GreenWorks 7402802 Manuals

Manuals and User Guides for GreenWorks 7402802. We have 1 GreenWorks 7402802 manual available for free PDF download: Service Manual

GreenWorks 7402802 Service Manual

GreenWorks 7402802 Service Manual (231 pages)

Brand: GreenWorks | Category: Utility Vehicle | Size: 14 MB

Table of Contents

Table of Contents
3
Chapter 1 General Information

9
- Cautions and Notes
  9
- Description
  10
- Identification Code
  11
- Safety
  12
- Operator Safety
  12
- Battery Safety
  15
- Cleaning Parts
  16
- Warning Labels
  16
- Serial Numbers
  16
- Fasteners
  16
- Torque Specifications
  17
- Self-Locking Fasteners
  17
- Washers
  17
- Cotter Pins
  17
- Snap Rings and E-Clips
  18
- Shop Sipplies
  19
- Lubricants and Fluids
  19
- Greases
  19
- Brake Fluid
  19
- Cleaners, Degreasers and Solvents
  19
- Gasket Sealant
  20
- Gasket Remover
  20
- Thread Locking Compound
  20
- Basic Tools
  20
- Screwdrivers
  21
- Wrenches
  21
- Adjustable Wrenches
  22
- Socket Wrenches, Ratchets and Handles
  22
- Impact Drivers
  23
- Allen Wrenches
  24
- Torque Wrenches
  24
- Torque Adapters
  24
- Pliers
  26
- Snap Ring Pliers
  26
- Hammers
  27
- Precision Measuring Tools
  27
- Dial Indicator
  27
- Insulation Tester
  27
- Multimeter
  28
- Ohmmeter (Analog) Calibration
  28
- Clip-On Ammeter
  29
- Electrical System Fundamentals
  30
- Voltage
  30
- Resistance
  30
- Amperage
  30
- Basic Service Methods
  31
- Removing Frozen Fasteners
  32
- Removing Broken Fasteners
  32
- Repairing Damaged Threads
  33
- Stud Removal/Installation
  33
- Removing Hoses
  34
- Bearings
  34
- Removal
  34
- Installation
  35
- Interference Fit
  36
- Seal Replacement
  37
- Basic Driving and Operating Methods
  38
- Proper Driving Methods
  38
- Operation before Leaving the EV
  40
- Motor Braking Function
  41
- Daily Safe Checking
  42
- Daily Safe Checking Items
  42
- Performance Checking Items
  43
- Maintence and Adjustment of the Ev
  44
- Periodic Service Schedule
  45
- Periodic Lubrication Schedules
  46
- Diagram of Regular Lubricant Points
  46
- The Storage and Cleaning
  46
- Cleaning
  46
- Storage
  47
- Important Electrical Components
  48
- Motor and Controller
  48
- Battery
  48
- Battery Charger
  48
- Charging Batteries
  49
- Charging Quantity Indicator
  50
- Charging Heating Strategy
  51
- Discharge Heating Strategy
  51
- Plug and Receptacle
  51
- Storage
  52
- Storage Area Selection
  52
- Preparing the EV for Storage
  52
- Returning the EV to Service
  52
- Troubleshooting
  53
- Electrical Testing
  54
- Preliminary Checks and Precautions
  54
- Intermittent Problems
  54
- Electrical Component Replacement
  55
- Test Equipment
  55
- Ammeter
  56
- Self-Powered Test Light
  56
- Ohmmeter
  56
- Insulation Tester
  57
- Jumper Wire
  57
- Test Procedures
  58
- Voltage Drop Test
  58
- Continuity Test
  59
- Testing for a Short with Self-Powered Test Light or Ohmmeter
  59
- Testing for a Short with Test Light or Voltmeter
  60
- Brake System
  60
- Soft or Spongy Brake Lever or Pedal
  60
- Brake Drag
  61
- Hard Brake Lever or Pedal Operation
  61
- Brake Grabs
  62
- Brake Squeal or Chatter
  62
- Leaking Brake Caliper
  62
- Leaking Master Cylinder
  62
Chapter 2 Specifications

63
- Conversion Table
  63
- Definition of Unit
  63
- Vehicle Specifications
  64
- Chassis Specifications
  66
- System Electrical Specifications
  67
- Lubrication Points and Lubricant Types
  70
Chapter 3 Maintence and Adjustment of the Ev

71
Chapter 4 Motor and Driving System

95
Chapter 5 Malfunction Inspection

111
- Panel and Cargo Bed
  114
- Direction System
  133
- Brake System
  143
- Wheel and Tire Parts
  155
- Transmission System
  160
- Suspension
  182
- Electrical Part
  192
- Bumper
  196
- Seat
  198
Chapter 6 Battery and Charger

201
- Batteries
  201
- Battery Handling Precautions
  201
- Number of Battery Cycles
  201
- Ambient Temperature Implications on Battery
  202
- Charger Operation
  202
- Battery Operation Range
  203
- Maintenance
  203
Chapter 7 Electrical System Malfunction Inspection

209
- Electrical Components
  209
- Charging System
  213
- Lighting System
  214
- Signaling System
  217
- 2Wd/4Wd Selecting System
  223
Chapter 8 Troubleshooting

226
- Body Parts and Protection Parts
  226
- Braking System
  226
- Electrical System
  227
- Running System
  228
- Electromotor Drive System
  229
- Faulty Brake
  230
- Shock Absorber Malfunction
  230
- Unstable Handling
  230
- Lighting System
  231

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