background image

Ball 

bearing 

696ZZ

1. Remove four M4x14 Pan head screws,

    and then separate Bearing box from

    Gear housing.

(1) Remove Ball bearing 696ZZ and Ring spring 11 from Spindle as drawn in 

Fig. 6

.

(2) Remove Spindle, Spiral bevel gear 37, Ball bearing 6201DDW etc. as drawn in 

Fig. 7

.

2. Remove Ball bearing 

    696ZZ with 1R269.

3. While opening the gap of Ring spring 11

    with 1R004 or 1R291, lever up the opposite 

    carefully with Slotted screwdriver.

    Ring spring 11 is removed from Spindle.

   

DISASSEMBLING

Fig. 6

Fig. 7

1R269

Ring spring 11

1R004 or 1R291

1. Receive Bearing box on 1R258.

    Provide an impact to Spindle carefully with

    Arbor press so that Arbor press does not touch 

    Spiral bevel gear 37 and Spindle sinks slightly. 

2. Press down Spindle with

    1R280. 

1R258

1R258

Note

: Be careful not to put the following 

           portions onto 1R258.

  * Protruded portion of Bearing box

  * Labyrinth ring of Spindle

3. Spindle and Spiral bevel gear 37

    are removed.

4. Remove Retaining ring R-32 with 

    1R291 from the groove in Bearing box.

5. Turn Bearing box upside down, and

    press down Ball bearing 6201DDW

    from Bearing box with 1R027. 

6. Flat washer 12 is removed

    from Bearing box.

Spindle

Spindle

Labyrinth

ring

Flat washer 12

Spiral bevel gear 37

Bearing box

Ball bearing 

6201DDW

Ball bearing 

6201DDW

(in Bearing box)

P 5/ 11

Slotted screwdriver

Retaining

ring R-32

Groove of

Bearing box

1R027

Small hole of Bearing box

1R280

7. Be careful about each position and the direction of Labyrinth ring

Note

: When Spindle is removed from Spiral bevel gear 37, Ball bearing 6201DDW has a damage during the removal

           process. Therefore, replace Ball bearing 6201DDW with a new one.   

Spindle Labyrinth ring

M4x14 Pan head

screw (4 pcs.)

Bearing box

Ball bearing

6201DDW

O ring 45

Ball bearing 696ZZ

Flat washer 12

Ring spring 11

Spiral bevel gear 37

Retaining ring

R-32

Gear housing

Bearing box
M4x14 Pan head 

screw (4 pcs.)

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Spiral bevel gear 37, Ball bearing 696ZZ / 6201DDW

R

epair

Summary of Contents for DGA405

Page 1: ...ergy capacity Wh 27 36 54 72 90 Charging time approx min 15 24 22 36 45 with DC18RC Wheel size mm Hole diameter 6 1 4 Max thickness Diameter 100 4 16 5 8 22 23 7 8 8 500 No Yes Yes Yes Yes Yes Paddle...

Page 2: ...bevel gear 37 to Spindle supporting Spindle when assembling Spiral bevel gear 37 to Spindle disassembling Rotor from Gear housing cover supporting Bearing box when removing Spindle from Spiral bevel...

Page 3: ...d hand turn M6 Hex nut counterclockwise with Wrench 10 Then remove Spiral bevel gear 10 4 Hook the jaws of 1R045 with Gear housing cover then push out Rotor ass y In this step Ball bearing 629LLB stil...

Page 4: ...cure the gear by turning M6 Hex nut clockwise with Wrench 10 Keep enough distance between Rotors so that they are out of their magnetic forces each other ASSEMBLING Spiral bevel gear 10 M6 Hex nut Fig...

Page 5: ...Spindle and Spiral bevel gear 37 are removed 4 Remove Retaining ring R 32 with 1R291 from the groove in Bearing box 5 Turn Bearing box upside down and press down Ball bearing 6201DDW from Bearing box...

Page 6: ...gear 37 Bearing box 1R029 1R036 Ball bearing 696ZZ Ring spring 11 3 Apply 1R268 to Shoulder pin 4 through the small hole on Pin cap and tap 1R268 with Metal hammer Shoulder pin 4 is removed from Gear...

Page 7: ...tor complete Assemble Stator complete as drawn in Fig 13 3 DISASSEMBLY ASSEMBLY 3 4 Stator complete ASSEMBLING Mating cavity on the left side and the right side tow each Terminal of Stator complete Ce...

Page 8: ...ace the broken wire s Lead wires are broken Check Lead wires or replace the broken wire s Rotor ass y is broken Stator complete is broken Switch is broken Replace Switch Terminal is broken a Mode lamp...

Page 9: ...everse attachment could spoil the test Wait until the display shows the value without fluctuation Terminal Terminal Insulating tape Switch lever complete black bar red bar P 9 11 1 Set Digital tester...

Page 10: ...and fasten the plate with the M3 5 screw of Switch Switch unit Tape Terminal Connector AWG24 AWG24 AWG28 AWG14 AWG28 AWG22 AWG14 AWG14 AWG14 Controller Line filter if used Stator P 10 11 Circuit diagr...

Page 11: ...Switch Route lead wires red yellow black of Terminal between Rib E and Rib F Put Line filter between Rib G and Rib H P 11 11 Wiring diagram Bend thick lead wires orange white blue of Controller here s...

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