Allen 38021 User manual

Diamond Head Grinder

OPERATIONS

PARTS MANUAL

BOOK

MMOO

OODD

DDEE

EELL

11 HP

1 HP Honda D.H.G

Honda D.H.G

9 HP

9 HP Kawasaki D.H.G

Kawasaki D.H.G # 038021

# 038021

# 032787

THIS MANUAL COVERS MACHINES BELOW

Printed 5/02

Diamond Head Grinder

OPERATIONS

PARTS MANUAL

BOOK

MMOO

OODD

DDEE

EELL

11 HP

1 HP Honda D.H.G

Honda D.H.G

9 HP

9 HP Kawasaki D.H.G

Kawasaki D.H.G # 038021

# 038021

# 032787

THIS MANUAL COVERS MACHINES BELOW

Printed 5/02

2002 - 2003 LIMITED W

2002 - 2003 LIMITED WARRANTY

ARRANTY

Allen Engineering Corporation warrants its products to be free of defects in material or workmanship for the fol-

lowing periods:

A. All New Machines and Part 6 Months

B. All New Gear Boxes 2 Years

C. All Factory Reconditioned Gear Boxes 1 Year

Warranty period begins on first day of use by End User. This first day of use is established by a completed war-

ranty card or a Bill of Sale to the end user. All warranty is based on the following limited warranty terms and

conditions.

1. Allen Engineering Corporation’s obligation and liability under this warranty is limited to repairing or replac-

ing parts if, after Allen’s inspection, it is determined to be a defect in material or workmanship. Allen

Engineering Corporation reserves the choice to repair or replace.

2. If Allen Engineering Corporation chooses to replace the part, it will be at no cost to the customer and will

be made available to the Distributor/Dealer from whom the customer purchased the product.

3. Replacement or repair parts, installed in the product, are warranted only for the remainder of warranty peri-

od of the product as though they were the original parts.

4. Allen Engineering Corporation’s warranty applies only to the products that are manufactured by Allen

Engineering and does not cover component parts such as engines and clutches. Allen Engineering

Corporation DOES NOT warranty clutches. Engine warranty claims should be made directly to an author-

ized factory service center for the particular engine make.

5. Allen Engineering Corporation’s warranty does not cover the normal maintenance of products or its compo-

nents (such as engine tune-ups and oil changes). The warranty also does not cover normal wear and tear

items (such as belts and consumables).

6. Allen Engineering Corporation’s warranty will be void if it is determined that the defect resulted from opera-

tor abuse, failure to perform normal maintenance on the product, modification to product, alterations or

repairs made to the product without the written approval of Allen Engineering Corporation. Allen

Engineering Corporation specifically excludes from warranty any damage to any trowels resulting from an

impact to the rotors. Allen Engineering Corporation also excludes from warranty any failure of clutches on

any engine driven piece of equipment.

7. If a new gear box has a factory defect within the first year of use, Allen Engineering Corporation will either

repair the gear box or replace it with a new gear box. If a new gearbox has a factory defect in the second

year of use, Allen Engineering Corporation will either repair it or replace it with a factory reconditioned gear

box. Impact damage is NOT covered under the gear box warranty.

8. Allen engineering Corporation will pay shop labor repair on warranty at the Allen Engineering Shop Labor

Rate in existence on the date of the warranty claim. An Allen Engineering Labor Chart will determine the

time allowed to complete a repair and will govern the shop labor hours that will be allowed.

9. Allen Engineering Corporation will pay freight on warranty replacement parts at Worldwide standard ground

rates. No warranty replacement parts will be shipped air freight at the expense of Allen Engineering

Corporation. Allen Engineering only pays outbound freight charges when sending warranty replacement

parts to the customer VIA ground service. Allen Engineering does not pay any inbound freight, however, if

Allen Engineering determines this to be warranty defect only then will Allen Engineering reimburse the cus-

tomer for inbound freight at standard ground rates.

10. Allen Engineering Corporation’s warranty policy WILL NOT COVER the following; taxes, shop supplies,

environmental surcharges, air freight, travel time, loss of rental revenue, or any other charges whatsoever

or any liabilities for direct, incidental, or consequential damage or delay.

11. Allen Engineering Corporation makes no other warranty, expressed or implied. This limited war-

ranty is in lieu of the warranty of merchantability and fitness. There are no other warranties that

extend beyond the description on this document.

12. No Allen Engineering Corporation employee or representative is authorized to change this warranty in any

way or grant any other warranty unless such change is made in writing and signed by an officer of Allen

Engineering Corporation. 1A-1

OPERATIONS

IDENTIFICATION PLATE

An identification plate listing the Model Number and Serial Number is attached to each unit and is located on the lower

right side of the rear panel on the mainframe. The plate should not be removed.

Please record the information found on this plate below so it will be available should the identification plate become lost or

damaged . When ordering parts or requesting service information you will always be asked to specify the model number

and serial number of the unit.

Serial Number:

The serial number found on the identification

plate is a six digit number. The model number

identifies your machine and will ensure that you

receive the correct replacement parts.

123456

Production Sequence

Identification

Plate

Location

FILL IN FOR FUTURE REFERENCES

Model Number:___________________

Serial Number:___________________

Date Purchased:__________________

Purchased From:_________________

________________________________

1A-2

Model Number:

DHG 11HP

Diamond Head Grinder

11 Hp Honda

9 Hp Kawasaki

OPERATIONS Diamond Head Grinder Operating Information

TABLE OF CONTENTS

1.1 Safety Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-6

1.2 Laws Pertaining to Spark Arrestors . . . . . . . . . . . . . . . . . . . . . . . . .1A-6

1.3 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-7

1.4 Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-8

1.5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-8

1.6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-9

1.7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-10

1.8 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-10

1.9 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-10

1.10 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-11

1.11 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-12

1.12 Battery Jump Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-13

This machine is built with user safety in mind. However, it can present hazards if

improperly operated and serviced. Follow operating instructions carefully!

If you have any questions about operating or servicing this equipment please contact

your Allen Engineering Distributor or Allen Engineering Corp. Customer Service at 1-

800-643-0095 or 1-870-236-7751.

1A-3

OPERATIONS

Important Reminder

Complete any warranty requirements as specified by the engine manufacturer in their instructions found inside

the battery box.

Your engine is not manufactured by Allen Engineering Corp., and therefore is not covered under Allen

Engineering warranty.

Your engine manufacturer should be contacted if you wish to purchase a parts manual or a repair manual for

your engine.

Refer to enclosed owners engine manual for complete O&M instructions. See your battery manufacturer for

battery warranty.

Your Distributor

Your Distributor has Allen Engineering trained mechanics and original Allen Engineering replacement parts.

Always contact the Allen Engineering Distributor who sold you this machine for Allen Engineering Certified

repairs and replacement parts.

Place distributor information here for future reference.

DISTRIBUTOR NAME PHONE NUMBER

ADDRESS

CITY STATE ZIP

SALESMAN

ADDITIONAL INFORMATION

1A-4

OPERATIONS THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED UPON THE MACHINES

IN PRODUCTION AT THE TIME (BEGINNING WITH SERIAL NUMBER 040102) OF PUBLI-

CATION. ALLEN ENGINEERING RESERVES THE RIGHT TO CHANGEANY PORTION OF

THIS DOCUMENT WITHOUT NOTIFICATION.

Information Contained in This Manual

Ordering Parts

This manual contains an illustrated parts list for help in ordering replacement parts for your machine. Follow

the instructions listed below when ordering parts to ensure prompt and accurate delivery. All orders for parts

must be made through your local authorized Allen Engineering dealer. All authorized Allen Engineering deal-

ers must fax a copy of the parts order to customer service. The fax number is (870) 236-3934). Facsimile

orders must contain the following information:

1. On all orders for service parts include SERIAL NUMBER and MODEL number.

2. Shipment may be delayed if this information is not included.

3. Include correct description and part number from part section 2A.

4. State exact shipping instructions including preferred routing and complete destination

address. Also please indicate your preferred freight carrier. If no freight carrier is

indicated Allen Engineering reserves the right to ship the shipment the best way

possible. Once a shipment leaves Allen Engineering’s docks it becomes the

responsibility of the freight carrier to insure that it arrives at it’s intended

destination.

5. DO NOT return parts to Allen Engineering without receiving written authorized Customer

Service Report(CSR) from Allen Engineering. All authorized returns must bee shipped pre-

paid. All unauthorized returns will be shipped back to the addressee at their expense.

Keep this manual or a copy of it with the machine. If you loose this manual or need an additional copy

please contact your Allen distributor or Allen Engineering Corporation at (800) 643-0095 and order lit-

erature part number 042526.

Change Without Prior Notice.

This manual provides information and procedures to safely operate and maintain the Allen Engineering

Diamond Head Grinders.

For your own safety and protection from personal injury carefully read, understand and observe the safety

instructions described in this manual.

Always operate and maintain this machine in accordance with the instructions described in this manual. A well

maintained piece of equipment will provide many years of trouble free operation. This manual is divided into the

sections listed below.

1A-5

OPERATIONS 2A

PARTS

OPERATIONS

1.1 Safety Notes

This manual contains NOTES, CAUTIONS and WARNINGS which must be followed to reduce the possibility of

improper service damage to the equipment or personal injury. Read and follow all NOTES, CAUTIONS and

WARNINGS included in this manual.

NOTE Contains additional information important to a procedure.

CAUTION Provides information important to prevent errors which could damage machine or components.

WARNING Warns of conditions or practices which could lead to personal injury or death.

1.2 Laws Pertaining to Spark Arrestors

Notice: Some states require that in certain locations arrestors be used on internal combustion engines. Aspark

arrester is a device designed to prevent the discharge of spark or flames from the engine exhaust. It

is often required when operating equipment on forested land to prevent the risk of fires. Consult the

engine distributor or local authorities and make sure that you comply with regulations regarding spark

arrestors.

1A-6

OPERATIONS

1.3 Operating Safety

Familiarity and proper training are required for the safe operation of this equipment! Equipment operated prop-

erly or by untrained personnel can be dangerous! Read the operating instructions contained in both this man-

ual and the engine manual and familiarize yourself with the location and proper use of all controls.

Safety Precautions

1. Read operating and safety instructions before using the Diamond Head Grinder.

Operate the machine in accordance with the manufacturer's instructions.

2. Inspect your D.H.G. for damage or tampering that can sometimes occur

during shipping.

3. If damage is found file a claim with your carrier immediately! Mark freight bill of

lading as damaged shipment.

4. Do not operate D.H.G. if any guards have been removed or if the "safety

switch" is not operational.

5. Only trained personnel should be allowed to operate your D.H.G.

6. Do not attempt to fill fuel tank or oil sump while the engine is running. Allow engine to

cool before refueling.

7. Never attempt to operate the D.H.G. on steep inclined surfaces.

8. Do not use over the counter hardware to replace manufacturer's hardware.

9. WARNING: When operating machines with gas engines in confined areas. The

fumes MUST be ventilated!

10. Always wear safety goggles, ear protection, and gloves when operating the D.H.G.

1A-7

OPERATIONS

1.4 Service Safety

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and

properly over a long period of time, periodic maintenance and occasional repairs are necessary.

DO NOT attempt to clean or service machine while it is running. Rotating parts can cause severe injury.

DO NOT crank a flooded engine with the spark plug removed. Fuel trapped in the cylinder will squirt out the

spark plug opening.

DO NOT test for spark if engine is flooded or the smell of gasoline is present . A stray spark could ignite the

fumes.

DO NOT use gasoline or other types of fuels or flammable solvents to clean parts especially in

enclosed areas. Fumes from fuels and solvents can become explosive and can be hazardous to

your health.

ALWAYS operate machine with all safety devices and guards in place and in working order.

ALWAYS keep area around muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could

ignite such items starting a fire.

ALWAYS replace worn or damaged components with spare parts designed and recommended by ALLEN

ENGINEERING.

ALWAYS disconnect battery on machines before servicing to avoid accidental start-up.

ALWAYS use water when wet cutting.

ALWAYS make sure grinding disc is clear of the ground before starting engine.

1.5 Dimensions

26-1/2”

673 mm

45”

1143 mm

39”

991 mm

1A-8

OPERATIONS

1.6 Technical Data

Engine Make & Model Honda 11HP V340K

Rated Power . . . . . . . . . . . . . . . . . . . . . . . .HP (kW) . . . . . . . . . . . . . . . .11(8.20)

Piston Displacement . . . . . . . . . . . . . . . . . .cu. in. (cc) . . . . . . . . . . . . . . .20.6 (337)

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . .type . . . . . . . . . . . . . . . . . . . .Champion RC 12 YC

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .volts . . . . . . . . . . . . . . . . . . .12

Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . .gal. (L) . . . . . . . . . . . . . . . . .1 (3.785)

Engine Oil Capacity . . . . . . . . . . . . . . . . . . .US qt. (L) . . . . . . . . . . . . . . .2 (1.9)

Engine Lubrication . . . . . . . . . . . . . . . . . . . .Oil Grade . . . . . . . . . . . . . . .SAE10W30 SG SF/CC,CD

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lbs. (kg) . . . . . . . . . . . . . . . . .68.4 (31)

Engine Make & Model Kawasaki 9HP FC290V

Rated Power . . . . . . . . . . . . . . . . . . . . . . . .HP (kW) . . . . . . . . . . . . . . . .9(8.20)

Piston Displacement . . . . . . . . . . . . . . . . . .cu. in. (cc) . . . . . . . . . . . . . . .17.5 (286)

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . .type . . . . . . . . . . . . . . . . . . . .Champion RC 12 YC

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .volts . . . . . . . . . . . . . . . . . . .12

Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . .gal. (L) . . . . . . . . . . . . . . . . ..58 (2.2)

Engine Oil Capacity . . . . . . . . . . . . . . . . . . .US qt. (L) . . . . . . . . . . . . . . .1.2 (1.1)

Engine Lubrication . . . . . . . . . . . . . . . . . . . .Oil Grade . . . . . . . . . . . . . . .SAE10W30 SG SF/CC,CD

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lbs. (kg) . . . . . . . . . . . . . . . . .57.3 (26)

Machine Specifications D.H.G.

Length w/ Handle . . . . . . . . . . . . . . . . . . . . .in. (cm) . . . . . . . . . . . . . . . . .45 (114) Honda

Length w/ Handle . . . . . . . . . . . . . . . . . . . . .in. (cm) . . . . . . . . . . . . . . . . .40 (102) Kawasaki

Width w/ Handle . . . . . . . . . . . . . . . . . . . . . .in. (cm) . . . . . . . . . . . . . . . . .26½ (67)

Height at Handle . . . . . . . . . . . . . . . . . . . . .in. (cm) . . . . . . . . . . . . . . . . .39 (99)

Operating Weight . . . . . . . . . . . . . . . . . . . . .lbs. (kg) . . . . . . . . . . . . . . . . .264 (120) Honda

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lbs. (kg) . . . . . . . . . . . . . . . . .228 (103) Kawasaki

Electric Start . . . . . . . . . . . . . . . . . . . . . . . . .Honda . . . . . . . . . . . . . . . . . .Yes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kawasaki . . . . . . . . . . . . . . .No

Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Honda . . . . . . . . . . . . . . . . . .Yes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kawasaki . . . . . . . . . . . . . . .No

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . .RPM . . . . . . . . . . . . . . . . . . .3600

Max. Grinding Disc Speed (unloaded) . . . . .RPM . . . . . . . . . . . . . . . . . . .1710

1A-9

OPERATIONS

1.7 Description

The Razorback®Diamond Head Grinder is an aggressive grinding machine that will reduce concrete levels

and leave a smooth surface. Because concrete grinding usually involves penetrating into the aggregate, this

grinder’s heavy duty design and high horsepower will finish jobs faster than any other grinders. The 11HP

Honda Powered unit is equipped with electric start and a light. The Razorback®Diamond Head Grinder is

also available with a 9HP Kawasaki gasoline engine. Both models use a 10” diameter disc with 20 diamond

segments and are ideal for grinding bumps or high spots on floors, as well as areas along construction joints

that have curled. Its speed on these types of jobs is unsurpassed! Both models also feature a height adjust-

ment device that prevents over-cutting and a water hook-up to increase diamond disc life.

1.8 Before Starting

Remove spark plug lead on gas engine. Tilt the machine back onto its handle. Remove the four mounting bolts

and fit the grinding disc. Replace the four bolts and make sure they are tight. Lower machine back into an

upright position. Replace the spark plug lead. Before starting engine, check all oil levels and make sure filter

is clean.

Before starting D.H.G. check the following:

*Oil level in engine:

* Fuel level:

*Condition of diamond disc:

*Condition of all fasteners on disc:

*Grease machine daily:

1.9 Starting

Before starting trowel refer to pictures below for location and identification of controls.

1. Turn key to the start-position. immediately release key when engine starts. If after two or

three attempts the engine has not started push in choke. This will open the choke. Attempt to

start machine again. Allow engine to warm up before operating.

Caution: Operating the starter for more than 5 seconds can damage the starter or engine. If engine fails to

start release the switch and wait 10 seconds before operating starter again.

LIGHT SWITCH

KEY SWITCH

1A-10

CHOKE

OPERATIONS

1.10 Operating

Make sure that the foot pedal is fully depressed and locked into position before starting the engine. Connect

the water supply to the hose adaptor fitting if wet cutting. Start the engine, the grinding head will now rotate.

Turn on the water supply for wet cutting. Unlock the foot pedal and allow it to slowly travel up the slot in the

back of the machine. This lowers the grinding head into position. Adjust the height adjustment assembly at the

front of the machine to acquire the correct depth of cut. To utilize yourAllen Engineering Razorback®Diamond

Head Grinder to its fullest capacity the machine should be moved in an oscillating fashion. In other words,

move the machine backwards and forwards at the acquired depth until it doesn’t cut anymore, then move for-

ward. For example, if you want to cut 1/4” into the concrete, do not set the depth of the disc to cut all of this at

once. It is much easier on the operator and the machine to do a little at a time. In this case an 1/8” would be

good and make two passes.

1A-11

Oscillate Back and Forth

Disc Adjustment Knob

Turn clockwise to lower and

counter-clockwise to raise.

OPERATIONS

1.11 Periodic Maintenance Schedule

The chart below list basic machine and engine maintenance. Refer to engine manufacturer's Operation Manual

for additional information on engine maintenance. A copy of the engine Operator's Manual was supplied with

the machine when it was shipped.

DAILY EVERY 20 EVERY 50 EVERY 100 EVERY 300

HOURS HOURS HOURS HOURS

CHECK FUEL LEVEL X

INSPECT AIR FILTERS X

REPLACE AS NEEDED

CHECK AND TIGHTEN X

EXTERNAL HARDWARE

CHECK DRIVE BELTS X

CHECK VALVE CLEARANCE X

CHANGE ENGINE OIL X

REPLACE OIL FILTERS X

REPLACE SPARK PLUG X

CLEAN AIR FILTER X

GREASE HEAD BEARINGS X

1A-12

OPERATIONS

1A-13

1.12 Battery Jump Start Procedure

Occasionally it may be necessary to jump start a weak battery. If jump starting is necessary the following pro-

cedure is recommended to prevent starter damage, battery damage, and personal injury.

Warning: Jump starting a battery incorrectly can cause the battery to explode resulting in severe personal

injury or death. Do not smoke or allow any ignition sources near the battery and do not jump

start a frozen battery.

Warning: Electrical arcing can cause severe personal injury. Do not allow positive and negative cable ends

to touch.

1. Use a battery of the same voltage (12V) as is used with your engine.

3. Attach one end of the positive booster cable (red) to the positive (+) terminal of the booster battery. Attach

the other end of the terminal of your engine battery.

4. Attach one end of the negative booster cable (black) to the negative (-) terminal on the booster. Attach the

other end of the negative cable to your engine battery.

5. Jump starting in any other manner may result in damage to the battery or the electrical system.

Caution: Over cranking the engine can cause starter damage. Allow 5 minutes for starter to cool if

engaged for more than 15 seconds.

1A-1

PARTS

Diamond Head Grinder Parts Information

TABLE OF CONTENTS

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-1

2.1 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-2

2.2 Lower Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-3

2.3 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-4

2.4 Ball Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-5

2.5 Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-6

2.6 Drive Line Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-7

2.7 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-8

2.8 Water Adaptor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-8

This machine is built with user safety in mind. However, it can present hazards if

improperly operated and serviced. Follow operating instructions carefully!

If you have any questions about operating or servicing this equipment please contact

your Allen Engineering Distributor or Allen Engineering Corp. Customer Service at 1-

800-643-0095 or 1-870-236-7751.

PARTS 2.1 Frame Assembly

2A-2

ILL. PART # DESCRIPTION QTY.

1. . . . . . . . . . . . . . . . . . . . . .021325 . . . . . . . . .SUB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. . . . . . . . . . . . . . . . . . . . . .028396 . . . . . . . . .FOOT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. . . . . . . . . . . . . . . . . . . . . .021139 . . . . . . . . .RUBBER SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. . . . . . . . . . . . . . . . . . . . . .021140 . . . . . . . . .GRINDING HEAD GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. . . . . . . . . . . . . . . . . . . . . .039420 . . . . . . . . .PLATE, ELECTRIC ENGINE ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. . . . . . . . . . . . . . . . . . . . . .021135 . . . . . . . . .HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. . . . . . . . . . . . . . . . . . . . . .021111 . . . . . . . . .FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. . . . . . . . . . . . . . . . . . . . . .036429 . . . . . . . . .BRACKET, WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. . . . . . . . . . . . . . . . . . . . . .021141 . . . . . . . . .DRIVE GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. . . . . . . . . . . . . . . . . . . . .038071 . . . . . . . . .BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. . . . . . . . . . . . . . . . . . . . .021130 . . . . . . . . .SECOND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. . . . . . . . . . . . . . . . . . . . .021143 . . . . . . . . .FIRST WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. . . . . . . . . . . . . . . . . . . . .019295 . . . . . . . . .BATTERY, 12 VOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. . . . . . . . . . . . . . . . . . . . .038075 . . . . . . . . .BATTERY STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15. . . . . . . . . . . . . . . . . . . . .029388 . . . . . . . . .RUBBER LATCH CLAMP ASSEMBLY (NOT SHOWN) . . . . . . . . . . . . . . . . . . .1

16. . . . . . . . . . . . . . . . . . . . .024981 . . . . . . . . .SPRING, FOOT PLATE (NOT SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. . . . . . . . . . . . . . . . . . . . .099297 . . . . . . . . .ROLL PIN, 5/16 x 2-1/2 (NOT SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18. . . . . . . . . . . . . . . . . . . . .038118 . . . . . . . . .MOTOR MOUNT BOLT (NOT SHOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2A-3

PARTS

2.2 Lower Unit Assembly

ILL. PART # DESCRIPTION QTY.

1. . . . . . . . .028399 . . . . . . .DIAMOND DISC . . . . . . . . . . . . . . . . .1

2. . . . . . . . .021105 . . . . . . .DRIVE PLATE . . . . . . . . . . . . . . . . . .1

3. . . . . . . . .037531 . . . . . . .COUPLING, RUBBER . . . . . . . . . . . .1

4. . . . . . . . .021104 . . . . . . .DRIVE SHAFT . . . . . . . . . . . . . . . . . .1

5. . . . . . . . .021109 . . . . . . .BEARING SEAL . . . . . . . . . . . . . . . . .2

6. . . . . . . . .021108 . . . . . . .BEARING . . . . . . . . . . . . . . . . . . . . . .2

7. . . . . . . . .021107 . . . . . . .BEARING CUP . . . . . . . . . . . . . . . . . .2

8. . . . . . . . .034073 . . . . . . .BEARING HOUSING . . . . . . . . . . . . .1

9. . . . . . . . .021352 . . . . . . .DISTANCE PIECE . . . . . . . . . . . . . . .1

10. . . . . . . .021348 . . . . . . .FLANGE / ELBOW ASSEMBLY . . . . .1

11. . . . . . . .021358 . . . . . . .LOCKNUT (NOT SHOWN) . . . . . . . .1

12. . . . . . . .021359 . . . . . . .TAB WASHER (NOT SHOWN) . . . . .1

13. . . . . . . .021361 . . . . . . .CIRCLIPS (NOT SHOWN) . . . . . . . . .2

14. . . . . . . .034392 . . . . . . .PIPE NIPPLE 1/8 x 5 (NS) . . . . . . . . .1

15. . . . . . . .010333 . . . . . . .PIPE COUPLING (NS) . . . . . . . . . . . .1

PARTS

2A-4

2.3 Handle Assembly

ILL. PART # DESCRIPTION QTY.

1. . . . . . . . . . . . . . . . . . .037668 . . . . . . .HAND GRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. . . . . . . . . . . . . . . . . . .021112 . . . . . . .HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. . . . . . . . . . . . . . . . . . .038076 . . . . . . .CONTROL PANEL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. . . . . . . . . . . . . . . . . . .038935 . . . . . . .HANDLE CLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PARTS

2A-5

2.4 Ball Unit Assembly

ILL. PART # DESCRIPTION QTY.

1. . . . . . . . . . . . . . . . . . .028589 . . . . . . .BALL UNIT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. . . . . . . . . . . . . . . . . . .021135 . . . . . . .HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. . . . . . . . . . . . . . . . . . .038079 . . . . . . .LIGHT MOUNT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. . . . . . . . . . . . . . . . . . .021333 . . . . . . .WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. . . . . . . . . . . . . . . . . . .028404 . . . . . . .NUT, 16mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

6. . . . . . . . . . . . . . . . . . .035685 . . . . . . .SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. . . . . . . . . . . . . . . . . . .021133 . . . . . . .BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. . . . . . . . . . . . . . . . . . .035684 . . . . . . .ADJUSTMENT HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. . . . . . . . . . . . . . . . . . .028749 . . . . . . .LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. . . . . . . . . . . . . . . . . .021331 . . . . . . .COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. . . . . . . . . . . . . . . . . .018289 . . . . . . .ROLL PIN, 3/16 x 1 1/4 (NOT SHOWN) . . . . . . . . . . . . . . . . . . . . . . .1

12. . . . . . . . . . . . . . . . . .021137 . . . . . . .BALL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

This manual suits for next models

Table of contents