The Makita XML02Z-DC18RD is a versatile and efficient lawn mower, designed to make lawn care a breeze. Powered by an 18V DC motor, it delivers reliable cutting performance with a cutting width of 460 mm. The XML02Z-DC18RD features 13 cutting height adjustments, ranging from 20 to 75 mm, allowing you to achieve your desired lawn height. With its compact design and foldable handles, it's easy to maneuver and store, making it an excellent choice for small to medium-sized gardens.
The Makita XML02Z-DC18RD is a versatile and efficient lawn mower, designed to make lawn care a breeze. Powered by an 18V DC motor, it delivers reliable cutting performance with a cutting width of 460 mm. The XML02Z-DC18RD features 13 cutting height adjustments, ranging from 20 to 75 mm, allowing you to achieve your desired lawn height. With its compact design and foldable handles, it's easy to maneuver and store, making it an excellent choice for small to medium-sized gardens.
REPAIR MANUAL
XML02
1 INDEX
1
INDEX .......................................................................................................................................................................................... 2
2 CAUTION .................................................................................................................................................................................... 3
3 NECESSARY REPAIRING TOOLS ........................................................................................................................................... 3
4 REPAIR ........................................................................................................................................................................................ 4
4-1 Lower pipe, Upper pipe complete, Switch lever .................................................................................................................. 4
4-1-1 Disassembling ............................................................................................................................................................. 4
4-1-2 Assembling .................................................................................................................................................................. 6
4-2 DC motor ............................................................................................................................................................................. 7
4-2-1 Disassembling ............................................................................................................................................................. 7
4-2-2 Assembling .................................................................................................................................................................. 8
4-3 Change lever, Adjust plate .................................................................................................................................................... 9
4-3-1 Disassembling ............................................................................................................................................................. 9
4-3-2 Assembling ................................................................................................................................................................ 10
4-4 Front wheel, Rear wheel .................................................................................................................................................... 11
4-4-1 Disassembling ........................................................................................................................................................... 11
4-4-2 Assembling ................................................................................................................................................................ 12
4-5 Connecting rod, Front shaft, Rear shaft .............................................................................................................................. 13
4-5-1 Disassembling ........................................................................................................................................................... 13
4-5-2 Assembling ................................................................................................................................................................ 14
4-6 Protective shield ................................................................................................................................................................. 15
4-6-1 Disassembling ........................................................................................................................................................... 15
4-6-2 Assembling ................................................................................................................................................................ 15
4-7 Rear flap complete ............................................................................................................................................................. 16
4-7-1 Disassembling ........................................................................................................................................................... 16
4-7-2 Assembling ................................................................................................................................................................ 16
5 Circuit diagram ........................................................................................................................................................................... 17
6 Wiring diagram ........................................................................................................................................................................... 18
7 TIGHTENING TORQUE SPECIFICATIONS .......................................................................................................................... 21
2 / 21
2 CAUTION
Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Follow the instructions described below in advance before repairing:
· Wear gloves.
· In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what are the parts.
It is also recommended to have boxes ready to keep disassembled parts by group.
· Handle the disassembled parts carefully. Clean and wash them properly.
· If some bolts and screws are too tight, use Impact driver.
Tighten the bolts and the screws to the specified torque as shown in "7 TIGHTENING TORQUE SPECIFICATIONS”.
3 NECESSARY REPAIRING TOOLS
Code No.
Description
Use for
1R243
Round bar for arbor 14-100
press-fitting Plane bearings 10
1R252
Round bar for Arbor 30-100
press-fitting Ball bearings 6200ZZ
1R285
Round bar for Arbor 11-50
removing Plane bearings 10
3 / 21
4 REPAIR
4-1 Lower pipe, Upper pipe complete, Switch lever
4-1-1 Disassembling
Fig. 4-1-1-1
[1] Remove Rear bag ass’y from Deck by lifting it up.
[2] While holding Lower pipe or Upper pipe complete, loosen two M8x35 Thumb screws and remove the assembled part of
Lower pipe and Upper pipe complete from Deck.
Remove
Upper pipe
complete
M8x35 Thumb
screw (2 pcs.)
Lower pipe
Rear bag ass'y
Deck
Upper pipe
complete
Remove
Lower pipe
M8x35 Thumb
screw (2 pcs.)
Fig. 4-1-1-2
[3] Pull out two Holders.
[4] Loosen two M6x50 Cup hex square neck bolts until the second thread is disengaged from M6 Thumb nut.
Note: The first thread remains engaged to prevent the bolts/nuts from falling off.
[5] Loosen two M6 Thumb nuts by turning and pulling them while pressing the head of the bolts to disengage the first thread.
Pull out
First thread
Press the head of bolt.
Holder
Holder
M6 Thumb nut
M6 Thumb nut
M6x50 Cup hex
square neck bolt (2 pcs.)
Upper pipe
complete
Lower pipe
[6] Remove Lower pipe from Upper pipe complete.
Second thread
4 / 21
Fig. 4-1-1-4
[9] Loosen four 4x18 Tapping screws, and remove Switch
box cover complete and Switch box.
Fig. 4-1-1-5
[10] Remove Tension spring 9, and loosen M4x20 Pan head
screw, and then remove Lever.
[11] Remove Switch lever and Upper pipe complete.
Fig. 4-1-1-3
[7] Loosen 4x18 Tapping screw, and remove Switch lever case cover and Switch lever case.
[8] Loosen M4x20 Pan head screw, and remove Arm.
Switch cover
Switch lever
case
Switch lever
case cover
4x18
Tapping screw
Arm
M4x20 Pan
head screw
Switch lever
Switch box
Switch box
cover complete
4x18 Tapping
screw (4 pcs.)
Tension spring 9
Switch lever
Lever
M4x20 Pan
head screw
5 / 21
4-1-2 Assembling
Fig. 4-1-2-1
[1] Mount Lever to Switch lever, and tighten M4x20 Pan head screw while holding Hex nut.
[2] Mount Tension spring 9. (
Fig. 4-1-1-5
)
Switch lever
M4x20 Pan
head screw
Hex nut
Lever
The tip of Lever faces
upward.
Fig. 4-1-2-2
[3] Route Power supply cord over Lower pipe.
Power supply
cord
Lower pipe
6 / 21
4-2 DC motor
4-2-1 Disassembling
Fig. 4-2-1-5
[7] Shift Change lever to the position of Cutting height
between 40 and 60mm.
Fig. 4-2-1-1
[1] Remove Blade 430.
[2] Pull Lock lever.
[3] Turn Battery cover complete.
Fig. 4-2-1-2
[4] Remove Battery cover complete by releasing Battery
cover complete from the hinges.
Lock lever
Battery cover
complete
Battery cover
complete
Hinge
Fig. 4-2-1-3
[5] Loosen two 5x25 Tapping screws, and remove Grip A.
Fig. 4-2-1-4
[6] Loosen seven 4x18 Tapping screws.
5x25 Tapping
screw (2 pcs.)
Grip A
Cowling
4x18 Tapping
screw (7 pcs.)
Change lever
Terminal
housing set
Fig. 4-2-1-6
[8] Pass Terminal housing through the square hole of
Cowling without disconnecting the lead wires as shown
below. Cowling can be removed.
Change lever
Square hole of
Cowling
Cowling
Terminal housing
7 / 21
4-2-2 Assembling
Fig. 4-2-1-7
[9] Loosen three M6x30 + Pan head screws using a No.3
Phillips screwdriver, and remove DC motor.
M6x30 + Pan head
screw (3 pcs.)
DC motor
Fig. 4-2-2-1
Assemble DC motor by aligning its notch with Boss of Deck.
U-shaped
notch
Boss of Deck
DC motor
8 / 21
4-3 Change lever, Adjust plate
4-3-1 Disassembling
[1] Remove Cowling. (4-2-1 Disassembling)
Fig. 4-3-1-2
[4] Put a wood under Deck to raise Wheels from the
ground.
Fig. 4-3-1-3
[5] Loosen two 4x18 Tapping screws, and remove the
assembled part of Adjust plate and Change lever toward
DC motor side from Connecting rod.
Wood
Adjust plate
Connecting rod
Change lever
4x18 Tapping
screw (2 pcs.)
DC motor side
Fig. 4-3-1-4
[6] The components of Change lever and Adjust plate are as follows:
Change lever cover
Compression
spring 9
Flat washer 9
Flat washer 4
4x18 Tapping
screw
Change lever
M6x30 Hex
bolt
Sleeve 6
Adjust plate
M6 Hex nut
4x18 Tapping
screw (2 pcs.)
Fig. 4-3-1-1
[2] Shift Change lever to the position of Cutting height at 75mm.
[3] Release Tension spring 16 from the hook with long nose pliers.
Hook
Tension spring 16
Long nose pliers
Change lever
9 / 21
4-3-2 Assembling
Fig. 4-3-2-2
[2] Lift up Connecting rod and insert the pin into the hole of
Connecting rod.
Fig. 4-3-2-1
[1] Put a wood under Deck to raise Wheels from the
ground.
Wood
Pin of
Connecting rod
Connecting rod
Hole of Change lever
Fig. 4-3-2-3
[3] Shift Change lever to the position of Cutting height at 75mm.
[4] Hook Tension spring 16 with the hook with long nose pliers.
Hook
Tension spring 16
Long nose pliers
Change lever
Fig. 4-3-2-4
[5] Shift Change lever to the position of Cutting height between 40 and 60mm, and assemble Cowling.
[6] Pass Terminal housing set through the square hole of Cowling, and assemble Terminal housing set to Cowling.
Terminal
housing set
Change lever
Square hole of
Cowling
Cowling
10 / 21
4-4 Front wheel, Rear wheel
4-4-1 Disassembling
Fig. 4-4-1-1
[1] Pull out Front wheel caps from Front wheels.
Remove Rear wheel caps in the same way.
Fig. 4-4-1-2
[2] Remove M8 Collared hex nuts and Front wheels from
Front shaft. Remove Rear wheels in the same way.
Pull out
Front wheel
cap
Front wheel
M8 Collared
hex nut
Fig. 4-4-1-3
[3] Tap the edge of each wheel with a plastic hammer. Ball
bearings 6200ZZ in the wheels are removed.
Fig. 4-4-1-4
[4] Remove each Plane bearing 10 with 1R285 and an arbor
press.
Front/Rear wheel
Ball bearing
6200ZZ
Plane bearing 10
1R285
Fig. 4-4-1-5
[5] The components of Front wheel section and Rear wheel section are as follows:
Ball bearing
6200ZZ
Front/Rear wheel
Plane bearing 10
M8 Collared hex nut
Front/Rear wheel cap
11 / 21
4-4-2 Assembling
Fig. 4-4-2-1
[1] Press-fit Plane bearings 10 to Front/Rear wheels with
1R243 and an arbor press.
Fig. 4-4-2-2
[2] Press-fit Ball bearings 6200ZZ to Front/Rear wheels
with 1R252 and an arbor press.
Plane bearing 10
1R243
Front wheel
1R252
Ball bearing
6200ZZ
12 / 21
4-5 Connecting rod, Front shaft, Rear shaft
4-5-1 Disassembling
[1] Remove the assembled part of Lower pipe and Upper pipe complete. (4-1-1 Disassembling)
[2] Remove Cowling. (4-2-1 Disassembling)
[3] Remove the assembled part of Change lever and Adjust plate. (4-3-1 Disassembling)
[4] Remove Front wheel and Rear wheel. (4-4-1 Disassembling)
Fig. 4-5-1-1
[5] Loosen two 4x18 Tapping screws, and remove Protective shield.
Fig. 4-5-1-2
[6] Loosen two M5-8 Hex lock nuts and two Flat washers 5, and remove Connecting rod.
4x18 Tapping screw
(2 pcs.)
Protective shield
Connecting rod
M5-8 Hex lock nut
(2 pcs.) and
two Flat washer 5 (2 pcs.)
13 / 21
4-5-2 Assembling
Fig. 4-5-1-3
[7] Loosen five 4x18 Tapping screws, and remove Front
cover.
4x18 Tapping screw
(5 pcs.)
Front cover
Fig. 4-5-1-4
[8] Loosen two 4x18 Tapping screws, and remove two Plates, Front shaft and Rear shaft.
Fig. 4-5-2-1
To distinguish between Front shaft and Rear shaft, check the white marking on Front shaft.
White marking
Rear shaft
Front shaft
Front shaft
Rear shaft
Plate
Plate
4x18 Tapping
screw (2 pcs.)
14 / 21
4-6 Protective shield
4-6-1 Disassembling
4-6-2 Assembling
Fig. 4-6-1-1
[1] Loosen two 4x18 Tapping screws, and
remove Protective shield section.
Fig. 4-6-1-2
[2] The component parts of Protective shield section are as follows:
4x18 Tapping
screw (2 pcs.)
Protective shield
Fig. 4-6-2-1
[1] Mount Protective shield into the grooves of Protective
shield holder.
Fig. 4-6-2-2
[2] Insert Rod 8 into Protective shield.
Protective shield
Protective shield holder
Rod 8
Stop ring E-7
Stop ring E-7
Rod 8
Protective shield
Grooves of Protective shield holder
Protective shield
Fig. 4-6-2-3
[3] Assemble two Stop rings E-7 to Rod 8.
Rod 8
Stop ring E-7
Stop ring E-7
15 / 21
4-7 Rear flap complete
4-7-1 Disassembling
4-7-2 Assembling
Fig. 4-7-1-1
The components of Rear flap complete section are as follows:
Fig. 4-7-2-1
Assemble Torsion spring 8 as shown below.
Top side of Deck
Top side of
Rear flap
complete
Stop ring E-5
Stop ring E-5
Stop ring E-5
Stop ring E-5
Torsion spring 8
Rod 6
Rear flap complete
Torsion spring 8
16 / 21
Circuit of Switch
5 Circuit diagram
Fig. 5-1
AWG: American wire gauge
(3)
Motor
Switch
Line filter C (P/N 688140-0)
(If used)
Fuse unit
(If used)
Key
Lead unit
Controller
Terminal (left side of the machine)
Closed end
splice
Flag receptacle
with lock
(#250, t=0.8mm)
Straight receptacle with lock
(#250, t=0.8)
Closed end
splice
Orange/ AWG 18
Blue/AWG18
Yellow/AWG18
Orange/ AWG 22
Blue/AWG22
Yellow/
AWG22
(2)
(1)
Closed end
splice
Red/
AWG16
Closed end splice
Line filter A
(P/N 688164-6)
(If used)
Red/ AWG 16
Blue/AWG16
Line filter B
(P/N 688131-1)
(If used)
Black/AW G16
White/ AWG16
Red/ AWG 16
Closed end
splice
Red/ AWG 16
Yellow/AWG22
Blue/AWG22
Orange/ AWG 22
Red/ AWG 16
Flag receptacle with lock
(#250, t=0.8)
Orange/ AWG 16
White/ AWG22
Blue/AWG16
Straight receptacle with lock
(#250, t=0.8)
Terminal (right side of the machine)
Straight receptacle
with lock
(#187, t=0.8)
AS
Black/AW G16
White/ AWG16
Red/ AWG 16
Yellow/AWG22
Black/AW G16
＋
－
AS
＋
－
LED circuit
complete
Power supply cord
17 / 21
6 Wiring diagram
Fig. 6-1
Put the lead wires
(yellow, blue, orange)
of Power supply cord
into any of these Lead
wire holders.
Put Closed end splice for
Controller lead wire
(red) and lead wires of
Lead unit in the rib D.
Put each closed end splice
(2-SD) into the rib C.
Route the lead wires of Power
supply cord through Line filters
C (if used), and set the Line
filters in the position shown
below.
Put the lead wires
of Power supply
cord in this
groove.
Put each closed end splice into the rib B.
Put the lead wires into any
of these Lead wire holders.
Put the lead wires in this
Lead wire holder.
Put the lead wires into
any of these Lead wire
holders.
Do not put lead wires on the rib E and Lead unit.
Face the longer part of lead wires of Power supply
cord to Deck.
Route the lead wires
(yellow, blue,
orange) of Power
supply cord
between the rib A
and Lead unit.
Set the sheath of Power supply cord inside A as
shown below.
Route the lead wires of
Controller as shown in the
figure.
Rib B
Lead unit
Put the lead wires from
Terminal into this lead wire
holder.
Power supply cord
Strain relief
Strain relief
3mm
10mm
A
Rib A
Rib E
Rib C
Rib D
Controller
Deck
18 / 21
Fig. 6-2
· Put Closed end splice (5.5-SD) that the
lead wires of Fuse unit and Motor lead
wire (red) are crimped into the rib H.
· Put the lead wires between the rib A and
Lead unit.
Put the slack of the lead wires (blue, red) of Motor into this lead wire holder.
Put the lead wires in this Lead wire
holder.
【
When Fuse unit is used
】
Pass Lead wires (blue and red) of Motor through Line filter
B (if used), and wind it around Line filter one time, and
then put the line filter in the position shown below.
Put the lead wire (red) of Motor and the lead wires (white,
black) into any of these Lead wire holders.
Controller
Put the lead wire
(red) of Motor
into this Lead
wire holder.
Pass the lead
wire (red) of
Motor through
Line filter A (if
used), and set
the line filter in
the position.
Motor
Put the lead wire
(red) of Motor
into this Lead
wire holder.
Put the lead wire
(blue) of Motor
into this Lead
wire holder.
Pass the lead
wire (blue) of
Motor through
Line filter A (if
used), and set
the line filter in
the position.
Rib H
Lead unit
Rib A
Fuse unit
19 / 21
Fig. 6-3
Connect Flag terminal as shown in the
figure on the right.
Flag receptacle
Terminal
Battery fuel gauge
Put the lead wires from
Battery fuel gauge Between
the rib F and Boss, Boss and
the rib G.
Switch
Rib F
Boss
Rib G
Put the lead wires from Switch
Between the rib G and Boss.
Put Closed end splices in this space.
Set the sheath of Power supply cord inside A as shown below.
A
Strain relief
3mm
10mm
20 / 21
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The Makita XML02Z-DC18RD is a versatile and efficient lawn mower, designed to make lawn care a breeze. Powered by an 18V DC motor, it delivers reliable cutting performance with a cutting width of 460 mm. The XML02Z-DC18RD features 13 cutting height adjustments, ranging from 20 to 75 mm, allowing you to achieve your desired lawn height. With its compact design and foldable handles, it's easy to maneuver and store, making it an excellent choice for small to medium-sized gardens.
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