HIKOKI CH 3656DA Service Manual
Power Tools Service Manual
PRODUCT NAME
36 V Cordless Hedge Trimmer
Model CH 3656DA
CONTENTS
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
CONFIDENTIAL
Jul. 2018
C
Page
STANDARD REPAIR TIME (UNIT) SCHEDULES ---------------------------------------------------------------------- 9
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Overseas Sales Management Dept.
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.
REPAIR GUIDE
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].
Disassembly
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].
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(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].
Reassembly
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.
• Connecting diagram
Switch 1 [11]
Battery Terminal [26]
Ferrite core
(White)
(Black)
Red)
(Red)
(Red)
Controller Ass’y [23]
Controller Ass’y [23]
Ferrite core
(White)
(Black)
Black)
Ferrite core
Switch 2 [11]
Diode [21]
Switch 1 [11]
(Red)
(Black)
(Red)
Connector
50092 [8]
(Red)
Ferrite core
Motor DC 36 V [20]
Diode [21]
Ferrite core
Switch 2 [11]
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(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.
• Mounting spring (E)
Switch 1 [11]
[24]
[25]
• Wiring diagram
LED circuit board
Switch 1 [11]
[21]
[8]
Switch 2 [11]
[26]
[24]
[25]
[23]
A
A
[20]
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