Koki Holdings RB 36DA User manual

PRODUCT NAME
36 V Cordless Blower
Model RB 36DA
TROUBLESHOOTING GUIDE -------------------------------------------------------------------------------------------- 1
REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 3
1. Precautions on disassembly and reassembly ----------------------------------------------------------- 3
Disassembly --------------------------------------------------------------------------------------------------- 3
Reassembly ---------------------------------------------------------------------------------------------------- 6
Connecting diagram ----------------------------------------------------------------------------------------- 8
Application of lubricant -------------------------------------------------------------------------------------- 8
Tightening torque --------------------------------------------------------------------------------------------- 8
Checking after reassembly --------------------------------------------------------------------------------- 8
Load current --------------------------------------------------------------------------------------------------- 9
2. Precautions in disassembly and reassembly of the charger ----------------------------------------- 9
3. How to check and replace the power supply unit ------------------------------------------------------- 9
STANDARD REPAIR TIME (UNIT) SCHEDULES ------------------------------------------------------------------- 11
CONTENTS Page
R
Power Tools Service Manual
CONFIDENTIAL
Jun. 2018
Overseas Sales Management Dept.

Ensure that the battery is fully charged before checking problems in the following chart.
Problem Cause Check Recovery
(1) Motor does
not rotate.
• Wires are not conducting electricity. • Check status of all wires. • Repair any defects.
• Foreign matter is caught between the
rotor ass’y and the stator FET PCB.
• Check and ensure that there is no foreign matter between the rotor
ass’y and the stator FET PCB.
• Remove any foreign matter.
• Faulty connection between the connector
cable (switch) and the connector cable
(CN3).
• Check that the connector is correctly plugged in.
• Check that there is no foreign matter inside the connector. (Refer to
“How to check and replace the power supply unit” on page 9.)
• Reconnect the connector.
• Remove any foreign matter.
• The switch circuit board is malfunctioning
due to presence of dust or water.
• Faulty connection with the switch circuit
board’s internal wire.
• Inspect the switch circuit board for any signs of swelling, scorching,
dust, or water.
• Inspect the internal wire of the switch circuit board for any damage
and ensure that the connection to the circuit board is not
disconnected.
• Replace the wiring ass’y.
• The controller ass’y is malfunctioning due
to presence of dust or water.
• Check status of the circuit board surface for any signs of swelling,
scorching, dust, or water.
• Replace the wiring ass’y.
• The stator FET PCB is malfunctioning
due to presence of dust, water, or
damage caused by impact.
• Check status of the circuit board surface for any signs of swelling,
scorching, dust, water, or damaged FET.
• Replace the wiring ass’y.
• The FET of the stator FET PCB is
malfunctioning.
• Check according to “How to check and replace the power supply unit”
on page 9.
• The rotor is not correctly attached to the
magnet.
• Check that the rotor is correctly attached to the magnet. • Replace the rotor ass’y.
• Faulty connection between the connector
cable (FET) and the connector cable
(controller).
• Check that the connector is correctly plugged in.
• Check that there is no foreign matter inside the connector. (Refer to
“How to check and replace the power supply unit” on page 9.)
• Reconnect the connector.
• Remove any foreign matter.
-1-
TROUBLESHOOTING GUIDE

-2-
Problem Cause Check Recovery
(2) Cannot
increase or
vary
speed.
• Malfunction with the controller ass’y. • Visually check status of the circuit board surface for any signs of
swelling, scorching, dust, water, or damage caused by impact.
• Replace the wiring ass’y.
• Faulty connection between the connector
cable switch and the connector cable
(CN3).
• Check that the connector is correctly plugged in.
• Check that there is no foreign matter inside the connector. (Refer to
“How to check and replace the power supply unit” on page 9.)
• Reconnect the connector.
• Remove any foreign matter.
• The switch circuit board is malfunctioning
due to presence of dust or water.
• Faulty connection with the switch circuit
board’s internal wire.
• Check status of the switch circuit board for any signs of swelling,
scorching, dust, or water.
• Check the internal wire of the switch circuit board for any damage and
ensure that connection to the circuit board is not disconnected.
• Replace the wiring ass’y.
• Faulty connection inside the switch. • Check that there is no abnormality in connection between the
connector cable switch and the connector cable (CN3), switch circuit
board, or switch circuit board’s internal wire.
• Replace the wiring ass’y.
(3) Cannot
switch
between
modes.
• Malfunction of the mode switch. • Press the mode switch and the turbo mode switch to check correct
operation.
• Replace the wiring ass’y.
• The internal wire of the controller ass’y is
disconnected.
• Check connection of the internal wire connecting the switch panel
circuit board and the controller ass’y circuit board.
• Malfunction of the controller ass’y. • Visually check status of the circuit board surface for any signs of
swelling, scorching, dust, water, or damage caused by impact.
(4) Mode lamp
does not
light.
• Malfunction of the mode indicator lamp. • Press the mode switch and the turbo mode switch to check if the
indicator lamp operates correctly.
• The internal wire of the controller ass’y is
disconnected.
• Check connection of the internal wire connecting the switch panel
circuit board and the controller ass’y circuit board.
• Malfunction of the controller ass’y. • Visually check status of the circuit board surface for any signs of
swelling, scorching, dust, water, or damage caused by impact.

-3-
Fig. 1 • Removing the fan
Wrench insertion opening
J-373 wrench
Motor housing (A)
Motor housing (B)
[19]
A
A
A—A
[21]
[22]
[23]
[24]
[17]
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 mounted on
the main body, the motor will 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 RB 36DA.
1. Removing housing (A).(B) set
(1) Remove three Tapping Screws (W/Flange) D5 x 20 [2] from the Nose Grill [27]. Then remove the Nose
Grill [27].
(2) Remove ten Tapping Screws (W/Flange) D5 x 20 [2], Tapping Screw (W/Flange) D3 x 16 [5], and Hex.
Hd. Tapping Screw D5 x 70 [7] from housing (B) of Housing (A).(B) Set [9].
(3) Remove the power supply unit including the Motor Housing Set [17], then remove the Fan [22], Nozzle
[8], and Trigger Lever [10] from housing (B).
2. Removing the fan
(1) Insert the J-373 wrench into the wrench insertion opening of the Motor Housing Set [17] and secure
the width across flats of the Rotor Ass’y [19]. Securely holding the J-373 wrench, remove the U-Nut M5
[24] to remove the Bolt Washer D7 [21], Fan [22], and Washer (A) [23]. Failure to securely hold the
J-373 wrench may result in damage to the wrench insertion opening.
Disassembly
REPAIR GUIDE

-4-
Fig. 2 • Disassembling the power supply unit
Noise suppressor
ass’y
Stator FET PCB
Switch
[11]
Switch panel
Connector cable
(switch)
Connector cable
(CN3)
Connector cable
(CN4)
Connector cable
(controller)
Connector cable
(FET)
[12]
[19]
[16]
Motor housing (A)
Connector
Connector
C
B
C
B
Connector cable
(controller)
Connector cable
(FET)
Locking arm Locking arm
3. Disassembling the power supply unit
Refer to “How to check and replace the power supply unit” on page 9 for details.
(1) Remove five Tapping Screws (W/Flange) D4 x 20 [15] and motor housing (B). Then remove the power
supply unit.
(2) Remove two Connectors [11].
(3) Peel off silicone coating from the connector that connects the connector cable (switch) to the connector
cable (CN3) with a flat-blade screwdriver. Pushing the locking arm with a flat-blade screwdriver,
disconnect the connector.
(4) Peel off silicone coating from the connector that connects the connector cable (FET) to the connector
cable (controller) with a flat-blade screwdriver. Pushing the locking arm with a flat-blade screwdriver,
disconnect the connector.
(5) Disconnect the internal wire (white) from the Battery Terminal [12].
Connector cable
(CN3)
Connector cable
(
switch
)

-5-
Fig. 3 • Removing the rotor ass’y from the stator FET PCB
4. Removing the rotor ass’y from the stator FET PCB
Because the Rotor Ass’y [19] has a strong magnetic force, securely hold the stator of the stator FET PCB
and pull out the Rotor Ass’y [19] towards the direction “D” as shown below.
Stator FET PCB
D
[19]
Stator

-6-
Conduct reassembly by reversing the disassembly procedure, but note the following.
1. Reassembling the power supply unit
Refer to “How to check and replace the power supply unit” on page 9 for details.
(1) Ensure all wire connections are made in accordance with Fig. 4 “Reassembling the power supply unit”
on page 7 when replacing the Wiring Ass’y [16]. Also refer to Fig. 2 “Disassembling the power supply
unit” on page 4 if necessary.
(2) Position the wires correctly according to the following instructions.
• Mount the stator FET PCB and Rotor Ass’y [19] to the Motor Housing Set [17]. Then fix them in place
with five Tapping Screws (W/Flange) D4 x 20 [15]. Check that the noise suppressor ass'y of the stator
FET PCB is positioned correctly. Also check that the connector cable FET, red internal wire, and black
internal wires are not pinched by the Motor Housing Set [17].
• Position the Motor Housing Set [17] correctly in housing (A) after mounting the Fan [22].
• Position the Battery Terminal [12] and the switch correctly in housing (A). Then correctly position the
white, red, and black internal wires connected to the Battery Terminal [12], red and black internal wires
of the Connector [11] and stator FET PCB, and red and black internal wires of the switch. At this time,
pass the white internal wire and the red and black internal wires of the switch under the connector in
housing (A).
• Position the controller ass'y correctly in housing (A). Then position the switch panel and the connector
cable (CN4) correctly.
• Position the connector cable FET of the Stator FET PCB, connector cable (controller), and connector of
the controller ass'y correctly. Be careful of the orientation of the locking arm when positioning the
connector.
• Position the connector cable (switch) of the Switch, connector cable (CN3), and connector of the
controller ass'y correctly. Be careful of the orientation of the locking arm when positioning the
connector.
(3) Position the Nozzle [8] correctly in housing (A) facing the marking of material “>PE<” upward.
(4) After mounting the Trigger Lever [10], mount housing (B) being careful not to pinch the internal wires.
Reassembly

-7-
[17]
Position of the forward/
reverse switching lever
Switch panel
Connector cable (CN4)
Connector cable (SW)
Connector
Connector
cable
(
CN3
)
Connector
Connector cable (FET)
Controller ass’y
[11]
[12]
Stator FET PCB
Connector
cable
(controller)
Pass the white, red, and black
internal wires under the connector.
Fig. 4 • Reassembling the power supply unit
[10]
Switch
Internal wire (white)
Internal wire (red)
Internal wire (black)
Internal wire (red)
Internal wire (black)

-8-
Fig. 5 • Connecting diagram
Apply a thin coat of NIPPECO SEP-3A grease to the inside of the Nozzle [8] where Nozzle (A) [1] is
mounted.
Item No. Part name Tightening torque
N•m kgf•cm
[2] Tapping Screw (W/Flange) D5 x 20 (Black) 3.0±0.5 30±5
[5] Tapping Screw D3 x 16 (Black) 1.3±0.3 13±3
[7] Hex. Hd. Tapping Screw D5 x 70 2.0±0.5 20±5
[15] Tapping Screw (W/Flange) D4 x 20 (Black) 2.0±0.5 20±5
[24] U-Nut M5 3.4±0.7 35±7
Check the following after reassembly.
(1) Check that the switch operates smoothly and the blower starts, stops, and changes speed securely.
(2) Check that the operating mode cycles from Mode 1 to Mode 4 securely each time the mode switch is
pressed.
(3) Press the turbo mode switch and check that the blower is switched to the turbo mode securely. Also
check that the turbo mode turns off automatically and returns to the previous mode after approximately
10 seconds.
(4) Keep pressing the battery remaining switch for two or more seconds and check that the battery
remaining lamp lights.
Application of lubricant
Checking after
r
eassembly
Tightening torque
Connecting diagram
Connector [11]
Connector [11]
Main PCB ass’y
FET PCB
ass’y
Noise suppressor
ass’y
TACT switch
PCB ass’y
Connector cable (FET)
Connector cable (Controller)
Connector cable
(
CN3
)
Connector cable (Switch)
Connector cable (CN4)
DC-speed control switch

-9-
Measure the load current values in the Mode 1 and in the turbo mode. Check that the measured values
are within the following range:
• Mode 1: 4.5±2 A
• Turbo mode: 21±2 A
NOTE: Perform measurement after operating the blower for several minutes using a fully charged
battery.
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 36YRSL.
3. How to check and replace the power supply unit
1. Problems caused by malfunction of the power supply unit
The table below lists the major problems that may be caused by malfunction of the power supply unit.
(The “●” mark indicates the possibility of a defect.)
Defective part
Problem
(1) Motor does
not rotate.
(2) Number of
revolutions
do not
increase.
(3) Cannot
switch the
mode.
(4) Mode lamp
does not
light.
(5) Battery
remaining
lamp does
not light.
Stator FET PCB ●
Switch ●●
Controller ass’y ●●●●●
* The above problem (1) found in the current brushless motor products was mostly caused by the
defective FET in the Stator FET PCB. Check the blower in accordance with “2. Checking the stator FET
PCB” below if the above problem (1) occurs.
Load current