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EGO LM2230E-SP Repair Manual

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REPAIR MANUAL
LM2230E-SP
Version: A
Introduction date: 2025
1

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Summary of Contents for EGO LM2230E-SP

  • Page 1 REPAIR MANUAL LM2230E-SP Version: A Introduction date: 2025...
  • Page 2 CONTENTS About the tool Diagnostics Repair Instructions...
  • Page 3 SECTION ABOUT THE TOOL Product features Service maintenance Wiring diagram...
  • Page 4 SECTION A.00 PRODUCT FEATURES KEY FEATURES WARRANTY DURATION LM2230E-SP DOMESTIC * Extended warranty period applies only after registering product on egopowerplus.eu/register within 30 days of Cutting Width 55 cm purchase. Otherwise standard warranty periods apply. • Standard domestic = 2 years •...
  • Page 5 SECTION A.10 SERVICE MAINTENANCE Maintenance Actions Each use Each season Sharpen the mowing blade  Clean the mower  ➀ ➁ ➁...
  • Page 6 SECTION A.20 WIRING DIAGRAM LAYOUT...
  • Page 7 SECTION A.21 WIRING DIAGRAM COMPONENTS A. Self-propel PCBA Controller for self-propel motor B. Switch PCBA Start/stop switches C. LED Electric Assembly D. Main PCBA Power supply to motor Power supply to self-propel PCBA LED headlights E. Mowing Motor F. Battery Contact G.
  • Page 8 SECTION DIAGNOSTICS Status LEDs Common faults Test main PCBA Test self-propelled PCBA Test motors (mowing and self-propel)

  • Page 9: Battery Led Status

    SECTION B.00 STATUS LEDS BATTERY LED STATUS Status Meaning Next actions Status Meaning Next actions Test: single press of battery power button Test: 5 second hold of power button Fully charged Battery condition ok Battery is reaching the end of service life. 100% - 80% charged State of health at 60% Operator may notice reduced performance.
  • Page 10 Tool status SECTION B.01 STATUS LEDS LED headlight indicator Blade speed mode indicator DASHBOARD STATUS Status Meaning Next actions TEST: Insert one battery and start the mowing blade. Inspect the tool status indicator. Mower working correctly 1. Adjust handlebar position locking screw. Handlebar set-up incorrect 2.
  • Page 11 SECTION B.10 COMMON FAULTS AND CAUSES Symptom / Test Next steps NO POWER TO MOWER OR DASHBOARD Insert a battery and check the battery indicator light. TEST: Press the power button. Activate the blade motor and the self-propel motor. Check the battery indicator light. Battery indicator solid green 1.
  • Page 12 SECTION B.11 COMMON FAULTS AND CAUSES Symptom / Test Next steps BLADE MOTOR DOES NOT START, SELF-PROPEL NOT WORKING, BUT DASHBOARD WORKS. Insert a battery and check for dashboard status. TEST 1: Activate LED headlights. Check if headlights turn on. No headlights 1.
  • Page 13 SECTION B.12 COMMON FAULTS AND CAUSES Symptom / Test Next steps BLADE MOTOR DOES NOT START, SELF-PROPEL WORKS Insert a battery and check for dashboard status. TEST: Activate the blade start switch. Look for the tool status indicator. 1. Inspect the terminal between the main PCBA and the blade motor Status LED solid green 2.
  • Page 14 SECTION B.13 COMMON FAULTS AND CAUSES Symptom / Test Next steps SELF-PROPEL NOT WORKING, BLADE MOTOR WORKS Insert a battery and check for dashboard status. TEST: Activate self-propel lever. Look for tool status indicator No status LED 1. Speed control lever may be set to “off”. Roll speed lever forwards to select a speed. 1.
  • Page 15 SECTION B.14 COMMON FAULTS AND CAUSES Symptom / Test Next steps SELF-PROPEL SPEED NOT CHANGED Insert a battery and check for dashboard status. TEST: Activate self-propel lever. Look for tool status indicator No status LED 1. Speed control lever may be set to “off”. Roll speed lever forwards to select a speed. 1.
  • Page 16 SECTION B.20 MAIN PCBA TEST MOSFETS - POSITIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Hold the black test lead on the wire within the power terminal block.
  • Page 17 SECTION B.21 MAIN PCBA TEST MOSFETS - NEGATIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Hold the test lead on the black wire within the power terminal block.
  • Page 18 SECTION B.30 SELF-PROPEL PCBA TEST MOSFETS - POSITIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Hold the black test lead on the wire within the power terminal block.
  • Page 19 SECTION B.31 SELF-PROPEL PCBA TEST MOSFETS - NEGATIVE CIRCUIT MOSFETs control the power and speed of a motor. Running a tool at high demand can cause early failure of the MOSFETs. 1. Set multimeter in “diode” measuring mode 2. Hold the test lead on the black wire within the power terminal block.
  • Page 20 SECTION B.40 Blade ELECTRIC MOTORS Motor TEST MOWING AND SELF-PROPEL MOTOR Measurement technique is the same for blade and self-propel motors. This tests the resistance of the wire windings. In the event of a short-circuit, the measured result may be the same as a normal motor. However, an open circuit result will always indicate a faulty motor.

  • Page 21: Repair Instructions

    SECTION REPAIR INSTRUCTIONS Top cover assembly replacement PCBAs under service cover replacement LED light ASSY replacement Battery box replacement Wheels replacement Parts in handle ASSY replacement Self-propelled unit replacement Blade motor replacement Front axel replacement Rear cover replacement...
  • Page 22 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Unfold the handle to the storage position and turn the mower upside down. Loosen the screw with a torque wrench with 14mm socket (50-60 Nm). Remove the washers, the blade set and the fan. Stabilizer Shaft Bolt Blade set...
  • Page 23 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Loosen the 2 screws with Torx20 screwdriver(0.8-1Nm) on the bottom of the deck. Open the battery box cover and loosen the 13 screws with Torx20 screwdriver (0.8~1.0 Nm) on the service cover.
  • Page 24 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Disconnect the 4 connectors. Connectors link to the battery contact...
  • Page 25 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Lift up the battery box and remove it from the mower. Wires from the Blade Motor Top Cover Assembly...
  • Page 26 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT To remove the top cover assembly, take off the clip selector knob by loosening the 2 screws using a PH1 bit. Clip Selector Knob...
  • Page 27 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Remove the cutting-height adjusting knob by loosening the 2 screws, using a PH1 bit. Remove the depth stop plate by loosening the 4 screws, using a Torx T20 bit. Take off the dust board as well. Cutting-height Adjusting Knob Dust Board...
  • Page 28 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT The top cover assembly is still seated on the deck by the tension spring which links to the rear axle of the self- propelled unit. Use a hook to lift the tension spring together with the spring seat away from the top cover assembly. And take them off.
  • Page 29 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Remove the main PCBA and position switch from the top cover, use a Torx20 bit to loosen and remove the 11 screws from the deck bottom and the 3 screws on the top.
  • Page 30 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Remove the top cover assembly. Blade Motor...
  • Page 31 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT When the top cover assembly is taken off from the deck, the clip selector cover assembly can be replaced by loosening 6 screws, using a Torx20 bit. Clip Selector Cover Assembly Top Cover Assembly...
  • Page 32 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Replace a new top cover assembly, pass through the blade motor wires and place the top cover assembly onto the deck. Note: Be careful to control the rod of the clip selector knob and the cutting-height adjusting knob when placing the top cover assembly (they may intervene the mounting).
  • Page 33 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Note: Make sure the top cover assembly is properly placed on the deck before securing with screws.
  • Page 34 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Secure the top cover assembly with the 3 screws on the top and 11 screws from the deck bottom by using a Torx20 bit.
  • Page 35 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Hook the tension spring onto the spring seat and place on the top cover assembly as shown below. Turn the mower on its side. Hook the tension spring to reach the rear axle. Spring Seat Tension Spring...
  • Page 36 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Adjust the cutting-height adjusting rod to find a proper position of the rear axle, so that the tension spring can be hooked onto it.
  • Page 37 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Re-assemble the cutting-height adjusting knob: place the dust board, secure the depth stop plate and mount the knob.
  • Page 38 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Re-assemble the clip selector knob.
  • Page 39 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Place back the main PCBA and re-connect all connectors as instructed in the previous section. Install the battery box on the top cover assembly.
  • Page 40 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Connect the 4 connectors and place them in the slot.
  • Page 41 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT Install the service cover and tighten 13 screws. Tighten the 2 screws on the bottom of the deck.
  • Page 42 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT To re-install the blade set, be sure to replace the parts in the exact order in which they were removed. Position the blade set onto the inner flange of the fan with the lower blade surface marked “THIS SIDE FACING GRASS”...
  • Page 43 SECTION C.00 TOP COVER ASSEMBLY REPLACEMENT 32. Put the conical spring washer onto the shaft bolt with the convex surface facing outside，and mount the shaft bolt into the shaft and finger-tighten the bolt CLOCKWISE. 33. Insert the metal rod (stabilizer) as aid. Use the 9/16" (14 mm) torque wrench to tighten the shaft bolt CLOCKWISE. The recommended torque for the blade set bolt is 50-60 Stabilizer...
  • Page 44 SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT SERVICE COVER REMOVAL Unfold the handle to the storage position. Open the battery box cover and loosen the 11 screws with Torx20 screwdriver (0.8~1.0 Nm) on the service cover.
  • Page 45 SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT SERVICE COVER REMOVAL The following parts can be replaced only when the service cover is removed from the mower. Main PCBA Position Switch Self-propelled PCBA...

  • Page 46: Main Pcba Replacement

    Main PCBA SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT MAIN PCBA REPLACEMENT Take out the main PCBA from the base and disconnect all cables on the main PCBA. Replace a new main PCBA and connect the cables on it. Put the terminals in the corresponding slots. Connected to the battery contact Connected to the blade motor Connected to the battery contact...
  • Page 47 SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT SELF-PROPEL PCBA REPLACEMENT Self-propel PCBA Take out the self-propel PCBA from the base and disconnect all cables on the self-propel PCBA. Replace a new self-propel PCBA and connect the cables on it. Put the terminals in the corresponding slots. Connected to the battery contact Connected to the self-propel motor Self-propel PCBA...
  • Page 48 SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT POSITION SWITCH REPLACEMENT Take out the position switch from the base and disconnect the cable on the position switch. Position Switch Replace a new position switch and connect the cable on it. Put the terminal in the corresponding slots. Connected to the main PCBA Position Switch...
  • Page 49 SECTION C.01 PCBAS UNDER SERVICE COVER REPLACEMENT SERVICE COVER INSTALLATION Install the service cover on the mower. Tighten the 11 screws with Torx20 screwdriver (0.8~1.0 Nm) on the service cover.
  • Page 50 SECTION C.02 LED LIGHT ASSY REPLACEMENT Unfold the handle to the storage position. Loosen the 2 screws on the bottom of the deck. Open the battery box cover and loosen the 13 screws with Torx20 screwdriver (0.8~1.0 Nm) on the service cover.
  • Page 51 SECTION C.02 LED LIGHT ASSY REPLACEMENT Disconnect the 4 connectors.
  • Page 52 SECTION C.02 LED LIGHT ASSY REPLACEMENT Lift up the battery box and remove it from the mower. Loosen the 2 screws on the bottom to disassemble the battery box.
  • Page 53 SECTION C.02 LED LIGHT ASSY REPLACEMENT Loosen the 4 screws to remove the LED light ASSY. Replace a new LED light ASSY and install in opposite sequence. LED Light ASSY...
  • Page 54 SECTION C.03 BATTERY BOX REPLACEMENT Unfold the handle to the storage position. Loosen the 2 screws on the bottom of the deck. Open the battery box cover and loosen the 13 screws with Torx20 screwdriver (0.8~1.0 Nm) on the service cover.
  • Page 55 SECTION C.03 BATTERY BOX REPLACEMENT Disconnect the 4 connectors.
  • Page 56 SECTION C.03 BATTERY BOX REPLACEMENT Lift up the battery box and remove it from the mower. Loosen the 6 screws on the bottom to disassemble the battery box.
  • Page 57 SECTION C.03 BATTERY BOX REPLACEMENT Remove the following parts from the battery box. Replace a new battery box. Connecting Seat Wire Assembly Release Button Compression Spring Sliding Block Supporting Structure Support Base Sliding Block Spring Battery Box...
  • Page 58 SECTION C.03 BATTERY BOX REPLACEMENT Install the battery box on the front cover assembly by tightening the 2 screws. 10. Place the release button on the battery box. Release Button...
  • Page 59 SECTION C.03 BATTERY BOX REPLACEMENT 11. Preassemble the slide bock and spring on the support base, then install it on the battery box.
  • Page 60 SECTION C.03 BATTERY BOX REPLACEMENT 12. Preassemble the connecting seat wire harness and the slide block, then install it on the battery box.
  • Page 61 SECTION C.03 BATTERY BOX REPLACEMENT 13. Install the compression spring on the battery box. 14. Insert the supporting structure on the battery box.
  • Page 62 SECTION C.03 BATTERY BOX REPLACEMENT 15. Tighten the 4 screws to fix the parts. 16. Install the battery box assembly on the mower.
  • Page 63 SECTION C.03 BATTERY BOX REPLACEMENT 17. Connect the 4 connectors and place them in the slot.
  • Page 64 SECTION C.03 BATTERY BOX REPLACEMENT 18. Install the service cover and tighten 13 screws. 19. Tighten the 2 screws on the bottom of the deck.

  • Page 65: Front Wheel Replacement

    SECTION C.04 WHEELS REPLACEMENT FRONT WHEEL REPLACEMENT Turn the mower on the side or back, remove the wheel hub cover by using a flat head screwdriver. Wheel Hub Cover...
  • Page 66 SECTION C.04 WHEELS REPLACEMENT FRONT WHEEL REPLACEMENT Remove the hex bolt by using a 13mm socket wrench. Remove the front wheel and wave washer from the front axle set. Replace any defective part as needed. Wave Washer Hex Bolt Wheel Hub Cover Front Wheel...
  • Page 67 SECTION C.04 WHEELS REPLACEMENT FRONT WHEEL REPLACEMENT Place the wave washer onto the front axle set. Mount the front wheel onto the front axle set. Front Axle Set...
  • Page 68 SECTION C.04 WHEELS REPLACEMENT FRONT WHEEL REPLACEMENT Secure the front wheel with the hex bolt. The recommended torque is 2.6-3.7ft-lb(3.5-5Nm). Close the wheel hub cover.

  • Page 69: Rear Wheel Replacement

    SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Turn the mower on its side, remove the wheel hub cover by using a flat head screwdriver. Wheel Hub Cover...

  • Page 70: Rear Wheel Assembly

    SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Remove the hex bolt by using a 13mm socket wrench to separate the wheel from its protecting cap, which is fixed on the self-propelled unit. Rear Wheel Assembly...
  • Page 71 SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Remove the wave washer from the shaft. Loosen the screw by a cross screwdriver (PH2). Wave Washer Protecting Cap...
  • Page 72 SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Remove the protective cap from the shaft. Replace any parts as needed. Wave Washer Wheel Hub Cover Screw Hex Bolt Rear Wheel Assembly Protecting Cap...
  • Page 73 SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Mount the protecting cap onto the self-propelled unit shaft as well as the wave washer. Fix the cap by tightening the screw. The recommended torque is 1.3-1.8 ft-lb (1.8-2.5Nm).
  • Page 74 SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Place the wave washer onto the shaft. Properly mount the rear wheel onto the self-propelled unit. NOTE: The rear wheel should be able to rotate smoothly on the self-propelled unit shaft.
  • Page 75 SECTION C.04 WHEELS REPLACEMENT REAR WHEEL REPLACEMENT Secure the rear wheel with the hex bolt. The recommended torque is 2.6-3.7 ft-lb (3.5-5Nm). Close the wheel hub cover.
  • Page 76 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Open the battery box cover and loosen the 11 screws by using a Torx20 bit to remove the service cover. Service Cover...
  • Page 77 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Find the connectors that links the main PCBA to the handle assembly bus wire harness. Bus Wire Harness of the Handle Assembly Main PCBA...
  • Page 78 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Disconnect the connectors. The handle assembly is secured on the mower by left/right fixing block. Right Fixing Left Fixing Block Block...
  • Page 79 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Use a Torx20 bit to loosen and remove the 4 screws securing the right fixing block. Right Fixing Block...
  • Page 80 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Use a Torx20 bit to loosen and remove the 4 screws securing the left fixing block. NOTE: Be careful to hold the handle assembly when loosen all screws. Left Fixing Block...
  • Page 81 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Now the handle assembly can be removed from the mower. Handle Assembly...
  • Page 82 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Take a closer look at the lower part of the handle assembly. It consists of adjusting lever set, left/right decorate cover and spindle assembly. Adjusting Lever Set Spindle Assembly Right Decorate Left Decorate Cover Cover...
  • Page 83 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Use a Torx20 bit to loosen and remove the 3 screws securing the left decorate cover. Left Decorate Cover...

  • Page 84: Compressio N Spring

    SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 10. Use a flat head screwdriver to remove the E-ring. Press the adjusting lever to loosen the pin and then pull it out. 11. Remove the compression spring. Replace any defective part. Adjusting Lever Set E-Ring...
  • Page 85 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 12. Use a flat head screwdriver to remove the second E-ring and pin. E-Ring...
  • Page 86 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 13. Use a flat head screwdriver to remove the second E-ring and pin. Adjusting Lever Compression Spring E-Ring E-Ring...
  • Page 87 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 14. Use a Torx20 bit to loosen and remove the 3 screws securing the right decorate cover. Right Decorate Cover...
  • Page 88 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 15. Remove the right decorate cover to expose the connecting rod. It is secured on the support by E-ring and pin. Right Decorate Cover...

  • Page 89: Connecting Rod Assembly

    SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 16. Use a flat head screwdriver to remove the E ring and the pin. 17. Pull out the connecting spindle together with the connecting rod assembly. The spring can be removed from the positioner.
  • Page 90 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 18. Use a Torx20 bit to loosen and remove the 2 screws securing the support. Support...
  • Page 91 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 19. Use a 10mm socket wrench to loosen and remove the flange nut & bolt.
  • Page 92 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 20. Use a 19mm socket wrench to loosen and remove the nut & sleeve. NOTE: Use a pincer pliers to keep the sleeve from rotating with the nut.
  • Page 93 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 21. Detach the other side in the same way. Sleeve Bolt Flange Nut...
  • Page 94 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 22. Now the lower part of the handle assembly is completed disassembled.
  • Page 95 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 23. Take a closer look at the middle part (beam assembly) of the handle assembly.
  • Page 96 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 24. Use a Torx20 bit to loosen and remove the 13 screws securing the beam assembly.
  • Page 97 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 25. Use a Torx20 bit to loosen and remove the 13 screws securing the beam assembly. Handle- Beam locking Clamp Assembly...
  • Page 98 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 26. Use a Torx20 bit to loosen and remove the 13 screws securing the beam assembly. Locking Assembly...
  • Page 99 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 27. To take the locking clamp set from the beam assembly, detach the hook of the spring from the positioner. Locking clamp set inside the beam assembly...
  • Page 100 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 28. Now the locking clamp set can be removed from the beam assembly. Locking Clamp Set...
  • Page 101 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 29. There is a magnetic block inside the beam assembly as shown below. It is used for activate the hall sensor switch inside the left telescope tube assembly when fully extend the handle assembly. Please make sure it properly seated.
  • Page 102 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 30. The upper part of the handle assembly consists of the switch box assembly, the LED electric assembly and the self- propel handle set.
  • Page 103 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 31. Use a Torx20 bit to loosen and remove the 2 long hexagon socket screw from the Handle Assembly. Each bolt has a corresponding hex nut. Hexagon Socket Screw Hex Nut...
  • Page 104 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 32. Flip the handle assembly to remove the 11 screws on the switch box bottom housing.
  • Page 105 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 33. Open the switch box gently.
  • Page 106 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 34. Take a closer look at the wires and connectors position inside the switch box.
  • Page 107 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 35. Disconnect the connectors connecting the hall sensor (inside the left telescope tube assembly) to the LED electric assembly. 36. Disconnect the 2 connectors connecting the self-propel handle set to the LED electric assembly. Self-propel Handle Set Left Telescope...
  • Page 108 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 37. There is one magnetic block and one magnet ring on the wires from LED electric assembly connecting to the self-propel handle set (speed adjusting knob). Remove them from the wires. NOTE: They are protection against electromagnetic interference, but not related to any function.
  • Page 109 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 38. Disconnect the connectors connecting the bus wire harness (inside the right telescope tube assembly) to the LED electric assembly. Now all connectors to the LED electric assembly are disconnected. Right Telescope Tube Assembly...
  • Page 110 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 39. Use a Torx20 bit to loosen the 2 screws to release the switch actuator and the control handle set from the switch box. Replace any worn parts. Control Handle Spring Compression Spring...
  • Page 111 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 40. Move the switches out of the slots. 41. Locate the film switch connector. Disconnect it from the switch box assembly. Film Switch Connector...
  • Page 112 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 42. Use a Torx20 bit to loosen and remove the 2 screws as shown below. Now the LED electric assembly can be removed. LED Electric Assembly...
  • Page 113 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 43. Use a Torx20 bit to loosen and remove the 2 screws securing the switch box assembly. Switch Box Assembly (half)
  • Page 114 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 44. Detach the left/right telescope tube assembly from the self-propel handle set. Replace any part as needed. Right Telescope Tube Assembly Self-propel Handle Set Left Telescope Tube Assembly...
  • Page 115 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT  Take a closer look at the LED electric assembly. Links to the film switch Links to the Hall Sensor Switch Links to the handle set (Self-propelled control) Links to the bus wire harness assembly...
  • Page 116 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 45. To re-assemble, insert the left/right telescope tube assembly onto the self-propel handle set. 46. Properly place them together into the switch box assembly.
  • Page 117 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 47. Fasten the 2 screws to secure the left/right telescope tube assembly, the self-propel handle set and the switch box assembly (half).
  • Page 118 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 48. To reassemble the LED electric assembly onto the switch box assembly, pass all switches, wiring harness and connectors through the hole.
  • Page 119 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 49. Mount the LED electric assembly in place and secure with 2 screws as shown below.
  • Page 120 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 50. Re-connect the film switch. And arrange it into the slot as shown below.
  • Page 121 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 51. Place the two switches into the slot and properly arrange the wires as shown below.
  • Page 122 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT 52. Re-connect the connectors connecting the hall sensor (inside the left telescope tube assembly) to the LED electric assembly and arrange the wires into the slot as shown below.
  • Page 123 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Mount the magnetic block and magnet ring on the wires from LED electric assembly connecting to the self-propel handle set (speed adjusting knob). NOTE: The wire harness needs to be wound twice around the magnetic ring.
  • Page 124 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Properly place the connectors and wires connecting to the self-propel handle set. Re-connect the bus wire harness (inside the right telescope tube assembly) to the LED electric assembly and place it into the slot.
  • Page 125 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Now all connectors and wires should be re-connected and placed properly.
  • Page 126 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Pre-assemble the spring and the safety button and place them into the slot.
  • Page 127 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Place the compression spring into the slot. Assemble the control handle set with the switch actuator.
  • Page 128 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Place the control handle set with the switch actuator into the switch box assembly and makes sure that the pin is placed against the compression spring. Mount the clamp and secure with 2 screws.
  • Page 129 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Make a final check of the connectors and wires layout before closing the switch box assembly.
  • Page 130 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Close the switch box assembly and secure with 11 screws. Turn the handle around and secure with 2 bolts and nuts.
  • Page 131 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Depress the safety button and pull the bail switch to check if the switches act and rebound normally.
  • Page 132 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Move the spring on the locking clamp set into place.
  • Page 133 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Keep the spring in place and mount the locking clamp set into the beam assembly. Hook the spring onto the positioner of the beam assembly.
  • Page 134 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Place the magnetic block into the slot. Fully extend the handle.
  • Page 135 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Align the mounting holes on the handle tube with the positioners on the beam assembly and properly assemble them together.
  • Page 136 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Pre-assemble the locking assembly and place them onto the beam assembly as shown below.
  • Page 137 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Close the other half of the beam assembly and close the locking clamp set to better secure the beam assembly. Secure with 13 screws.
  • Page 138 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Fully extend the retract the side rails to check if the beam assembly can be locked as design.
  • Page 139 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Now what’s left is to re-assemble the lower part of the handle assembly. It’s basically the reverse order of disassembly. Re-assemble the spindle assembly with the fasteners as shown below.
  • Page 140 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Re-assemble the support, the connecting rod assembly and the connecting spindle as shown below. NOTE: Place the spring properly in place.
  • Page 141 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Re-assemble the adjusting lever set as shown below.
  • Page 142 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Re-assemble the adjusting lever set as shown below.
  • Page 143 SECTION C.05 PARTS IN HANDLE ASSY REPLACEMENT HANDLE ASSEMBLY REPLACEMENT Mount back the handle assembly in the reverse order as instructed in the front part of this section.
  • Page 144 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Before replacing the self-propelled unit, there are two connections needs to be released. One is the tension spring between the spring seat on the top cover assembly and the self-propelled unit. The other is the self-propelled motor wires connecting to the self-propelled PCBA going through the deck.
  • Page 145 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Open the battery box cover and loosen the 11 screws by using a T20 Torx bit to remove the service cover.
  • Page 146 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Locate and disconnect and self-propelled motor connector.
  • Page 147 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Secure the service cover (with one or two screws) to keep all the electrical assembly from falling off the deck. Then turn the mower over. Remove the rear wheels as instructed in “Wheel Replacement” section.
  • Page 148 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT The transmission parts of the self-propelled unit can be replaced without taken the whole self-propelled unit off the deck. Use a flat head screwdriver to remove the e-ring, and the rest can be removed with no issue. E-ring Transmission Assembly...
  • Page 149 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Remove the e-ring, washer, spring, small gear and gasket.
  • Page 150 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT The transmission parts are as shown below. Spring Clamp washer Rubber gasket Plain washer E ring Clutch gear...
  • Page 151 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Re-assemble the transmission parts in the reverse order: place back the gasket, then the small gear as shown below.
  • Page 152 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT 10. Place back the spring, two washers (smaller one under the big one) and secure with the e-ring, as shown below.
  • Page 153 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT 11. The trail shield can be replaced if needed. Use a Torx20 bit to loosen and remove the 3 screws. Trail Shield Bevel Support...
  • Page 154 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT 12. Adjust the cutting-height to the largest position to less stretch the tension spring. Stretch the tension spring with a hook to release it from the self-propelled unit as shown below. Largest cutting- height setting Tension Spring...
  • Page 155 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT 13. Use a Torx20 bit to loosen and remove the 6 screws as shown below.
  • Page 156 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT 14. Gently lift the self-propelled unit from the deck to make room to use a 3/8” open-ended spanner to loosen and remove the nut connecting the self-propelled unit to the connecting rod assembly, as shown below.
  • Page 157 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Disengage the self-propelled unit from the connecting rod assembly. Lift the self-propelled unit away from the deck. NOTE: Be careful not to over-stretch the self-propel motor wires.
  • Page 158 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT The self-propelled unit is as shown below. Self-propelled Unit...
  • Page 159 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT The self-propelled unit can be further disassembled to replace inner parts, as needed.
  • Page 160 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Use a Torx T20 bit to loosen the 2 screws. The support can be taken off. Support...
  • Page 161 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Use a PH1 bit to loosen the 2 small screws. Use a Torx T20 bit to loosen the other screw. Then gently detach the dust cover from the other one. Dust Cover...
  • Page 162 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Use a Torx T20 bit to loosen the 2 screws for securing the motor & gear assembly. The motor & gear assembly and the earth plate can be removed. Earth Plate Motor & Gear Assembly...
  • Page 163 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Use a Torx20 bit to loosen the screw and remove the other dust cover. Dust Cover...
  • Page 164 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT To open the gear box, use a Torx20 bit to loosen and remove the 5 screws. Use long screw here...
  • Page 165 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Now the gear box can be opened.
  • Page 166 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT The gear set can be replaced. Gear Set...
  • Page 167 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Here are the disassembled parts from the self-propelled unit. Gear Set Dust Cover Support Dust Cover Motor & Gear Earth Plate Assembly...
  • Page 168 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT To re-assemble, place the gear set into the gear box and close it. Secure the gear box with 5 screws. Use long screw here Gear Set...
  • Page 169 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Place the motor & gear assembly back and secure it with 2 screws. NOTE: Make sure that the motor gear meshing inside the gear set. And the earth plate has been secured at the motor side as well.
  • Page 170 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Mount the two dust covers back.
  • Page 171 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Mount the support back and arrange the self-propelled motor wires into the slot. Now the self-propelled unit is re- assembled.
  • Page 172 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Lift the self-propelled unit above the mower.
  • Page 173 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Pass the self-propelled motor wires connector through the deck. Connect the self-propelled unit with the connecting rod assembly, as shown below.
  • Page 174 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Secure the connection with a nut. And properly mount the self-propelled unit onto the deck.
  • Page 175 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Secure the self-propelled unit with 6 screws. NOTE: Secure the earth plate on the support side as well.
  • Page 176 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Hook the tension spring back onto the self-propelled unit. NOTE: Adjust the cutting height to make the self-propelled hooking plate at a desired angle for assembling.
  • Page 177 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Assemble the trail shield with the bevel supports and secure them with 3 screws.
  • Page 178 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Assemble the rear wheels as instructed in “Wheel Replacement” section.
  • Page 179 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Turn the mower back and open the service cover. Re-connect the self-propelled motor wires connector. And place it into the slot.
  • Page 180 SECTION C.06 SELF-PROPELLED UNIT REPLACEMENT Close the service cover, and secure with 11 screws by using a T20 bit.
  • Page 181 SECTION C.07 BLADE MOTOR REPLACEMENT Remove the top cover assembly refer to “TOP COVER ASSEMBLY REPLACEMENT” section. Remove the blade motor by using a 10mm socket wrench to loosen and remove the 3 bolt and washer sets Blade Motor Blot and Washer Set...
  • Page 182 SECTION C.07 BLADE MOTOR REPLACEMENT To reassemble the blade motor, place the motor onto the motor support. There is a positioner here to help locate. Tighten the 3 bolts to secure the blade motor in place. Note: During this process, there is a risk of blade motor dropping. It should be supported by someone or something. Install the top cover assembly refer to “TOP COVER ASSEMBLY REPLACEMENT”...
  • Page 183 SECTION C.08 FRONT AXEL REPLACEMENT Remove the top cover assembly refer to “TOP COVER ASSEMBLY REPLACEMENT” section.
  • Page 184 SECTION C.08 FRONT AXEL REPLACEMENT Use a 10mm socket wrench to loosen and remove the nut. Then separate the front axle and the connecting rod assembly. Front Axle...
  • Page 185 SECTION C.08 FRONT AXEL REPLACEMENT Once the front axle is separated from the connecting rod assembly, it can be replaced by loosening the 2 screws securing the mounting plate. Mounting Plate...
  • Page 186 SECTION C.08 FRONT AXEL REPLACEMENT Replace any parts as needed. Front Wheel Front Axle Set Wheel Hub Cover Locking Mounting Wave bolt Plate Washer...
  • Page 187 SECTION C.08 FRONT AXEL REPLACEMENT Remove the E-ring. Then the plain washer and pin shaft can be taken off. E-Ring Plain Washer Pin Shaft...
  • Page 188 SECTION C.08 FRONT AXEL REPLACEMENT Use a 3/8” open-ended spanner to loosen and remove the nut connecting the rear axle with the connecting rod assembly.
  • Page 189 SECTION C.08 FRONT AXEL REPLACEMENT Now the connecting rod assembly can be removed and replaced. Connecting Rod Assembly...
  • Page 190 SECTION C.08 FRONT AXEL REPLACEMENT Use a Torx20 bit to loosen and remove the 4 screws securing the adjust handle set. Adjust Mounting Handle Set Plate...
  • Page 191 SECTION C.08 FRONT AXEL REPLACEMENT To re-assemble, place the adjust handle set into the slot as shown below. 10. Secure the two mounting plates.
  • Page 192 SECTION C.08 FRONT AXEL REPLACEMENT Before placing back the connecting rod assembly, make sure that the lower side is connecting to the front axle and the higher side is connecting to the rear axle, as shown below. NOTE: The cutting height can’t be adjusted if the connecting rod assembly is mounted incorrectly. Higher Side Lower Side...
  • Page 193 SECTION C.08 FRONT AXEL REPLACEMENT Assemble the rear axle with the connecting rod assembly. Finger tight the nut and fasten it with a 3/8” open-ended spanner.
  • Page 194 SECTION C.08 FRONT AXEL REPLACEMENT Align the hole in the connecting rod assembly with the one of the adjust handle set. Insert the pin shaft, mount the plain washer and lock them with E-ring.
  • Page 195 SECTION C.08 FRONT AXEL REPLACEMENT Assemble the front axle with the connecting rod assembly. Finger tight the nut and fasten it with a 3/8” socket wrench.
  • Page 196 SECTION C.08 FRONT AXEL REPLACEMENT Move the cutting-height adjusting rod back and forth to check if the deck will raise and lower accordingly (before re- assemble the top cover assembly). Install the top cover assembly refer to “TOP COVER ASSEMBLY REPLACEMENT” section.
  • Page 197 SECTION C.09 REAR COVER REPLACEMENT To replace the supporting plate or rear cover, the handle assembly needs to be removed first. Remove the handle assembly from the mower as instructed in “Handle Assembly Replacement” section.
  • Page 198 SECTION C.09 REAR COVER REPLACEMENT Take a closer look: the rear cover assembly is between the left/right supporting plate. So one supporting plate needs to be removed before the rear cover can be removed.
  • Page 199 SECTION C.09 REAR COVER REPLACEMENT The bottom board is easy to replace. Use a Torx20 bit to loosen the 2 screws. Bottom Board...
  • Page 200 SECTION C.09 REAR COVER REPLACEMENT Use a Torx20 bit to loosen the 3 screws and remove the right supporting plate. Right Supporting Plate...
  • Page 201 SECTION C.09 REAR COVER REPLACEMENT After one supporting plate is removed, the rear cover can be replaced. Pull out the shaft to take the rear cover off the deck. Shaft...
  • Page 202 SECTION C.09 REAR COVER REPLACEMENT Remove the left supporting plate and replace any parts as needed. Shaft Torsion Spring Rear Cover...
  • Page 203 SECTION C.09 REAR COVER REPLACEMENT Pre-assemble the torsion spring with the rear cover as shown below. NOTE: Short pin in the slot.
  • Page 204 SECTION C.09 REAR COVER REPLACEMENT Mount the rear cover back to the deck. NOTE: The torsion spring pin should be in place as shown below. Insert the shaft.
  • Page 205 SECTION C.09 REAR COVER REPLACEMENT Reassemble the left / right supporting plate and then the handle assembly in the reverse order.