuator slot with the buttons highest rib (Fig. 1). Button Higher Rib Actuator Slot Mounting Slot...
  • Page 85 2. The Safety Button Replacement LM2120E-SP Lawn Mower Place the plain washer onto the actuator and tighten it with a screw (Fig. 1). Locate the actuator between the main switch and the housing (Fig. 2) .
  • Page 86 2. The Safety Button Replacement LM2120E-SP Lawn Mower 6. Place the spring onto the actuator and make sure it is securely located(Fig. 1). 7. Close the switch box cover as steps in following “Close the Switch Box Cover” part show.
  • Page 87 3. The Main Switch Set(Lever/Trigger) Replacement LM2120E-SP Lawn Mower 1. Loosen the 2 screws . Remove the clamp, spring and switch lever set. 2. Replace with a new switch lever or trigger if any distortion or malfunction appears. Clamp Main Switch Lever...
  • Page 88 3. The Main Switch Set(Lever/Trigger) Replacement LM2120E-SP Lawn Mower 3. Mount the switch trigger to the switch lever. NOTICE：The flat position on the lever should be fixed as the fig. 3 show. Flat Position Here...
  • Page 89 3. The Main Switch Set(Lever/Trigger) Replacement LM2120E-SP Lawn Mower 4. Put the spring into the hole. Mount the main switch set onto the spring with the hook outside the spring(Fig. 1). 5. Align the clamp slot with the locating rib on the housing(Fig. 2).
  • Page 90 4. The Top Handle Replacement LM2120E-SP Lawn Mower 1. Pull the top handle, removing the handle from the plastic bushings in the aluminum tubes. 2. Replace with a new one if it appears worn or broken. 3. Insert the two sides into the plastic bushings and press them into place.
  • Page 91 5. To Replace the Top & Bottom Switch Box Cover LM2120E-SP Lawn Mower 1. Remove all the switches as well as their cables from the top switch box cover; 2. Remove the main switch lever and self-propelled lever from the top switch box cover;...
  • Page 92 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB LM2120E-SP Lawn Mower 1. Remove the main switch, self-propelled switch and speed adjustment PCB assembly from the top switch box cover. Replace the damaged part accordingly. Main Switch Speed Adjustment PCB Self-propelled Switch...
  • Page 93 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB ① IF the main switch is broken, disconnect it from the wires and replace with a new one by resoldering. NOTICE: Note the soldering sequence as following picture show. 2- Yellow @ black Red- 1 4-Black Black- 3...
  • Page 94 6. The Main Switch/Self-propelled Switch/Speed-adjusting PCB ② If the Self-propelled switch is broken, disconnect it from the wires and replace with a new one by resoldering. NOTICE: Note the soldering sequence as following picture show. White- NO Black- NC Pink- COM...
  • Page 95 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB ③ IF the speed-adjusting PCB is broken, disconnect it from the wires and replace with a new one by resoldering. ④ If the speed-adjusting knob is also broken, replace it with a new one. NOTICE: Mind soldering sequence as Fig.
  • Page 96 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB 2. Test ① Test the main switch: • Insert a fully charged battery pack into the battery case. • Adjust the handle to the operating position and fully extend the side rails and lock with the side clamps.
  • Page 97 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB 3. Align the bellows into the housing groove with at least five threads located in (Fig. 1) . 4. Align the self-propelled speed-adjusting PCB wires into the grooves (Fig. 2). At least 5 threads of the bellows located in the housing groove...
  • Page 98 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB 5. Align the wires of the main switch and self-propelled switch into the groove and place the main switch into the holder following the steps NO. in figures below.
  • Page 99 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB 6. Align the self-propelled lever into the top switch box cover. ① First place the spring onto the self-propelled lever. Description Part Number SPEC Spring 3660562001 11×38 Self-propelled Switch Lever 3127928001...
  • Page 100 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB ② Align the self-propelled lever into the grooves on the top switch box cover. Spring Position...
  • Page 101 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB 7. Align the self-propelled speed-adjusting PCB and knob set into the housing hole correctly. ① Assemble the self-propelled speed-adjusting knob to the PCB initially. ② Mount the PCB and knob set into the place correctly.
  • Page 102 6. The Main Switch/Self-propelled Switch/Speed- adjusting PCB NOTICE: If the self-propelled speed-adjusting PCB has been inserted into the groove incorrectly, the knob can’t be put into place meaning the cover can’t be closed.
  • Page 103 7. Closing the Switch Box Cover LM2120E-SP Lawn Mower 1. Fully extend the side rails to mount the top switch box cover to the handle, making sure the ribs on the handle locate on the ribs on the switch box cover.
  • Page 104 7. Closing the Switch Box Cover LM2120E-SP Lawn Mower 2. Close the switch box set and fix them by tightening the 8 screws on the bottom switch box cover firstly and the 4 bolts on the top switch box cover to lock the cover set, making sure the...
  • Page 105 7. Closing the Switch Box Cover LM2120E-SP Lawn Mower THE END...
  • Page 106 REPAIR GUIDELINE PART 5: HANDLE LOCKING CLAMP_LM2120E-SP Lawn Mower...
  • Page 107 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower Description Part Number Handle Locking Clamp Set 2823714002...
  • Page 108 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower 1. Use a pin and a hammer to tap out the shaft carefully and remove the clamp, shaft and spring from the tube. Spring Clamp Shaft...
  • Page 109 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower 2. Move the handle downwards to take out the rubber pad and rubber base. 3. Replace the broken or worn parts. Rubber base Rubber pad...
  • Page 110 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower 4. Put the rubber pad and rubber base into the recess with the rubber pad on the inside and the rubber base on the outside.
  • Page 111 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower 5. Insert the short foot of the spring into the hole in the clamp, then mount the clamp into the joint.
  • Page 112 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower 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 should not retract...
  • Page 113 Handle Locking Clamp Replacement LM2120E-SP Lawn Mower Description Part Number Picture Handle Locking Clamp Set 2823714002 THE END...
  • Page 114 REPAIR GUIDELINE PART 6: LEFT/RIGHT BEAM HOUSING_LM2120E-SP Lawn Mower...
  • Page 115 Table of Contents LM2120E-SP Lawn Mower Contents Page Opening the Right Beam Housing Closing the Right Beam Housing 7-10 Opening the Left Beam Housing 11-12 Closing the Left Beam Housing 13-14 Replacing the Left/Right Inner Tube ASSY/Beam Tube 15-19...
  • Page 116 Left/Right Beam Housing Replacement LM2120E-SP Lawn Mower When opening the left/right beam housing, the following parts can be replaced: Left inner tube ASSY Left beam housing set Description Part Number Micro switch 4870500001 Beam tube Left beam housing set 2824427001...
  • Page 117 1. Opening the Right Beam Housing LM2120E-SP Lawn Mower 1. Remove the 8 tapping screws to open the right beam housing. NOTICE: The micro switch is located in the right beam housing. Right beam housing set Description Part Number SPEC...
  • Page 118 1. Opening the Right Beam Housing LM2120E-SP Lawn Mower 2. Remove the top housing, rubber pad and rubber base, switch actuator and spring (fixed on the switch actuator). Switch actuator Spring Micro switch Top housing Rubber pad Rubber base Description...
  • Page 119 1. Opening the Right Beam Housing LM2120E-SP Lawn Mower 3. Remove the micro switch and cable from the bottom housing. 4. Replace with a new switch if it malfunctions. 5. Test the micro switch. • Leave the trigger of the micro switch un-depressed. Turn on the mower, the mower should be turned on properly.
  • Page 120 2. Closing the Right Beam Housing LM2120E-SP Lawn Mower 1. Align the cable in the bottom housing; press the cable into place. 2. Align the locating hole with the locating pin on bottom housing, position the switch into place. Locating hole...
  • Page 121 2. Closing the Right Beam Housing LM2120E-SP Lawn Mower 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.
  • Page 122 2. Closing the Right Beam Housing LM2120E-SP Lawn Mower 5. Fix the switch actuator into the bottom housing. Description Part Number Switch Actuator 3126768001 Locating pin into the This corner into the locating hole in housing outer tube Spring 3660287002...
  • Page 123 2. Closing the Right Beam Housing LM2120E-SP Lawn Mower 6. Attach the rubber pad and base into the rectangle groove of the outer tube. 7. Close the top housing with the 8 tapping screws. Rectangle groove Rubber pad and base...
  • Page 124 3. Opening the Left Beam Housing LM2120E-SP Lawn Mower 1. Remove the 8 tapping screws to open the left beam housing. Left beam housing set Description Part Number SPEC Tapping Screw 5610032004 ST4x16...
  • Page 125 3. Opening the Left Beam Housing LM2120E-SP Lawn Mower 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 to be worn.
  • Page 126 4. Closing the Left Beam Housing LM2120E-SP Lawn Mower 1. Mount the top housing onto the side rail and beam tube. 2. Turn the handle to lock it in any of the operating positions.
  • Page 127 4. Closing the Left Beam Housing LM2120E-SP Lawn Mower 3. Position the rubber pad and rubber base into the groove of bottom housing, making sure the rubber pad pointing outside. 4. Close the bottom housing using screws. Rubber pad pointing...
  • Page 128 5. Replacing the Left/Right Inner Tube ASSY/Beam Tube LM2120E-SP Lawn Mower 1. Remove the switch box covers (see Part 4). 2. Pull the top handle and remove it from the plastic bushings in the two side aluminum tubes. 3. Remove the left/right beam housing (see page 3-6 and 11-12 in this guide)
  • Page 129 5. Replacing the Left/Right Inner Tube ASSY/Beam Tube LM2120E-SP Lawn Mower 4. Pull the left/right inner tube assembly from the outer tube. 5. Replace damaged tubes. Right inner tube ASSY Left inner tube ASSY Beam Tube Description Part Number Left Inner Tube ASSY...
  • Page 130 5. Replacing the Left/Right Inner Tube ASSY/Beam Tube LM2120E-SP Lawn Mower 6. Insert the left/right tube assembly into the outer tube. The left and right inner tubes are not interchangeable. Opening in the plastic sleeve on right side Right inner tube ASSY...
  • Page 131 5. Replacing the Left/Right Inner Tube ASSY/Beam Tube LM2120E-SP Lawn Mower Right inner tube ASSY Left inner tube ASSY...
  • Page 132 5. Replacing the Left/Right Inner Tube ASSY/Beam Tube LM2120E-SP Lawn Mower 7. Close the left/right beam housing (see page 7-10 and 13-14 in this guide). 8. Mount the top hand and switch box covers back (See part 4). THE END...
  • Page 133 REPAIR GUIDELINE PART 7: QUICK ADJUSTING LEVER_LM2120E-SP Lawn Mower...
  • Page 134 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower Description Part Number Quick Adjusting Lever 2824250001...
  • Page 135 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 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 5610032004 ST4x16...
  • Page 136 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 2. Remove the clamping ring with a flat head screwdriver . Flat head Clamp ring screwdriver Description Part Number Clamping Ring 5660003003...
  • Page 137 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 3. Press the lever to loosen the pin and then draw it out. Draw the pin out Description Part Number 3550048003 Press the pin...
  • Page 138 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 4. Remove the spring, adjusting lever and decorative cover from the side tube. 5. Replace the damaged parts accordingly. Description Part Number Decorative Cover 3126912001 Quick Adjusting Lever 2824250001 Spring 3660565001...
  • Page 139 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 6. Pass the adjusting lever through the decorative cover (Fig. 1). 7. Move the handle to Grass bag removal position. 8. Align the locking pin with the nut bushing, fully force the pin into the bushing and let the pin extend out of the side tube so that the handle can be locked at the position (Fig.
  • Page 140 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 9. Align the screw dome with the hole in the side tube and mount the decorative cover onto side tube. 10. Fix the spring between the adjusting lever and the side tube. Hole in the tube...
  • Page 141 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 11. Hold the tube and lever, depress the lever to align the hole in the lever with the hole in the plastic part. 12. Fully insert the pin and lock the pin with the clamping ring from the backside.
  • Page 142 Quick Adjusting Lever Replacement LM2120E-SP Lawn Mower 13. Lock the decorative cover with two tapping screws. 14. Test the lever function to check if it can lock the handle at different positions. THE END...
  • Page 143 REPAIR GUIDELINE PART 8: Self-propelled PCBA and Unit Replacement_LM2120E-SP Lawn Mower...
  • Page 144 Table of Contents LM2120E-SP Lawn Mower Contents Page Self-propelled PCBA and Unit Replacement Preparation Self-propelled PCBA Replacement 6-11 Motor in Self-propelled Unit Replacement 12-16 Gear Box in Self-propelled Unit Replacement 17-22...
  • Page 145 1. Self-propelled PCBA and Unit Replacement Preparation LM2120E-SP Lawn Mower 1. Before replacing or maintaining the PCBA or parts in self-propelled unit, fold the handle to the grass bag removal position to remove the service cover from the mower. Service Cover...
  • Page 146 1. Self-propelled PCBA and Unit Replacement Preparation LM2120E-SP Lawn Mower 2. Cut the red and black thin wires, connecting the self-propelled PCBA to the self-propelled motor. Service Cover Self-propelled PCBA...
  • Page 147 1. Self-propelled PCBA and Unit Replacement Preparation LM2120E-SP Lawn Mower 3. Test the motor voltage between the three wires by using a multimeter. If the motor is open-circuit, disassembling the self-propelled unit and replace the motor. a) Set the multimeter function to “Resistance measuring”...
  • Page 148 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower 1. Remove the screw with its washer. Tapping screw Washer Description Part Number SPEC Washer 3700353001 Tapping screw 5610042014 ST4.2x19...
  • Page 149 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower 2. Disconnect the self-propelled PCBA from the power unit, switches and motor. Pull to release Pull to release Cut off by scissors Pull to release Press to release...
  • Page 150 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower 3. Replace with a new PCBA. 4. Connect the new PCBA by soldering and plugging. Soldered with self-propelled Linked with speed and handle position switch adjustment PCB Linked with self-propelled motor by plugging...
  • Page 151 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower 5. Put the PCB into its place and align the wires into the grooves. Step 1 Step 2 Connect Put into groove Step 3 Step 4 Right sight view...
  • Page 152 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower Step 5 Step 7...
  • Page 153 2. Self-propelled PCBA Replacement LM2120E-SP Lawn Mower 6. Tighten the screw with the washer to fix the PCBA. 7. Turn on the self-propelled trigger by pressing it. Then adjust its speed-control lever to test whether the PCBA is assembled correctly.
  • Page 154 3. Motor in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 1. Adjust the mower to the highest cutting position and then turn the mower on its back. 2. Remove the E-clip and plain washer on the joint. Description Part Number Plain washer...
  • Page 155 3. Motor in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 3. Remove the 4 screws 1# and 4 screws 2#. There are 4 plain washers under screw 2#. Screw 1# Screw 2# Screw 1# Plain washer Description Part Number SPEC Screw 2#...
  • Page 156 3. Motor in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 4. Separate the self-propelled unit from the mower by prizing up the joint with a flat head screwdriver. Self-propelled motor Gear box Screwdriver Wheels 5. If the wheels are damaged, replace them(See Part 9).
  • Page 157 3. Motor in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 6. Remove the 2 screws to detach the motor from the self-propelled unit. Plug Motor Description Part Number SPEC Motor 2824920002...
  • Page 158 3. Motor in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 7. Replace with a new motor and fix the motor assembly onto the self-propelled unit. NOTICE: Before mounting the new motor, check whether the gasket and planetary gears are in place. If not, mount them back into place.
  • Page 159 4. Gear Box in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 1. If the gear box is worn, disassemble them and replace with a new one. 2. Remove the 4 screws to detach the gear box from the rear axle set and 2 screws on the motor cover.
  • Page 160 4. Gear Box in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 3. Mount the connectors on the rear axle set. If the rear axle is damaged, replace it with a new rear axle set. Rear axle set Description Part Number Rear axle set...
  • Page 161 4. Gear Box in Self-propelled Unit Replacement LM2120E-SP Lawn Mower 4. Mount the gear box set onto the rear axle. Fix it by tightening the four 3# screws. 5. Mount the motor set onto the gear box and lock it with the two 2# screws.
  • Page 162 4. Gear Box in Self-propelled Unit Replacement LM2120E-SP Lawn Mower Gasket Assembling the planetary gears and gasket. Planetary gears are worn on the shaft Ring gear Planet gear Description Part Number Gasket 3703931002 Planet gear 3520868001 Ring gear 3520519001 THE END...
  • Page 163 REPAIR GUIDELINE PART 9: Wheels Replacement_LM2120E-SP Lawn Mower...
  • Page 164 Table of Contents LM2120E-SP Lawn Mower Contents Page Rear Wheel Replacement Front Wheel Replacement 9-10...
  • Page 165 1. Rear Wheel Replacement LM2120E-SP Lawn Mower Gasket If the rear wheel is damaged, replace it. 1. Turn the mower on its back or side and separate the hubcap with a screwdriver. Hubcap Hex bolt Description Part Number SPEC Hubcap...
  • Page 166 1. Rear Wheel Replacement LM2120E-SP Lawn Mower 2. Remove the hex bolt using a socket wrench (S=13mm) to separate the wheel assembly from its protective cap, which is fixed on the self-propelled unit. Hex bolt Socket wrench (S=13mm) Wheel protective cap...
  • Page 167 1. Rear Wheel Replacement LM2120E-SP Lawn Mower Gasket 3. Remove the gear from the wheel assembly by loosening the 3 screws. 4. Replace with a new wheel assembly. Fix it onto the self-propelled unit in reverse order(Notice see next slide).
  • Page 168 1. Rear Wheel Replacement LM2120E-SP Lawn Mower Gasket NOTICE: During wheel reassembly, pay attention to which side of the gear faces the wheel. This side facing wheel This side facing protective cap...
  • Page 169 1. Rear Wheel Replacement LM2120E-SP Lawn Mower 5. If the wheel protective cap is broken, replace it with a new one. Gasket 6. Loosen the screw and remove it with its spring washer and plain washer. Detach the wheel protective cap from the shaft as well as the wave washer.
  • Page 170 1. Rear Wheel Replacement LM2120E-SP Lawn Mower 7. Mount a new protective cap onto the self-propelled unit shaft as well as the wave washer. Fix the cap by tightening the screw with spring washer and plain washer. The recommended torque is 1.8-2.5Nm.
  • Page 171 2. Front Wheel Replacement LM2120E-SP Lawn Mower Gasket If the front wheel is damaged, replace it. 1. Separate the hubcap from the wheel and remove the hex bolt in the same way as the rear wheel. Front wheel Hubcap Wave...
  • Page 172 2. Front Wheel Replacement LM2120E-SP Lawn Mower Gasket 2. Replace with a new front wheel. 3. Mount it onto the axle with the wave washer beneath it. 4. If the axle is broken, replace it (see Part 10). Bent shaft...
  • Page 173 REPAIR GUIDELINE PART 10: Housing Cover and Front Axle Replacement_LM2120E-SP Lawn Mower...
  • Page 174 Table of Contents LM2120E-SP Lawn Mower Contents Page Housing Cover Replacement Front Axle Replacement 7-11...
  • Page 175 1. Housing Cover Replacement LM2120E-SP Lawn Mower Gasket 1. Remove the blade(see Part 1). 2. Remove the service cover and power unit(see Part 2.1) 3. Turn the mower on its back to remove the 14 screws on the poly deck.
  • Page 176 1. Housing Cover Replacement LM2120E-SP Lawn Mower Gasket 4. Remove the power unit of the mower(see Part 2.1). 5. Remove the 2 screws on the height adjusting knob to remove the height adjusting knob. Screw Height adjusting knob Description Part Number...
  • Page 177 1. Housing Cover Replacement LM2120E-SP Lawn Mower 6. Remove the 2 screws on the depth stop plate. 7. Move the height adjusting lever outwards to remove the depth stop plate. Depth stop plate Rubber pad Gasket Height adjusting lever Description...
  • Page 178 1. Housing Cover Replacement LM2120E-SP Lawn Mower 8. Remove the housing cover from the mower. 9. If the housing cover is damaged, replace it with a new one. Assemble it in reverse order. Decorative cover Housing cover Description Part Number...
  • Page 179 2. Front Axle Replacement LM2120E-SP Lawn Mower 1. If the front axle is damaged, remove the housing cover as previous steps show. Front axle Joint...
  • Page 180 2. Front Axle Replacement LM2120E-SP Lawn Mower 2. Remove the E-clip and plain washer on the joint. Front axle E-ring Description Part Number E-clip 5660139002 Plain washer 5650025004...
  • Page 181 2. Front Axle Replacement LM2120E-SP Lawn Mower 3. Separate the joint by hand. WARNING: Take care when performing this operation. Please wear gloves.
  • Page 182 2. Front Axle Replacement LM2120E-SP Lawn Mower 4. Turn the mower on its side. 5. Remove the 2 screws and remove the 2 mounting plates as well as the front axle with wheels. Description Part Number SPEC Tapping screw 5610042014 ST4.2x19...
  • Page 183 2. Front Axle Replacement LM2120E-SP Lawn Mower 6. Disassemble the front wheels(see Part 9). 7. Replace the broken front axle with a new one. 8. Mount the wheels onto the new front axle(see part 9). 9. Mount the front axle into the...