Service Manuals, User Guides, Schematic Diagrams or docs for : MAKITA BFH090-TE
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T ECHNICAL INFORMATION
Models No. BFH040, BFH040F, BFH090, BFH090F, BFH120F
L
PRODUCT
P 1 / 20
Description 12V Cordless Screwdrivers
CONCEPTION AND MAIN APPLICATIONS
The above cordless screwdriver series enable you to work
also in the hazardous location which is defined by
UL1604, Class I, Division 2.
The conformation to UL1604, Class I, Division 2 has been achieved by using H
1. Brush-less DC motor for spark-free armature rotation.
2. Battery inter lock system
In addition to the above features, they have the following features.
* Soft start for suppressing starting shock
* Delayed restarter for avoiding unintentional over fastening
W
* Indication lamp, informing operator of the result of
fastening
They come to market wit the following model name and the specification.
BFH040 BFH040SAE * Battery 1220 x 2pcs. Dimensions (mm [inch])
BFH040F BFH040FSAE * Charger DC14SA Length (L) 190 [7-1/2]
BFH090 BFH090SAE with * Torque adjsut grip
BFH090F BFH090FSAE * Accessory case Width (W) 71 [2-13/16]
BFH120F BFH120FSAE * Steel carrying case With BH1220 266 [10-1/2]
Height (H)
With BH1233 289 [11-3/8]
Specification
Model No. BFH040 BFH040F BFH090 BFH090F BFH120F
Type of cell Ni-MH
Battery Voltage : V 12
2.0 Ah with battery BH1220
Capacity : Ah
3.3 Ah with battery BH1233
No load speed : min-1 = rpm 400
Fastening torque Hard joint 0.8 - 4.5 3.4 - 9.0 5 - 12
: N.m (7 - 40) (30 - 80) (44 - 106)
(in.lbs) Soft joint 0.8 - 4.5 3.4 - 9.0 5 - 12
(7 - 40) (30 - 80) (44 - 106)
LED Job Light No Yes No Yes Yes
Driving shank Hex 6.35mm (1/4")
Electric brake Yes
Torque adjustment Yes (Adjust grip is required.)
Soft starter Yes
Reverse switch Yes
Over load protector Yes
Net weight w/ 2.0Ah battery 1.5 (3.3)
: Kg (lbs) w/ 3.3Ah battery 1.8 (4.0)
Standard equipment
* Battery BH1220 ...................................................... 2 pcs.
* Charger DC14SA .................................................... 1 pc.
* Torque adjust tool ................................................. 1 pc.
* Accessory case ........................................................ 1 pc.
* Steel carrying case .................................................... 1 pc.
< Note > The standard equipment for the tool shown may differ from country to country.
Optional accessories
* Battery BH1220 * Adjust grip
* Battery BH1233 * ADP 03 Automatic Refreshing Adapter
* Charger DC14SA
* Charger DC24SA
Features and benefits P 2 / 20
BFH040, BFH040F, BFH090, BFH090F, BFH120F
Hazardous Location Tool
Conforming to UL1604, Class I, Division 2 , Group A- D Brush-less DC motor
(See "The hazardous location tools in UL1604" below.) provides spark-free rotation
High torque accuracy
7%Cm < 1.67
Indication
Bit sleeve, covered with rubber
lamp
to protect workpiece from
accidental scratches Refer to "List of the Electronic
Functions and Reminders" on
LED Job light exclusively for page 2 and 3.
BHF120F, BHF090F and BHF040F
Push button type
The spark comes out of the terminals, reverse switch
if battery is removed while switch
ON-OFF switch with
trigger is pulled.
soft start feature for
Battery inter lock system has solved suppressing starting
this trouble. shock.
Because of this system, it is impossible
to remove battery without releasing
switch trigger.
Hand strap of parachute 550 type
Battery inter lock can be attached.
lever
12 V Ni-MH battery with
new charging system Anti-slip dimpled grip
The hazardous location tools in UL1604
The standards for the electric tools and utensils which are ranked in;
* Class I, Division 2
UL1604
* Class II, Division 2
* Class III,
* Class I : The division in which ignitable gases, vapors or liquids BFH series models are
are to exist. ranked in this Class I.
Class
* Class II : The division in which ignitable dust is to exist.
* Class III : The division in which ignitable fibrous dust is to exist.
* Division 1 : where ignitable concentrations of flammable gases, vapors or
liquids are likely to exist constantly or temporally, under normal
operating conditions.
Division
* Division I1 : where ignitable concentrations of flammable gases, vapors or BFH series models are
liquids are not likely to exist under normal operating conditions, ranked in this Division
but likely to exist under abnormal conditions. II.
The ignitable gas or materials which are ranked in Class I
Group A : atmospheres such as "acetylene", gases or vapors of equivalent hazard BFH series models can
Group Group B : atmospheres such as "hydrogen", gases or vapors of equivalent hazard be used under the
Group C : atmospheres such as "ethylene", gases or vapors of equivalent hazard condition of Group
Group D : atmospheres such as "propane", gases or vapors of equivalent hazard A- D.
Features and benefits P 3 / 20
List of the electronic function and reminders
1. In case of no trouble on the result of work and on the machine itself, the lamp and beeper inform
of the following matters.
Lamp Beeper Auto stop What the lamp, beeper and auto stop system inform of.
Turns on in the A series of Under testing the function of indication
order of green, short beeps lamp and beeper, when installing battery.
red and white.
Finish of single fastening process with reaching
the pre-set fastening torque.
Turns on At this time, clutch works and delayed restarter
No beep ON
in green. keeps the motor still for one second after finishing
sufficient fastening process, to avoid the unintentional
over-tightening which will occur by mis-operation
of switch trigger.
2. In case of trouble on the result of work, or on the machine itself, the lamp and buzzer inform of the following matters.
What the lamp, beeper and
Lamp Beeper Auto stop auto stop system inform of. Action to be taken
Insufficiently finished single Try again to fasten the screw
fastening process, without or bolt.
Turns on A long
reaching the pre-set fastening It is important to pull the switch
in red. beep
torque. trigger on, till the clutch works.
Remaining battery Motor rotates on, however, it is
A series power is little. recommended to replace with
Blinks in red of long the fully charged battery in the
slowly. beeps appropriate time.
Impossible to fasten screws Immediately replace the
A long
or bolts with the pre-set old battery with the fully
Turns on beep ON
fastening torque any more. charged battery.
in red.
Blinks in A series Warning of abnormal drop in Motor does not rotate in spite of
red and green of long battery voltage for some pulling switch trigger.
ON
alternately. beeps reason. The warning by lamp and beeper
stops with removing battery.
A series Warning of over heat on Motor does not rotate in spite of
Blinks controller or motor. pulling switch trigger.
of short ON
in red Remove the battery immediately
beeps
quickly. and cool the machine down.
Blinks A series Operation error in removing Release the switch trigger and
in green of long battery lower the battery interlock lever.
slowly. beeps
Blinks in A series Reminding the abnormal Ask Makita service centers.
red and green of long ON condition of motor.
alternately. beeps
Blinks in A series This indicates abnormality of
red and green ON battery interlock lever, when Ask Makita service centers.
of short
alternately. beeps the battery has been inserted.
Comparison of products P 4 / 20
Model No. BFH040 BFH040F BFH090 BFH090F BFH120F
Type of cell Ni-MH
Voltage : V 12
Battery 2.0 with battery BH1220
Capacity : Ah
3.3 with battery BH1233
Energy : Wh 24.0 with battery BH1220
39.6 with battery BH1233
Charging time with Approx. 30 min. for battery BH1220
DC14SA Approx. 50 min. for battery BH1233
No load speed : min-1 = rpm 400
Motor type DC brush less
Fastening torque Hard joint 0.8 - 4.5 3.4 - 9.0 5 - 12
: N.m (7 - 40) (30 - 80) (44 - 106)
(in.lbs) Soft joint 0.8 - 4.5 3.4 - 9.0 5 - 12
(7 - 40) (30 - 80) (44 - 106)
LED Job Light No Yes No Yes Yes
Beeper No Yes No Yes Yes
Indication lamp Yes Yes Yes Yes Yes
Driving shank Hex 6.35mm (1/4")
Electric brake Yes
Torque adjustment Yes (Torque adjust tool is required.)
Soft starter Yes
Reverse switch Yes
Over load protector Yes
Length (L) : mm 190
["] [7-1/2]
Dimensions
Width (W) : mm 71
["] [2-13/16]
266
with battery BH1220
Height (H) : mm [10-1/2]
["] 289
with battery BH1233
[11-3/8]
Net weight w/ 2.0Ah battery 1.5 (3.3)
: Kg (lbs) w/ 3.3Ah battery 1.8 (4.0)
Repair P 5 / 20
< 1 > Lubrication
Apply MAKITA grease N. No.2 to the following portions designated by black triangle to protect
parts and product from unusual abrasion. See Fig. 1.
Ball bearing Gear case
44 6805LLB 47 48 49 50 Lock washer 54
Motor bracket
Fig. 1
Position Portion Amount : g
No. Parts item to be lubricated ( oz )
Carrier
44 Shaft portion which accept 47: spur gear 18.
complete B
47 Spur gear 18 Teeth portion
48 Spur gear 9 Shaft portion which accept 49: spur gear 19. Approx. 2
complete Teeth portion of spur gear 9 (0.08)
in total
49 Spur gear 19 Teeth portion
50 Internal gear 47 Teeth portion where 47: spur gear 18 and 49: spur gear 19 roll.
54 Rotor Teeth portion
< 2 > Disassembling bit holder section
( 1 ) Remove ring spring 10. Then, flat washer 11, compression spring 13, sleeve and 2 pcs of steel 3 can be removed
from spindle. See Fig. 2.
1R291
Ring spring 10 Retaining Ring S and R Pliers
Flat washer 11
Compression spring 13
Sleeve
Spindle Steel ball 3
Head of clutch case
Steel ball 3
Fig. 2
< 3 > Assembling bit holder section
( 1 ) Mount 2 pcs. of steel ball 3.
( 2 ) Mount sleeve.
( 3 ) Mount compression spring 13. See Fig. 2.
( 4 ) Mount flat washer 11.
( 5 ) Secure the above parts with ring spring 10 to spindle.
Repair P 6 / 20
< 4 > Disassembling spindle (as a bit holder) and clutch case
( 1 ) After removing bit holder section, remove ring 38 by unscrewing pan head screw M4x4, and clutch case cover
by unscrewing pan head screw M4x8. And then, remove compression spring 2 and switch lever. See Fig. 3.
( 2 ) Remove clutch case by unscrewing 4 pcs. of pan head screw M4x22. See Fig. 4.
< Note > Compression spring 5 can easily fall off clutch section. Be careful, not to lose compression spring 5
in this step.
( 3 ) Remove retaining ring R-21 from clutch case. And then, knock the edge of clutch case with plastic hammer.
So, spindle (as a bit holder) can be removed from clutch case. See Fig. 5.
( 4 ) Remove ring spring 11 from spindle. And then remove ball bearing 6801LLB on the ring spring 11 side.
See Fig. 6.
( 5 ) After removing ring 12, remove the another ball bearing 6801lLB. See Fig. 7.
Pan head screw M4x8 Pan head
Ring 38 screw M4x22
(black)
Clutch case cover Clutch case
Compression
spring 2 Clutch section
Switch lever
Pan head
screw M4x4 (silver) Compression
spring 5
Clutch case
Fig. 3
Fig. 4
No.1R311 1R004
Retaining Ring Pliers Retaining ring S plier Ball bearing 6801lLB
Retaining ring R-21 with Long Bent Nails
Ring spring 11
1R269
Fig. 6 Bearing Extractor
Spindle Ball bearing
Ring 12 6801LLB
Ball bearing 6801lLB
Fig. 5 Ring 12
Spindle
Fig. 7
Repair P 7 / 20
< 6 > Assembling spindle (as a bit holder) and clutch case
( 1 ) Set ball bearing 6801LLB on 1R035 "Bearing setting plate". Mount spindle to ball bearing 6801LLB by pressing
with arbor press. See Fig. 8
( 2 ) Mount ring 12 to spindle. See Fig. 9.
( 3 ) Set another ball bearing 6801LLB on 1R035 "Bearing setting plate". Mount spindle to the ball bearing 6801LLB
by pressing with arbor press. See Fig. 10.
( 4 ) Secure 2 pcs. of ball bearing 6801LLB and ring 12 with ring spring 11. See Fig. 11.
< Note > Do not use the used ring spring 11. It has to be always replaced with the fresh one.
Ball bearing Ball bearing
6801LLB 6801LLB
Spindle 1R004
Retaining ring S plier
1R035 Ring 12
Bearing setting plate Ring spring 11
Fig. 10
Fig. 8 Fig. 9
Fig. 11
( 5 ) Mount the spindle section to clutch case as illustrated in Fig. 12.
( 6 ) Secure the spindle section in the clutch case with retaining ring R-21. See Fig. 13.
Retaining ring R-21
1R237
Round bar for arbor
No.1R311
Clutch case Retaining Ring Pliers
with Long Bent Nails
Fig. 13
Pan head
1R036 screw M4x22
Bearing setting plate Fig. 12
Clutch case
( 7 ) Mount clutch section to motor housing. Mount Clutch section
compression spring 5 to the clutch section. Fasten
the clutch case to the motor housing with 4 pcs.of
pan head screw M4x22 See Fig. 13.
Compression
spring 5
Fig. 14
Repair P 8 / 20
( 8 ) Mount compression spring 2 and switch lever. And secure clutch case cover
with pan head screw M4x8 (black). See Fig. 15.
( 9 ) Secure ring 38 to clutch case with pan head screw M4x4 (silver). See Fig. 16.
Pan head
screw M4x8 (black)
Clutch case cover Ring 38
Compression spring 2
Switch lever
Clutch case
Pan head
screw M4x4 (silver)
Fig. 15 Fig. 16
< 6 > Disassembling clutch section
( 1 ) Remove ring 38 and clutch case cover referring to "< 4 > Disassembling spindle (as a bit holder) and clutch case".
( 2 ) Remove clutch section from motor housing. See Fig. 17.
( 3 ) Insert torque adjust tool into the hole of adjust ring complete.
Turn torque adjust tool anti-clockwise, until adjust ring complete
is free from the compression spring 19. See Fig. 18.
Then, lock nut M12 can be separated from adjust ring complete Compression
by turning clockwise with your hand. See Fig. 19. spring 5
( 4 ) Remove adjust ring complete, flat washer 18 and
compression spring 19 from spindle. See Fig.20.
Clutch section
Torque adjust tool
(Standard equipment) Compression Fig. 17
spring 19
Adjust ring
Lock nut M12 complete Flat washer 18
Adjust ring
complete Fig. 18 Compression
spring 19
Spindle
Lock nut M12
Fig. 19 Fig. 20
Repair P 9 / 20
(5) Insert hex wrench into the hole of spindle and hold the hex wrench with vise. Insert torx wrench T25 into
the hole of torx counter sunk head screw M5x10. And turn torx wrench T25 anti-clockwise. See Fig. 21.
Use the hex wrench with the
Hex wrench
following size. Torx wrench T25
6mm Torx counter sunk
head screw M5x10.
Fig. 21
(6) After removing torx counter sunk head screw M5x10, the clutch section can be disassembled in the order of
flat washer 7, steel balls 3.0, cam A and steel balls 4. See Fig. 22.
Remove steel balls 5. Then, cam B can be removed from spindle. See Fig. 23.
Cam D Cam A Torx counter sunk Cam B
head screw M5x10.
Spindle
Flat washer 7
Steel balls 3.0
Steel ball 4 (13 pcs.) Steel ball 5
(3 pcs.) (3 pcs.)
Fig. 22 Fig. 23
Pay attention, not to lose steel
balls, when disassembling.
< 7 > Assembling clutch section
(1) Before mounting, take the following steps. See Fig. 24.
1. Apply MAKITA grease N. No.2 to 3 pcs. of steel ball 5 and 3 pcs. of steel ball 4.
2. For effective adhesion, clean the screw hole of spindle and torx counter head sunk screw M5x10 with petrol.
Screw hole for
torx counter sunk head
Spindle screw M5x10 Torx counter sunk
head screw M5x10
Fig. 24
Repair P 10 / 20
(2) Mount steel balls and cam B and cam A in the order of Fig. 25, Fig. 26, Fig. 27 and Fig.28.
Fig. 25 Fig. 26 Fig. 27 Fig. 28
Steel balls 5 Cam B Steel balls 4
(3 pcs.) (3 pcs.) Cam A
Mount steel balls 5 Mount cam D to spindle
to spindle. with aligning its 3 grooves Mount steel balls 4 Mount cam A.
with steel balls 5. to cam B.
(3) Before mounting, apply MAKITA grease N. No.2 to 13 pcs. of steel balls 3.0.
Assemble steel balls 3.0, flat washer 7 and torx counter sunk head screw M5x10 as illustrated in Fig. 29, Fig.30
and Fig. 31.
Fig. 29 Fig. 30 Fig. 31
Steel balls 3.0 Torx counter sunk
(13 pcs.) Flat washer 7 head screw M5x10
Pay attention, not to spot Apply here the
the screw hole of spindle adhesive by 0.1CC,
with the grease, when before screwing.
assembling steel balls.
Mount steel balls 3.0 Mount flat washer 7 After applying 0.1cc (3 drops) of
to cam A. to cam A. adhesive, "Lock tight 603" in the
screw hole, fasten flat washer 7
with torx counter sunk head
screw M5x10.
The fastening torque for the
screw is 8 - 10 N.m.
(4) Before mounting, apply MAKITA grease N. No.2 to threaded portion of spindle.
Assemble compression spring 19, flat washer 18 and adjust ring complete and lock nut 12
in the order of Fig. 31 and Fig. 32.
Fig. 31 Fig. 32
Lock nut 12
Adjust ring Compression
complete Flat spring 19
washer 18
While pressing lock nut 12 strongly, turn torque adjust tool
clockwise. Then, lock nut M12 turns anti-clockwise
and fastened to spindle.
Repair P 11 / 20
< 8 > Disassembling motor section and gear section
( 1 ) Remove ring 38, and clutch cover from housing referring to "< 4 > Disassembling spindle (as a bit holder)
and clutch case".
( 2 ) After removing clutch section, separate housing L from housing R by unscrewing 8 pcs.
of pan head screw M3x20. See Fig. 33.
Compression spring 5 Plate
Housing L Housing R
Clutch
section
Lens
Pan head
screws M3x20
Fig. 33
( 3 ) Remove gear section with motor section from housing R . See Fig. 34.
( 4 ) Turn motor bracket anti-clockwise. So gear section can be separated from motor section. See Fig. 35.
Motor bracket
Gear section
Motor section
Fig. 34 Fig. 35
( 5 ) Pull off rotor from motor control unit and remove motor bracket. See Fig. 36.
Motor bracket
Motor control unit
Rotor
Be careful, not to be pinched your finger
between motor control unit and rotor.
Because, rotor is pulled toward motor
control unit by the strong magnetic force.
Fig. 36
Repair P 12 / 20
( 6 ) Turn lock washer, and pull off it. See Fig. 37.
( 7 ) Then, gear section can be disassembled as illustrated in Fig. 38 and Fig. 39.
Carrier
Fig. 37 Fig. 38 Fig. 39 complete B
Lock washer
Spur gear 9 Ball bearing
complete 6805LLB
Spur gear 18 x 3 pcs.
Gear case
Spur gear 19 x 3 pcs. Internal gear 47
< 9 > Assembling motor section and gear section
( 1 ) Referring to "< 1 > Lubrication", apply MAKITA grease N No.2 to the gears and shaft portions of spur gear 9
and carrier complete B.
( 2 ) Mount ball bearing 6805LLB and carrier complete B to gear case. See Fig. 40
( 3 ) Mount internal gear 47 to the gear case. See Fig. 41.
( 4 ) Engaging internal gear 47, mount 3 pcs. of spur gear 18 to the shaft portion of carrier complete B. See Fig. 42.
( 5 ) Engaging spur gears 18, mount spur gear 9 complete. See Fig. 43.
( 6 ) Engaging internal gear 47, mount 3 pcs. of spur gears 19 to the shaft portion of spur gear 9 complete.
See Fig. 44.
( 7 ) Mount lock washer to the gear case by turning. See Fig. 45.
( 8 ) Mount motor bracket to the gear case by turning clockwise. The assembling of gear section has been completed
in this step. See Fig. 46.
Carrier Spur gear 18 Spur gear 9
complete B
complete
Ball bearing
6805LLB
Gear case
Internal
gear 47
Gear case
Fig. 40 Fig. 41 Fig. 42 Fig. 43
Spur gear 19 Motor bracket
Lock washer
Fig. 44 Fig. 45 Fig. 46
Repair P 13 / 20
( 9) Insert armature into motor control unit. See Fig. 47. The assembling of motor section has been completed
in this step.
(10) Join the motor section to the gear section. See Fig. 48.
Motor control unit
Rotor
Be careful, not to be pinched Gear section
your finger between motor control
unit and rotor.
Because, rotor is pulled toward
motor control unit by the strong
magnetic force.
Fig. 47 Fig. 48
(11) Facing switch unit to the plate installing side, mount the motor and gear section to housing R.
and mount trigger switch section, LED circuit to housing R. See Fig. 49.
As for buzzer circuit, lever guide, switch lever B and interlock switch, mount as illustrated in Fig. 49A
and Fig. 49B.
(12) Mount plate and lens. And secure housing L with 8 pcs. of pan head screw M3x20. See Fig. 50.
Switch unit Fig. 49A
Plate installing side
Press switch lever B toward lever guide
through housing R. Then hooks of switch
LED circuit lever B are interlocked in the assembling
(for BFH...F series) hole of lever guide.
Trigger switch Switch
section lever B
Interlock
Buzzer switch
circuit
(for BFH...F series)
Lever guide
Spacer Lever guide
Terminal Hooks of Switch lever B
Fig. 49
Plate
Fig. 49B Housing R
Housing L
Housing R
Buzzer circuit
Lens
Interlock
switch unit
Boss for protecting
interlock switch unit Pan head
screws M3x20
Fig. 50
Lever guide
Bosses on Housing R
P 14 / 20
<10> Disassembling Switch Section
(1) Remove Clutch case section and Housing L from Housing R.
(2) Remove Switch unit of trigger section by carefully extending hooks. See Fig. 51
(3) And then, by removing Tapping bind screw PT3x16 and Cover, you can disassemble Switch section as illustrated
in Fig. 52;
Hook
Switch unit of
trigger section
Fig. 51
Tapping bind screw PT3x16
Cover
Leaf spring
Change lever
Switch lever A
Switch unit for rotational direction change
Compression spring 4 Switch base
Fig. 52 Switch unit of trigger section
<11> Assembling:
(1) Set Leaf spring in place on Change lever, and install Compression spring 4 on Switch lever A.
And then, set the following parts in place on Switch base;
Switch unit for rotational direction change
Switch unit of trigger section
(2) While pushing Change lever with Cover, assemble the parts in Fig. 52 with PT3x16 Tapping bind screw. (Fig. 53)
Take care not to allow Compression spring 4 and protruding portion of Change lever to get out of place.
Protruding portion of Change lever
Switch lever A
Install the protruding portion of the Change lever
in the Switch lever A.
Fig. 53
P 15 / 20
<12> Disassembling Interlock Section
Switch lever B and Lever guide can be removed by carefully expanding hooks of Switch lever B in Interlock section
with slotted driver, etc. (Fig. 54)
Fig. 54 Slotted driver
Switch
lever B
Lever guide
Lever guide Hooks of Switch lever B
<13> Caution fort handling rotor
Keep the following minimum distances, when put or store the plural rotors. Failure to keep the minimum distances
will be cause of breakage. See Fig. 55.
10.0 mm (3/8")
15.0 mm
(9/16")
20.0 mm
(13/16")
Fig. 55
Circuit diagram P 16 / 20
Color index of lead wires' sheath
Black Orange
White Blue
Red Purple
Yellow Gray
Switch Section
ON/OFF switch Reverse switch
Connector
Stator of
Controller DC brushless
motor
Terminal
Motor control unit
Switch unit
LED
(interlock)
circuit
Buzzer Switch unit
circuit (clutch)
Wiring diagram
When connecting Connectors, be sure to connect together two Connectors that have lead wires of the same colors.
(1) Wiring in the rotor fan side of housing
Set Motor section in place on Housing R, and then as illustrated in Fig. A, route the lead wires which connects
Motor section and Controller section.
Fig. A
Motor section of
Motor control unit
Controller section of
Motor control unit
Housing R
Lead wire (blue)
Lead wire (white)
Lead wire (orange)
(1) First, route the three lead wires:
blue, white and orange.
(2) And then put the other wires
under the three lead wires.
Wiring diagram P 17 / 20
(2) Wiring near the LED circuit and clutch switch unit
Put Controller section in place on Housing R, and install LED circuit on Housing R. And then as illustrated in
Fig. B, pull the following parts out of Housing R: Lead wires and Connectors from LED circuit, Clutch switch unit.
Fig. B
These parts must be
placed out of Housing R.
Controller section of
1 6 7 Motor control unit
1. Clutch switch unit
2. Lead wire to Motor control unit (yellow)
3. Lead wire to Motor control unit (purple)
2 4. Lead wire from LED circuit (gray)
3 5. Lead wire from LED circuit (blue)
4 6. Lead wire to Motor control unit (gray)
5 7. Lead wire to Motor control unit (blue)
LED circuit Housing R
(3) Wiring near the trigger switch section
Place Switch section in place on Housing R. See Fig. C for the wiring.
The lead wires to Switch unit of Trigger section must be placed between Pin 1 and Pin 2.
Also do not fail to place the lead wire to Switch unit for rotational direction change between Pin 2 and Pin 3.
Fig. C
Lead wire to Switch unit for
rotational direction change
Switch unit of trigger section (yellow)
Lead wire to switch unit of Lead wire to Switch unit for
trigger section (white) rotational direction change
(blue)
Lead wire to switch unit of
trigger section (yellow) Pin1
Lead wire to Switch unit for Pin2
rotational direction change
(yellow) Pin3
Lead wire to Switch unit for
rotational direction change Lead wire from Lead wire from
(blue) Motor control unit (yellow) Motor control unit (blue)
P 18 / 20
(4) Wiring near the buzzer circuit and interlock switch
Place the lead wires from Buzzer between the boss and the wall of Housing R as illustrated in Fig. D.
And then fix Interlock switch unit to Housing R by fitting the through holes of the Switch unit to the bosses
on Housing R as illustrated in Fig. E.
Fig. D
Boss of Housing R for holding Buzzer
Wall of Housing R
Buzzer Lead wire from Buzzer (white)
Lead wire from Buzzer (red)
Fig. E
Housing R
Interlock switch unit
Boss for protecting Interlock switch unit
Lead wire from Interlock switch unit (red)
Lead wire from Interlock switch unit (yellow)
Bosses on Housing R
(5) Wiring near the terminal
1. Connect Terminal to Motor control unit as follows.
There is a flag receptacle on each of the two lead wires (black one and red one) from Motor
control unit.
Connect these receptacles with Terminal as illustrated in Fig. F.
Be sure to connect the flag receptacle on the red lead wire to the (+) terminal, and connect
the other one on the black lead wire to the (-) terminal.
Fig. F
Flag receptacle on Flag receptacle
black lead wire on red lead wire
Terminal
P 19 / 20
2. After connecting flag receptacles, set Terminal in place on Housing R, and put the lead wires
(black one and red one), which connect Terminal to Motor control unit, on the lead wires from
Interlock switch unit illustrated in Fig. G.
And then apply gentle pressure to lead wires (black one and red one) in order to hold down the lead wires which
is laid under them.
Fig. G
< Note >
Make sure that spacer has been mounted
to housing R, before setting terminal.
Refer to Fig. 49 in page 13.
Red lead wire which connects Terminal
to Motor control unit
And black one
Terminal
(5) Wiring around clutch case
Put the lead wire of clutch switch unit as illustrated in Fig. H
Fig. H
Top view of clutch switch unit
Clutch switch unit Lead holder
Contain the slack portion
Pin
of lead wires and connectors
into this pace.
Clutch case
Pass the lead wires, covered by shrink tube,
through the pin.
And hold them with lead holders at clutch case.
Wiring diagram P 20 / 20
(7) Handling connectors
You can disconnect the connectors which connects up the 6 units/circuits listed below by pulling the connectors to
the directions designated by the arrows as illustrated in Figs. H, I and J:
Buzzer circuit, Interlock switch unit, Switch unit of Trigger section,
Switch unit for rotational direction change, Clutch switch unit, LED circuit
Note: Never hold the wires when separating the connectors, because they are very thin and fragile.
Therefore, always hold the connectors when disconnecting the connectors.
Fig. H Fig. I Fig. J
Switch unit for rotational Clutch switch unit
direction change
Buzzer circuit Interlock Switch unit of Trigger section LED circuit
switch unit
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