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CAUTION Repair the machine in accordance with "Instruction manual" or "Safety instructions". Follow the instructions described below in advance before repairing: Wear gloves. In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what the parts are. It is also recommended to have boxes ready to keep disassembled parts by group.
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REPAIR Disassembling 4-1-1 Body section Fig. 1 Remove Tapping screws PB3.5x14 [1] (6 pcs), then remove Rear base [2] from Front base. Fig. 2 Remove Tapping screws PB3.5x14 [1] (2 pcs), then remove Cable cover [3] from Front base [2]. Fig.
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Fig. 4 Remove Legs [3] (3 pcs) from Handle set [2] by 1R479 tapping Pins [1] (3 pcs) with 1R461 and 1R479. 1R461 Fig. 5 Remove Tapping screws PB3.5x14 [1] (6 pcs), then remove Front base [3] from Body section [2]. Disconnect Connector [4].
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Fig. 8 Remove Release button [2] from Handle set [1]. Remove the following parts from Release button [2]: Pin [3] Spring [4] Latch [5] Fig. 9 Remove Screw PM5.0x30 [1], then remove the following parts from Base [2]: ...
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Fig. 12 Remove Tapping screws PB3.5x14 [1] (6 pcs), then remove Handle [3] from Handle supporter [2]. Fig. 13 Remove Tapping screws CB4.0x20 [1] (6 pcs), then remove Handle supporters [3] (3 pcs) from Lamp housing [2]. Fig. 14 Remove Screw PM4.0x38 [1], then remove the following parts from Pole clamp B [2]: ...
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Fig. 16 Pull out Pole B [2] from Body [1]. Remove Sleeve L [3] and Sleeve R [4] from Pole B [2]. Fig. 17 Remove Screw PM4.0x38 [1], then remove the following parts from Pole clamp A [2]: Spring [3] ...
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Fig. 19 Pull out Pole A [2] from Body [1]. Remove Pole sleeve [3] from Pole A [2]. Fig. 20 Remove Tapping screws PB3.5x14 [1] (6 pcs), then pull out Body [3] from Battery holder [2]. 4-1-2 Lamp housing section Fig.
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4-1-3 Electrical parts section Fig. 23 Remove Tapping screws PB3.5x14 [1] (13 pcs), then remove Housing cover [3] from Battery housing [2]. Fig. 24 Remove Power key [2] and Mode key [3] from Housing cover [1]. Fig. 25 Remove Tapping screws PWB3x8 [1] (2 pcs), then remove Battery cover [3] from Battery housing [2].
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Fig. 26 Remove Gasket [2] from Battery housing [1]. Fig. 27 Remove Tapping screws PB3.5x14 [1] (2 pcs), then remove Cord clamp [3] from Battery housing [2]. Fig. 28 Remove Tapping screws PB3x8 [1] (4 pcs), then remove Key PCBAs [3] (2 pcs) from Battery housing [2].
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Fig. 30 Remove Push plate [2] and Springs [3] (2 pcs) from Battery housing [1]. Fig. 31 Remove Tapping screws PB3x8 [1] (4 pcs), then remove Heatsink [3] from Main board [2]. Fig. 32 Remove Gasket [2] from PCBA box [1]. Remove Tapping screws PB3x8 [3] (2 pcs), then remove Main board [4] and Cable [5] from PCBA box [1].
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Assembling 4-2-1 Electrical parts section Fig. 34 Pass Cable through PCBA box [1]. Assemble Connectors [2] to Main board [3]. Fig. 35 Assemble Main board [2] and Cable [3] to PCBA box [1], then tighten Tapping screws PB3x8 [4] (2 pcs).
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Fig. 38 Assemble Gasket [2] to Battery housing [1]. Fig. 39 Assemble Main board [2] to Battery housing [1]. Assemble Key PCBAs [3] (2 pcs) to Battery housing [1] with Tapping screws PB3x8 [4] (4 pcs). Note Be careful with the mark of Key PCBAs [3] (2 pcs) of Battery housing [1].
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Fig. 42 Assemble Torsion springs [2] (2 pcs) to Battery cover [1] with Tapping screws PWB3x8 [3] (2 pcs). Assemble Battery cover [1] to Battery housing [4]. Note Hook Torsion spring [2] in the notch of Battery housing [4]. Fig. 43 Assemble Power key [2] and Mode key [3] to Battery housing [1].
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4-2-2 Lamp housing section Fig. 45 Assemble the following parts to Base [1] with Screws PW5.0x12 [2] (2 pcs): Flat washers [3] (4 pcs) Square washers [4] (2 pcs) Spring washers [5] (2 pcs) Flat washers [6] (2 pcs) Fig.
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Assembling Body section Fig. 47 Pass Cable [1] through Cable holder of Housing cover [2] with 1R411, then assemble them to the notch of Body [3]. Fig. 48 Assemble Body [2] to Battery housing [1] with Tapping screws PB3.5x14 [3] (6 pcs). Fig.
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Fig. 50 Assemble Bush A [2] and Ring [3] to Pole A [1] with 1R362. 1R362 Assemble Pole clamp A [4] to Pole A [1] with 1R362. 1R362 Fig. 51 Push Pole clamp A [1] into Battery housing [2] with 1R362.
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Fig. 53 Assemble Sleeve L [2] and Sleeve R [3] to Pole B [1]. Insert Pole B [1] into Body [4]. Tips Align the notch of Pole B [1] with the protrusion of Sleeve L [2] and Sleeve R [3]. Fig.
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Fig. 56 Assemble Nut M4 [2] to Pole clamp B [1], then tighten Screw PM4.0x16 [3]. Assemble Pin [5] and Screw PM4.0x38 [6] to Clamp [4]. Assemble Clamp [4] to Pole clamp B [1]. Assemble Spring [7] and Lock nut [8] to Pole clamp B [1], then tighten Screw PM4.0x38 [6].
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Fig. 60 Assemble LED cable B [2] and Pole cover [3] to Body section [1], then tighten Tapping screws PB3.5x14 [4] (4 pcs). Note Be careful with the shape of Pole cover [3] and LED cable B [2]. Fig. 61 Assemble Lamp housing section [2] to Body section [1].
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Fig. 63 Assemble Handle set [1] with Tapping screws PB3.5x14 [2] (11 pcs). Fig. 64 Push Release button [1] and insert Handle set [3] into Body section [2]. Fig. 65 Pass LED cable B [1] through Front base [2]. Note Be careful with the tension of LED cable B [1].
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Fig. 66 Assemble Rear foot L [2] to Front base [1], then put Connector [3] into Rear foot L [2]. Assemble Cable cover [4] to Rear foot L [2]. Assemble Cord clamp [5] to Front base [1]. Tighten Tapping screws PB3.5x14 [6] (6 pcs). Fig.
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WIRING DIAGRAM Fig. 69 KEY PCBA DML813 For MODE MAIN BOARD PCBA KEY PCBA For ON/OFF Fig. 70 KEY PCBA DML814 For MODE MAIN BOARD PCBA PCBA KEY PCBA For ON/OFF PCBA 24 / 25...
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TROUBLESHOOTING Change: KEY PCBA When Worklight does MAIN BOARD not power on. CABLE Change: LED ASSEMBLY/HEATSINK When LED does not light COMPLETE up completely. MAIN BOARD LED CABLE/COILED CABLE Change: MAIN BOARD When LED blinks. LED CABLE/COILED CABLE Change: The mode of KEY PCBA Worklight cannot be MAIN BOARD...
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