HIKOKI CH 3656DA User manual

-1-
PRODUCT NAME
36 V Cordless Hedge Trimmer
Model CH 3656DA
REPAIR GUIDE------------------------------------------------------------------------------------------------------------------1
1. Precautions on disassembly and reassembly -------------------------------------------------------------1
• Disassembly ---------------------------------------------------------------------------------------------------1
• Reassembly ----------------------------------------------------------------------------------------------------2
• Lubrication points and type of lubricant -----------------------------------------------------------------8
• Tightening torque ---------------------------------------------------------------------------------------------8
2. Precautions on disassembly and reassembly of the charger------------------------------------------8
STANDARD REPAIR TIME (UNIT) SCHEDULES ----------------------------------------------------------------------9
CONTENTS Page
Power Tools Service Manual
CONFIDENTIAL
Jul. 2018
Overseas Sales Management Dept.
C

-1-
WARNING: Be sure to remove the battery from the main body before starting repair or
maintenance work. If the switch is activated inadvertently with the battery still
mounted on the main body, the motor may turn unexpectedly and could cause serious
injury.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts list and exploded
assembly diagram for the Model CH 3656DA.
1. Removing the bottom cover ass’y
(1) Remove the Bottom Cover Ass’y [44] by removing four Tapping Screws (W/Flange) D5 x 20 [46] that
secure the Bottom Cover Ass’y [44] to the main unit.
(2) Slide the Cam Rod Holder [45] in the direction of the blade. Then remove the Washer [39] (bottom
cover), Cam Rod [40] (bottom cover), Gear [41], First Gear [43], Cam Rod [40] (housing), and Washer
[39] (housing). Finally, remove the Cam Rod Holder [45].
2. Removing the blade ass’y
CAUTION: Be sure to attach the Blade Case [58] before removing the Blade Ass’y [51].
Pull up the Blade Ass’y [51] fitted in the housing toward the bottom cover. Then remove the Cushion [35],
Spacer [36], and Blade Ass’y [51]. If the Blade Ass’y [51] is too tightly fitted and cannot be removed from
the housing, loosen the Tapping Screw (W/Flange) D4 x 20 [32] securing the housing in place near the
Blade Ass’y [51], and then remove the Blade Ass’y [51].
3. Removing the spacer from the blade ass’y
Remove two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [37] and two Nylon Nuts M6 [34], then remove the
Spacer [36].
NOTE: Loosen the two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [37] by putting a hexagonal
wrench through the holes in the upper and lower blades.
4. Removing the sub handle ass’y
Remove two Machine Screws (W/Washer) M5 x 30 [13]. Then pull the Sub Handle Ass’y [3] outward to
remove it from Housing (A).(B) Set [27].
5. Removing housing (B)
(1) Remove twelve Tapping Screws (W/Flange) D4 x 20 [32] and Tapping Screw (W/Flange) D3 x 16 [31].
Then housing (B) can be removed with all internal parts retained in housing (A).
(2) Grasp the Motor DC 36 V [20] and lift it out of housing (A). The entire power supply section including
the Motor DC 36 V [20], Switch [11], Controller Ass’y [23], and Battery Terminal [26] can be removed.
(3) Remove Battery Rubber (B) [29], Trigger [25], and Push Pin [17] being careful not to lose Spring (E)
[24] of the Trigger [25] and Spring (D) [12] of the Push Pin [17].
6. Disassembling the power supply unit
(1) Use a soldering iron to remove solder for removing the black internal wire of the Motor DC 36 V [20]
from the Switch [11]. Remove the red internal wire from the Connector [8] by cutting it at the junction
with the Connector [8] with nippers.
(2) Use a soldering iron to remove solder for removing the internal wires of the Controller Ass’y [23] from
the Battery Terminal [26] and two Switches [11].
Disassembly
REPAIR GUIDE

-2-
• Connecting diagram
Connector
50092 [8]
Battery Terminal [26]
Switch 2 [11]
(Black)
(
Black
)
(White)
(Red)
Controller Ass’y [23] Motor DC 36 V [20]
(Red)
(
Red
)
(White)
(Black)
Switch 1 [11]
(Red)
(Red)
(Red)
(Black)
Ferrite core
Ferrite core Diode [21]
Ferrite core
Ferrite core
Ferrite core
Controller Ass’y [23]
Diode [21]
Switch 1 [11]
Switch 2 [11]
(3) Use a soldering iron to remove solder for removing the two red, two black, and one white internal wires
of the Switch [11], and two red and three black internal wires of the other Switch [11].
(4) Use a soldering iron to remove solder for removing the red, black, and white internal wires of the
Battery Terminal [26].
NOTE: Do not disassemble the Switches [11] and Controller Ass’y [23].
Conduct reassembly by reversing the disassembly procedure. However, note the following precautions.
1. Wiring the power supply section
(1) Be sure to make wiring connections according to the connecting diagram. Pay attention to the colors of
internal wires and terminals to be soldered.
Reassembly

-3-
• Mounting spring (E)
• Wiring diagram
[21]
[20]
Switch 1 [11]
[25]
[26]
LED circuit board
[23]
[24] A
(2) Pay attention to the soldering direction when soldering the internal wires of the two Switches [11].
(3) Pay attention to the polarity of the Diode [21] when mounting it.
(4) Pay attention to the soldering direction when soldering the internal wires of the Controller Ass’y [23] to
two Switches [11] and Battery Terminal [26].
(5) Mount the Motor DC 36 V [20] and the assembly of the Controller Ass’y [23], two Switches [11], and
Battery Terminal [26] to housing (A) of Housing (A).(B) Set [27] aligning the concave portions of the
Motor DC 36 V [20] with the convex portions of housing (A).
(6) Mount the Trigger [25], Spring (E) [24], Push Pin [17], Spring (D) [12], and Battery Rubber (B) [29] to
the specified positions in Housing (A).(B) Set [27].
NOTE: Mount Spring (E) [24] at a right angle to the Switch [11]. Check that Spring (E) [24] is not
bent, misaligned, or dropped.
Switch 1 [11]
[25]
[24]
[8]
Switch 2 [11]
A

-4-
• Mounting the protector and packing (A)
2. Reassembling the housing section
(1) Ensure that no internal wire is loose or caught when mounting housing (B) of Housing (A).(B) Set [27].
Check that Spring (E) [24] is not bent, misaligned, or dropped.
(2) Fit the Protector [14] into Housing (A).(B) Set [27] with Packing (A) [15] firmly pressed.
(3) Properly position housing (B) of Housing (A).(B) Set [27]. Insert the Ball Bearing 626ZZ [42] and Ball
Bearing 608DD [38] into the ball bearing chambers in the housing. Then tighten twelve Tapping
Screws (W/Flange) D4 x 20 [32].
NOTE: Tighten the screw “A” first as shown in the wiring diagram on page 3 being careful not
to catch any internal wire.
(4) Put Shaft (D) [7] through the hole of the Push Pin [17]. Fit the convex portions of the Sub Handle Ass’y
[3] in the concave portions of Housing (A).(B) Set [27]. Then tighten two Machine Screws (W/Washer)
M5 x 30 [13] being careful not to drop the two Nuts M5 [18].
(5) Insert the flange of the Felt [6] into the groove of Housing (A).(B) Set [27].
3. Mounting the blade ass’y and gear
(1) Put the two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [37] through the Spacer [36]. Put a hexagonal
wrench through the holes of the upper and lower blades and tighten the two Nylon Nuts M6 [34].
NOTE: Mount the Spacer [36] facing its protrusion to the tip of the Blade Ass’y [51].
(2) Fit the Blade Ass’y [51] in Housing (A).(B) Set [27]. If the Blade Ass’y [51] is caught on the Cushion
[35], loosen the Tapping Screws (W/Flange) D4 x 20 [32] around the Cushion [35] and then fit the
Blade Ass’y [51] in Housing (A).(B) Set [27] again. Be sure to retighten the loosened Tapping Screws
(W/Flange) D4 x 20 [32]. Replace the Cushion [35] with new one if it is scratched or cracked.
(3) Apply grease (Nippeco SEP-3A) to the inside of the Cam Rod Holder [45] and put the Blade Ass’y [51]
through the Cam Rod Holder [45].
NOTE: Face the wedge-shaped joint of the Cam Rod Holder [45] toward the HiKOKI logo of
housing (A).
(4) Apply grease (Nippeco SEP-3A) to the tooth surface of the First Gear [43] and then insert the First
Gear [43] into the Ball Bearing 626ZZ [42].
(5) Apply grease (Nippeco SEP-3A) to both sides of the Cam Rod [40] (on the housing side), inner
diameter of the cam mounting hole, and blade pin mounting hole. Then fit the blade pin (on the
housing side) in the Cam Rod [40].
NOTE: Mount the Cam Rod [40] with its shear droop surface facing toward the Gear [41] (on the
blade side).
[14]
Packing (A)
Insert the flange of the Felt [6] into the groove.
[27]

-5-
• Mounting the blade ass’y, cam rod holder, and cam rod
(6) Apply grease (Nippeco SEP-3A) to the tooth surface on the Gear [41], sliding portion on the Cam Rod
[40], and the cam. Put the Washer [39] on the Ball Bearing 608DD [38], and insert the shaft of the
Gear [41] into the Ball Bearing 608DD [38]. Check that the Cam Rod [40] engages with the cam of the
Gear [41].
(7) Apply grease (Nippeco SEP-3A) to both sides of the Cam Rod [40] (on the bottom cover side), inner
diameter of the cam mounting hole, and blade pin mounting hole. Then fit the blade pin and cam of the
Gear [41] in the Cam Rod [40]. Fit the Washer [39] onto the shaft of the Gear [41].
NOTE: Mount the Cam Rod [40] with its shear droop surface facing toward the Gear [41] (on the
blade side).
(8) Slide the Cam Rod Holder [45] toward the Gear [41] so that the upper and lower blades are
sandwiched between the two Cam Rods [40] in the Cam Rod Holder [45].
[39]
[45]
[43]
[40]
Sandwich the upper and
lower blades between the
two Cam Rods [40] in the
Cam Rod Holder [45].

-6-
• Orientation of the cam rod holder and cam rod
• Mounting the spacer
Insert a hexagonal wrench into the hole of the
Blade Ass’y [51] and tighten the Hex. Socket
Hd. Bolt (W/Button) M6 x 25 [37] and Nylon Nut
M6
[
34
]
(
2
p
laces
)
.
Cushion [35]
Face the protrusion of the Spacer [36]
toward the tip of the Blade Ass’y [51].
Face the concave side of the Spacer
[36] toward the Blade Ass'y [51]. Blade Ass'y [51]
Face the wedge-shaped joint toward
the HiKOKI logo on housing (A).
Cam Rod Holder [45]
Face the shear droop surface of the Cam
Rod [40] inward (toward the Gear [41]).
Cam Rod [40]
Cam Rod [40]
Gear [41]

-7-
• Mounting the bottom cover ass’y
• Positioning the cam rod holder
4. Mounting the bottom cover ass’y
(1) Slide the Cam Rod Holder [45] toward the Gear [41] and align the edge of the Cam Rod Holder [45]
with the edges of Housing (A).(B) Set [27] ribs.
(2) Mount the Bottom Cover Ass’y [44] so that the Cam Rod Holder [45] is correctly positioned between
the ribs on the Bottom Cover Ass’y [44]. Then tighten the four Tapping Screws (W/Flange) D5 x 20
[46].
Slide the Cam Rod Holder [45]
toward the Gear [41].
Ribs on Housing (A).(B) Set [27]
A
lign the edge of the Cam Rod Holder [45] with
the edges of Housing (A).(B) Set [27] ribs.
Ribs on the Bottom Cover Ass’y [44]
[44]
[45]
[44]

-8-
Apply specified amount of SEP-3A grease to the following portions.
• Pinion of the Motor DC 36 V [20] ··············································································· 0.5 g
• Tooth surface of the First Gear [43]·············································································· 0.5 g
• Tooth surface of the Gear [41] and its sliding portion with the cam and the Cam Rod [40] ····· 3 g
• Outer circumference of the blade pin and its sliding portion with the Cam Rod [40] ················ 2 g
• Gear chamber of Housing (A).(B) Set [27] ······································································ 7 to 10 g
Item No. Part name
Tightening torque
N•m kgf•cm
[13] Machine Screw (W/Washer) M5 x 30 (Black) 2.4±0.5 25±5
[31] Tapping Screw (W/Flange) D3 x 16 (Black) 1.3±0.3 13±3
[32] Tapping Screw (W/Flange) D4 x 20 2.4±0.5 25±5
[34] Nylon Nut M6 9.8±2.0 100±20
[46] Tapping Screw (W/Flange) D5 x 20 (Black) 2.9±0.5 30±5
[49] Hex. Socket Hd. Bolt (W/Flange) M5 x 8 5.9±1.5 60±15
2. Precautions on disassembly and reassembly of the charger
Refer to the Service Manual for precautions on disassembly and reassembly of the charger Model
UC 18YSL3.
Tightening torque
Lubrication points and type of lubricant

-9-
Model
Repai
r
time 10 20 30 40 50 60 min.
CH 3656DA
General assembly
Housing
(A).(B) Set
Switch x 2
Push Pin
Motor
DC 36V
Controller
Ass’y
Trigger
Wo
r
k Flow
Bottom
Cover Ass’y
First Gear
Ball Bearing
(626ZZC2)
x 2
Gear
Ball Bearing
(608DD)
x 2
Cam Rod x 2
Cam Rod
Holder
Blade Ass’y
Cushion x 2
Spacer
Guard Plate
STANDARD REPAIR TIME (UNIT) SCHEDULES

Model CH 3656DA
CORDLESS HEDGE TRIMMER
LIST NO. K884
2018·2·14
(E1)
32
3
1
31
502
27
2
7
13
14
28
11
25
16
23 20
10
11
12
17
18
29
30
33
24
9
8
4
501
26
15
6
22
21
19
19
19
42
38
49
50
48
35
36
34
38
39
40
41
42
43
39
37
37
35
46
56
57
53
58
40
45
47
52
55
54
51
44
5

PARTS CH 3656DA
DESCRIPTION REMARKS
1 MV LABEL (A) 1
2 BRAND LABEL 1
3 335015 SUB HANDLE ASS'Y 1 INCLUD.4,5
4 333341 SPRING (C) 1
5 335347 COLLAR 2
6 335761 FELT 1
7 335019 SHAFT (D) 1
8 959141 CONNECTOR 50092 (10 PCS.) 1
9 335345 INTERNAL WIRE (L96) 1
10 335344 INTERNAL WIRE (L186) 1
11 335018 SWITCH 2
12 333344 SPRING (D) 1
13 336239 MACHINE SCREW (W/WASHER) M5 X 30 (BLACK) 2
14 335010 PROTECTOR 1
15 335762 PACKING (A) 1
16 335343 INTERNAL WIRE (L204) 1
17 333343 PUSH PIN 1
18 302012 NUT M5 (BLACK) 2
*
19 334379 FERRITE CORE 3 EXCEPT FOR NZL
20 335016 MOTOR DC 36V 1
21 335346 DIODE 1
22 PANEL SHEET 1
*
23 373109 CONTROLLER ASS'Y 1 INCLUD.19,22,26
*
23 373108 CONTROLLER ASS'Y 1 INCLUD.22,26 FOR NZL
24 373361 SPRING (E) 1
25 333761 TRIGGER 1
26 372228 BATTERY TERMINAL 1
27 373110 HOUSING (A).(B) SET 1
*
28 371750 BATTERY BSL 36A18 (EUROPE,AUS,NZL) 1 INCLUD.502
29 370328 BUTTERY RUBBER (B) 1
30 MV LABEL (B) 1
31 313687 TAPPING SCREW (W/FLANGE) D3 X 16 (BLACK) 1
32 339250 TAPPING SCREW (W/FLANGE) D4 X 20 12
33 NAME PLATE 1
34 6698766 NYLON NUT M6 2
35 335021 CUSHION 2
36 335020 SPACER 1
37 6699113 HEX. SOCKET HD. BOLT (W/BUTTON) M6 X 25 2
38 608DDM BALL BEARING 608DD 2
39 335022 WASHER 2
40 373362 CAM ROD 2
41 335014 GEAR 1
42 335669 BALL BEARING 626ZZC2 PS2-L 2
43 335013 FIRST GEAR 1
44 335017 BOTTOM COVER ASS'Y 1 INCLUD.38,42
45 335677 CAM ROD HOLDER 1
46 302089 TAPPING SCREW (W/FLANGE) D5 X 20 (BLACK) 4
47 337893 SUPPORT PLATE 1
48 6699108 U-NUT M5 5
49 6699065 HEX. SOCKET HD. BOLT (W/FLANGE) M5 X 8 1
- 2 - 2 - 18
*ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.CODE NO.

PARTS CH 3656DA
DESCRIPTION REMARKS
50 6699062 GUARD PLATE 1
51 6600409 BLADE ASS'Y (620MM) 1 INCLUD.37,48,52-57
52 6600360 BLADE LINER 1
53 6699114 WASHER (A) 1
54 6699179 SHOULDER BUTTON BOLT M5 X 31 1
55 6699112 WASHER (B) 4
56 6699111 WASHER M7 5
57 6699109 SHOULDER BUTTON BOLT M5 X 25 4
58 335011 BLADE CASE (620MM) 1
DESCRIPTION REMARKS
501 CHARGER (MODEL UC 18YSL3) 1
502 329897 BATTERY COVER 1
DESCRIPTION REMARKS
601 6600410 BLADE ASS'Y (780MM) 1
602 336102 BLADE CASE (780MM) 1
2 - 18 Printed in Japan - 3 -
(180214N)
OPTIONAL ACCESSORIES
*ALTERNATIVE PARTS
STANDARD ACCESSORIES
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.