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BFL081F-TE


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T    ECHNICAL INFORMATION
   Models No.                 BFL081F
                                                                                                                          NEW TOOL
                                                                                                                            P 1 / 17

   Description                Cordless Angle Screwdriver 12V                                                L
                                                                                                                                         H
CONCEPT AND MAIN APPLICATIONS
   BFL081F is sister cordless angle screwdriver to model BFL080F,
   featuring higher rotational speed than the predecessor while having                                                          W
   the same torque range and the following features.
     * Soft start
     * Delayed re-starter                                                                    Dimensions : mm ( " )
     * LED Job light                             with battery    BH1220                      BH1220C       BH1233              BH1233C
     * Indication lamp for telling               Length ( L ) 430 (17)                       413 (16-1/4)   454 (17-7/8) 421 (16-5/8)
       the fastening result
                                                 Width ( W ) 71 (2-13/16)                    74 (2-15/16)   71 (2-13/16) 74 (2-15/16)
                                                 Height ( H ) 92 (3-5/8)                     92 (3-5/8)     92 (3-5/8)   107 (4-1/4)

    The variations of this model are as listed below.
       Model No.             Driving shank                Charger        Battery
       BFL081FZ           9.5mm (3/8") square               No             No
       BFL081F5Z          6.35mm (1/4") square              No             No


 Specification
               Type of cell                                      Ni - MH
       Battery Voltage : V                                           12
                                                     2.0 Ah w/ BH1220, BH1220C
                  Capacity
                                                     3.3 Ah w/ BH1233, BH1233C
      No load speed : min -1 = rpm                                  700
      Fastening                Soft joint                  2 - 7.5 (17.7 - 66.4)
       torque : N.m (in.lbs) Hard joint                     2 - 8 (17.7 - 70.8)
      Electric brake                                                Yes
      Torque adjustment                            Yes (Torque adjust tool is required.)
      Soft starter                                                  Yes
      Reverse switch                                                Yes
      Net         with battery BH1220                            1.7 (3.7)
      weight:     with battery BH1233                            2.0 (4.4)
       kg (lbs) with battery BH1220C                             1.6 (3.5)
                  with battery BH1233C                           1.9 (4.2)

 Standard equipment
   * Torque adjust tool ........................ 1 pc. (exclusively for some country)
   * Protector ...................................... 1 pc. (exclusively for some country)

   < Note > The standard equipment for the tool shown may differ from country to country.


 Optional      accessories
   * Battery BH1220, 12V 2.0Ah                        * Charger DC24SA                            * Protector (clear red)
   * Battery BH1220C, 12V 2.0Ah                       * Charger DC14SA                            * Protector (clear blue)
   * Battery BH1233, 12V 3.3Ah                        * Auto refresh adapter ADP03                * Protector (clear yellow)
   * Battery BH1233C, 12V 3.3Ah                       * Angle head set                            * Protector (clear)
                                                      * Torque adjust tool
                                                                                                                P 2 / 17
Features   and benefits

 *High rotational speed: 700 min.-1                      Indication Lamp and Beeper
                            ( No load speed)        inform user of;
                                                    * Sufficient fastening = Green on
                                                    * Insufficient fastening = Red on
                                                                             and Beeping
    *Higher Torque Accuracy                         * Warning that remaining battery
 Torque accuracy:                                          power is little = Red on
 Plus or minus 10%,                                                           and Beeping
 Cm is more than or equal to 1.67                   * Too little power to operate
                                                             the machine = Motor stops with Red on
                                                                             and Beeping

 Torque adjusting system                                                    D28 Type Motor
 just for the manufacturing line
                                                                        Externally accessible brushes
 Impossible to change fastening torque
                                                                        Two-piece motor with replace-
 originally set by factory, without
                                                                        able armature
 torque adjust tool.
                                                                        Uses compact and light, yet
                                                                        powerful rare earth magnet
 Extra-rigid, Aluminum-alloy
          Angle Head

 Head height:
 28.5mm (1- 1/8")



                                                                                                Anti-Slip Dimpled Grip

                                                       Trigger switch provides one second start-delay between
        Center height:                                 fastening cycles to prevent overtightening
        13.5mm (1/2")
                                                                                                Auto Stop System
                                                         *Conveniently Located                  By sensing battery's
                                                      Forward / Reverse Push Button             power drop.

                                                           Built in Electronic System featuring

                                           Soft start to suppress   Delayed re-starter
                                           return torque            The restarting delayer controls the motor
               Built-in                    at start-ups             so that it does not start without passing one second
              Job Light                                             after finishing single tightening work, even if switch
                                                                    trigger is pulled.
      Lighting up automatically
      when motor starts, and                                        Consequently, reduced considerably deviation
      turns off within 10 sec. after                                from pre-set fastening torque , which is caused
      switching off.                                                by unintentional over-tightening.


                                                                Batteries with new charging system
      Protector (option)
      Protects workpiece from scratches.                        2.0Ah Battery BH1220
                                                                2.0Ah Battery BH1220C
       Uses Machine Screws for                                  3.3Ah Battery BH1233
       Assembling Motor Housing                                 3.3Ah Battery BH1233C
                                                                                                             P 3 / 17
Lists of the Electronic Functions and Reminders
1. When a screw has been driven completely at preset torque, or when there is no trouble in the machine;

                     Electronic Reminders
                                                  When Function                What LED Indicator Lamp and
    Function       LED Indicator Beeping                                       Alarm Buzzer Remind the User
                      Lamp        of Buzzer          Works

                Turns on first                                       To ensure that LED indication lamp and alarm
 Checking LED                     Rapid      Just after the
                in green, then                                       buzzer works normally; if there is no trouble in
 Lamp and Alarm                succession of battery is installed
                in red and fi-                                       electronic parts, each reminder turns on and beeps
 Buzzer                                      on the machine.
                nally in white. short beeps                          as described to the left columns.
                                                                   To ensure that a screw has been driven completely
                                                 When a screw has at preset torque. The auto fastening stop system
                                                 been fastened     helps the user avoid overtightening.
 Auto Fastening      Turns on                                      For approximate one second after auto fastening
                                                 completely at
 Stop & Delayed                   No beeping
                     in green.                   preset torque and stop system works, the tool does not start even if
 Restart                                                           the trigger switch is pulled as long as the lamp is
                                                 the clutch is
                                                 released.         on in green. The delayed restart system helps the
                                                                   user avoid accidental overtightening which will be
                                                                   caused by fault operation of trigger switch.

2. When a screw has not been driven completely at preset torque, or when there is some trouble in the machine;

                     Electronic Reminders
                                                  What LED Indicator Lamp and
    Function       LED Indicator Beeping                                                  Corrective Action to Take
                                                  Alarm Buzzer Remind the User
                      Lamp        of Buzzer
                                             Incomplete tightening has been             Tighten the screw once again.
 Warning Against
                     Turns on                performed, because the trigger switch      It is important to keep on
 Incomplete                      A long beep
                      in red.                has been released before the fastening     pulling the trigger switch till
 Tightening
                                             torque reaches preset one.                 the clutch is released.
                                                                                     Although the motor will run,
                                     Slow      It is appropriate time to replace the it is recommended to replace
 Battery Power     Blinks slowly
                                 repetition of battery with full-charged one because the battery by full-charged one.
 Reminder              in red.
                                  long beeps the battery power is getting low.       The reminders turn off when
                                                                                     battery voltage recovers.
                                                                                        Replace the battery with full-
                                                                                        charged one to avoid incomplete
 Auto Battery        Turns on                    There is not battery power enough
                                 A long beep                                            tightening.
 Shut-off             in red.                    to tighten a screw at preset torque.
                                                                                        The reminders turn off when
                                                                                        the battery cartridge is removed.
                                                                                        Replace the battery with full-
                                                 Abnormal drop in battery voltage
                   Blinks in red                                                        charged one to avoid incomplete
 Anti-Resetting                  Repetition of   has been caused for some reason.
                     and green                                                          tightening.
 of Controller                    long beeps     The motor does not start even if the
                    alternately.                                                        The reminders turn off when
                                                  trigger switch is pulled.
                                                                                        the battery cartridge is removed.
                                                                                        Immediately remove the battery,
 Warning Against                  Quick      The controller is overheated.
                 Blinks in red Repetition of The motor does not start even if the       and cool down the machine.
 Overheated
                   quickly.                                                             The reminders turn off when the
 Controller                     short beeps trigger switch is pulled.
                                                                                        machine temperature gets low.
                                            Some trouble has occurred in clutch
Warning Against Blinks in red               system, keeping the micro switch            Ask Makita Authorized or Fac-
                              Repetition of turned on.
Abnormal Clutch and green                                                               tory Service Center for repairs
                               long beeps The motor does not start even if the
Work             alternately.                                                           or adjustment.
                                            trigger switch is pulled.
 Warning Against Blinks in red Repetition of      The battery cartridge has been        Release the trigger switch.
 Fault Position of   and green   long beeps       installed on the machine with the     The reminders turn off when
 Trigger Switch     alternately.                  trigger switch being pulled to the    the trigger switch is released.
 (when installing                                 "On" position.                        This function helps the user
 the battery on the                                                                     avoid accidental start-ups when
 machine)                                                                               installing the battery cartridge
                                                                                        on the machine.
                                                                                                                      P 4 / 17

Comparison            of products

                                                                      Makita                       Competitor A
                                       Model No.
  Specifications                                        BFL081F             BFL080F            A                  B
                   Type of cell                                     Ni-MH                  Pneumatic       Pneumatic
    Battery        Voltage ; V                             12                    9.6
                   Capacity : Ah                                    2.0 / 3.3
    No load speed : min -1=rpm.                           700                   450          1,100            700

    Fastening                        Soft joint                     2 - 7.5                 2.5 - 7          3.5 - 7
     torque range : N.m
                                     Hard joint                       2-8
    Auto stop sensing
                                                                      Yes                     No              No
    the remaining battery power
    Built in job light                                                Yes                     No              No
    Soft start feature                                                Yes                     No              No
  Indication lamp for checking
  fastening performance                                               Yes                     No              No

                                   Length : mm ( " )   430 (17)
               with                Width : mm ( " )     71 (2-13/16)
               Battery BH1220
                                   Height : mm ( " )    92 (3-5/8)
                                   Length : mm ( " )   413 (16-1/4)
               with
                        Width : mm ( " )
               Battery BH1220C                          74 (2-15/16)
                        Height : mm ( " )               92 (3-5/8)
                        Length : mm ( " )              454 (17-7/8)                        Overall          Overall
      with                                                                                 length :         length :
  Dimensions




      Battery BH1233    Width : mm ( " )                71 (2-13/16)
                                                                                             334              290
                        Height : mm ( " )               92 (3-5/8)
                                                                                           (13-1/8)         (11-3/8)
                        Length : mm ( " )              421 (16-5/8)
      with
      Battery BH1233C Width : mm ( " )                  74 (2-15/16)
                        Height : mm ( " )              107 (4-1/4)
                        Length : mm ( " )                                430 (17)
     with
     Battery BH9020 / A Width : mm ( " )                                  74 (2-15/16)
                        Height : mm ( " )                                 65 (2-9/16)
                        Length : mm ( " )                                454 (17-7/8)
     with
     Battery BH9033 / A Width : mm ( " )                                    74 (2-15/16)
                        Height : mm ( " )                                   65 (2-9/16)
                         Battery BH1220                 1.7 (3.7)
                         Battery BH1233                 2.0 (4.4)
                                                                                            1.5 - 1.7       1.4 - 1.5
  Weight : kg (lbs)      Battery BH1220C                1.6 (3.5)
                                                                                           (3.3 - 3.8)     (3.1 - 3.3)
           including     Battery BH1233C                1.9 (4.2)
                        Battery BH9020 / A                                    1.7 (3.8)
                        Battery BH9033 / A                                    2.0 (4.4)
                                                                                                                     P 5 / 17
Repair
< 1 > Lubrication
     Apply the grease to protect parts and product from unusual abrasion. See the list below and Fig. 1.

                  The parts to be lubricated with MAKITA grease N. No.2                            Amount to be applied
           Spindle complete              Apply to the bevel gear portion.
            O ring 14                    Apply to the whole portion.
           Carrier complete              Apply to the shafts for accepting spur gears 13.
           Spur gear 13                  Apply to the whole portion.
                                                                                                   approx. 4.1 g in total
                                         Apply to the shafts for accepting spur gears 18
           Spur gear 20 complete
                                         and pinion gear portion.
           Spur gear 18                  Apply to the whole portion.
           Internal gear 47              Apply to the teeth portion for engaging spur gears 18.
           Armature                      Apply to the gear portion for engaging spur gears 18.


                  The parts to be lubricated with seal grease                                      Amount to be applied
           Spindle                      Apply to the threaded portion.
           Steel ball 5.0               Apply to the whole portion.                                approx. 0.7 g in total
           Steel ball 4.0                Apply to the whole portion.
            Steel ball 3.0               Apply to the whole portion.

                  The parts to which adhesive "Lock Tight 603" is applied
                  for prevention against loosening
           Bearing retainer 14-23                       Apply to the threaded portion.
           Torx counter sunk head screw M5x10           Apply to the threaded portion.



  Fig. 1

                                                                       Steel ball 5.0             Steel ball 4.0
                                                                                                            Steel ball 3.0




                                                                    Spindle
                                                                                                     Torx counter sunk
                                Spindle complete                                                     head screw M5x10
                                    O ring 14

                                    Bearing retainer 14-23




                 Spur gear 13                                Spur gear 18

                                                   Spur gear 20 complete                                 Armature
      Carrier complete                                                        Internal gear 47
                                                                                                                   P 6 / 17
Repair
< 2 > Disassembling the LED light section
   1. After removing 2 pcs. of pan head screw M4x8, remove light cover. See Fig. 2.
   2. Take out LED circuit and disconnect the connector of LED circuit. See Fig. 2.

< 3 > Reassembling the LED light section
   1. Hold the lead wires with lead holders. See Fig. 2.
   2. Mount light cover by inserting the tab of light cover into the cut of housing. And fasten light cover with
      pan head screw M4x8. See Fig. 2.

               Fig. 2

                                       Pan head
                                       screw M4x8                                              Tab
                                                                      Light cover




                                                                                              Housing
                              Put the connectors and
                              extra of LED lead wires              Light holder
                              into the space for the LED
                              circuit.




                         LED circuit

                                 Connector

                                                              Hold the lead wires with lead holders


< 4 > Removing bearing retainer 14-23
   1. For removing bearing retainer 14-23 from angle head, turn it clockwise with wrench. See Fig. 3.
      < Note > Adhesive "Lock Tight 603" is applied to the threaded portion of bearing retainer 14-23.
               Powerfully turn the bearing retrainer .
   2. Press down bearing retainer 14-23 for removing it from spindle complete. See Fig. 3.
               Fig. 3


                            24mm

                                          Bearing retainer 14-23                         Spindle complete




                   Angle head          For removing, turn bearing
                                       retainer 14-23 with wrench
                                       clockwise.
                                                                                                                   P 7 / 17
Repair
< 5 > Remounting bearing retainer 14-23
   1. Apply MAKITA grease N No.2 to O ring 14. Mount flat washer 14, the O ring 14 and bearing retainer 14-23
      to spindle complete. See Fig. 4
   2. Apply MAKITA grease N No.2 to the gear room of angle head.
      Pay attention, not to apply the grease to the threaded portion of angle head to which bearing retainer 14-23
      is mounted.
   3. Apply adhesive, "Lock Tight 603" to the threaded portion of bearing retainer 14-23.
      Mount flat washer 6 to the gear room of angle head. See Fig. 4.
      Mount the bearing retainer 14-23 assembled in Fig. 4, by turning it counter clockwise. See Fig. 4.
      The fastening torque for bearing retainer 14-23 is 20 - 40 N.m.

 Fig. 4

                                                                                                             1R219
                    Spindle complete                                                                         Torque wrench

                    Flat washer 14          Mount them to
                    O ring 14               spindle complete.
                                                                         Spindle
                      Before mounting, apply MAKITA                      complete
                      grease N No.2 to O ring 14
                                                                                                            1R220
                                                                     Bearing
                                                                                                            Ratchet head
                          Apply adhesive, "Lock Tight 603"           retainer 14-23
   Bearing                to the threaded portion.                                                         1R222
   retainer 14-23                                            Flat washer 6                                 Socket adapter
                           Apply 2 g of MAKITA grease N No. 2.
                                                                                                           134841-3
                                                                                                           Socket 24-45
                              
                              Do not apply the grease to the
                              threaded portion to which bearing
               Angle head     retainer 14-23 is mounted.                       Angle head

< 6 > Removing spiral bevel gear 9
   1. Remove light cover as illustrated in Fig. 2. And remove switch lever and compression spring 2. See Fig. 5.
   2. After removing 4 pcs. of pan head screw M4x22, separate angle head complete from housing. See Fig. 5.
      Fig. 5

                                                                                    Switch lever
                    Compression spring 2

                                                                                            Switch unit




                Angle head complete


          Pan head                                                                       Housing
          screw M4x22



                        Compression
                        spring 5
            Be careful, not to lose
            compression spring 5.
                                                                                                                     P 8 / 17
Repair
    3. Remove retaining ring R-22 for securing ball bearing 6900LLB, with No. 1R291 "Retaining Ring S and R
       Plier". See Fig. 6.
    4. Knock the edge of angle head complete with plastic hammer, Then, spiral bevel gear 9 section can be removed
       from angle head complete. See Fig. 6.
      Fig. 6

                                               Retaining ring R-22
                                                                                                    Spiral bevel
                                                                                                    gear 9 section




                Angle head complete
       1R291
       Retaining Ring S and R Plier




    5. Remove retaining ring S-10 and then, remove ball bearing 6900LLB as illustrated in Fig. 7.
    6. Now spacer and needle baring 1210 can be removed from spiral bevel gear 9. See Fig. 7.

      Fig. 7
               1R291
               Retaining Ring S and R Plier
                                                Ball bearing 6900LLB          Spiral bevel gear 9

                                                                                            Needle bearing 1210




               Retaining ring S-10                                                              Spacer
                                                       1R269
                                                       Bearing extractor



< 7 > Remounting spiral bevel gear 9
     1. Mount needle bearing 1210 and spacer to spiral bevel gear 9. Refer to Fig. 7.
        < Note >
          Pay attention to the mounting direction of spacer. See Fig. 8.
    2. Mount ball bearing 6900LLB with arbor press. See Fig. 9.
     Fig. 8                                                  Fig. 9


                                                                      Ball bearing
                                                                      6900LLB


                                      Spacer



                                                              1R034
                                                              Bearing setting plate 12.2
                                                                                                                        P 9 / 17
Repair
    3. Mount retaining ring S-10 to secure ball bearing 6900LLB. Refer to Fig. 7. Now spiral bevel gear 9 section
       has been completed.
    4. Mount the assembled spiral bevel gear 9 section to angle head, and secure it with retaining ring R-22.
       Refer to Fig. 6.

< 8 > Disassembling clutch assembly
     It is recommended to replace them as a "Clutch Assembly". However, clutch assembly can be replaced as a
     single part as illustrated in Fig. 10, 11 and 12.
    1. Remove angle head complete. See Fig. 5. And then, remove clutch assembly. See Fig. 10.
    2. Insert torque adjust grip into the hole of adjust ring complete and turn the torque adjust grip counter clockwise,
       until the pressure of compression spring 19 on adjust ring complete and lock nut M12 gets week. See Fig. 10.
       Now lock nut M12 can be removed by turning it clockwise by hand. See Fig. 10.
    3. Adjust ring complete, flat washer 18 and compression spring 19 can be removed from spindle. See Fig. 10.

      Fig. 10

                     Clutch assembly




                                                          Lock nut M12 can be removed         Adjust ring
                                                          by turning it clockwise by hand     complete
                                                          in this step.
        Lock nut M12                                                                 Flat washer 18
        Adjust ring
        complete


                                                                                                                 Compression
                                                                                                                 spring 19
                                                                                                                 Spindle
                 Hole of adjust ring         Torque adjust tool


    4. Pull down cam D toward the threaded portion of spindle, while holding cam C in the original position.
       Now steel ball 5.0 (3 pcs.) and steel ball 4.0 (3 pcs.) can be removed as illustrated in Fig. 11.
    5. Pull down cam C toward the threaded portion of spindle, while holding flat washer 7 in the original position.
       Now steel ball 3.0 (13 pcs.) can be removed as illustrated in Fig. 12.

       Fig. 11                                                            Fig. 12

                                                                                                            Flat washer 7
                   Steel ball 4.0 (3 pcs.)                                          Steel ball 3.0 (13 pcs.)
                                                         Cam C

                                                                                                                Cam C
                                                         Cam D
        Steel ball 5.0 (3 pcs.)



                 Threaded portion                                            Threaded portion
                 of spindle                                                  of spindle
                                                                                                              P 10 / 17
Repair
< 9 > Reassembling clutch assembly
   1. Apply seal grease to steel ball 5.0, 4.0 and 3.0, before mounting.
   2. Mount the above steel balls with referring to Fig. 11 and 12.
   3. Apply seal grease to the threaded portion of spindle. And mount compression spring 19, flat washer 18, adjust ring
      complete. Mount lock nut M12 by turning it with torque adjust tool counter clockwise.
      Refer to Fig. 10.
< 10 > Disassembling gear case section
   1. Remove carbon brushes.
   2. Remove light cover, switch lever, compression spring 2 and angle head complete
      as illustrated in Fig. 2 and Fig. 5.
   3. Remove 6 pcs. of pan head screw M3x22. Housing L can be separated from housing R. See Fig. 13.
         Fig. 13
                  Housing R

            Housing L




            Light holder

                   Carbon brush

            Brush holder cap          Pan head
                                      screw M3x22

   4. Remove switch unit from gear case, and pull off motor (yoke) with gear case from endbell complete,
      while lifting up them. See Fig. 14.
        Fig. 14

                                                                          Pull off them from
                                           Lift up motor                  endbell complete.
                    Gear case              with gear case.


                   Switch unit




                                                                       Motor
                                            Housing R viewing from                Endbell complete
                                                                       (Yoke)
                                            switch unit side

   5. Remove gear case from motor (yoke) by turning motor
      bracket toward the direction disgnated with white
      arrow. See Fig. 15.
         Fig. 15




          Gear case        Motor bracket     Motor (Yoke)
                                                                                                                    P 11 / 17
Repair
     5. Remove lock washer from gear case by twisting it. Then, gear case section can be removed as illustrated in Fig. 16.
     Fig. 16

                             Gear case
                                                            Internal gear 47

                                                                     Spur gear 20
                                                                     complete
                        Lock washer


                                           Spur gears 13
                                           (3 pcs.) which
                                           are removed
                                           from carrier        Spur gears 18                Carrier
                                           complete .          (3 pcs.)                     complete
                                                                                                          Ball bearing
                                                                                                          6805LLB

< 11 > Reassembling gear case section
     1. Referring to "< 1 > Lubrication", apply MAKITA grease N No.2 to the parts for gear case section,
        before mounting.
     2. Referring to Fig. 16, mount the parts for gear case section as follows.
         1. Mount ball bearing 6805LLB to carrier complete, and mount the carrier complete with ball bearing 6805LLB
            to gear case.
         2. Mount 3 pcs. of spur gear 13 to the shafts of carrier complete respectively.
         3. Mount internal gear 47
         4. Mount spur gear 20 complete.
         5. Mount 3 pcs. of spur gear 18 to the shafts of spur gear 20 complete respectively.
         6. Mount lock washer.
        Now the gear case section has been completed in this step.
     3. Referring to Fig. 15, secure the gear case section to motor bracket, by twisting motor bracket clockwise.
     4. Insert the ball bearing of armature's commutator end to endbell complete. Mount switch unit to gear case.
        And mount the above assembled section to housing R with paying attention to the following matters.
           * Face the cut of yoke to housing R. See Fig. 17.
           * Face the mounted switch unit to the light cover side. See Fig. 17.
     Fig. 17
                                                                                Endbell complete
                               Motor bracket                  Ball bearing of
               Switch unit                     Yoke           armature's
                                                              commutator end
          Gear case




      Cut of yoke




                                                         Housing R viewing from
                                                         light cover side
                                                                                                                  P 12 / 17

Repair
     5. Insert plate and lens into the mounting slit of housing R respectively. See Fig.18.
        Secure housing L with 6 pcs. of pan head screw M3x20. See Fig.18.

         Fig. 18




           Light holder
                                      Plate

                                                                                                     Housing R


                                                                  Lens
                                                                              Housing L




                Pan head
                screw M3x20




< 12 > Disassembling Switch
     1. Remove screw for securing micro switch. See Fig. 19.
     2. While pulling micro switch in the direction designated by black arrow, twist in the direction designated by
        white arrow. Then, micro switch can be removed from reverse switch. See Fig. 19.

         Fig. 19




          Reverse switch                                                                2. Twist in the direction
                                                                                           designated by white arrow
                                                                                           for removing,

             Micro switch


           Screw for securing                                                 1. While pulling in the direction
           micro switch                                                          designated by black arrow,
                                                                                                               P 13 / 17
Repair
< 13 > Reassembling Switch
     1. Secure micro switch with the screw. See Fig. 20. The fastening torque for the screw for micro switch
        is 0.29 - 0.34Nm.
     2. Mount F/R change lever to the switch trigger of reverse switch. See Fig. 20.
        The assembling of switch has been completed in this step.
     3. Mount the switch to housing R.
                Fig. 20
                       Mount F/R change lever, while aligning
                       this concave portion to the boss of
                       trigger of reverse switch.

                                                                   Boss of trigger
                     F/R change lever




                               Micro switch




                          Tighten this screw to 0.29 - 0.34Nm
                          in fastening torque, when mounting
                          micro switch.
Circuit     diagram                                                                   P 14 / 17

         Color index of lead wires
      Black
      White
      Red
      Yellow
      Orange
      Blue
      Purple
      Gray



                                             ON - OFF Switch
                                             (Micro Switch)


                Connectors
                                             COM        NO




                             Binding tapes



   LED unit


                                                               S1      M1


                                                               S2             DC
  Switch unit                                  Controller           Reverse
                                                                              Motor
                                                                    switch

                                                               M2      M2

                 Lamp unit



  Buzzer
  circuit

                                                                                      Terminal
                  Binding tapes
                                                                                                        P 15 / 17
Wiring       diagram


                                   Wiring around the switch and controller section




                                                                         Rib                     Ribs

                Switch viewing from
                another side

                                                     Switch



  1

        2

  3
            Hold the following lead
            wires with lead holders designated
            with    .                                                             Pass the lead wires which are
            1. Endbell's lead wire (black)                                        put in the rear side of switch,
            2. Controller's lead wire (blue)                                      between the ribs as illustrated
            3. Controller's lead wire (white)                                     above.

                                                                               Buzzer
                                                                               circuit
      Pass the lead wires
      by the rib.
                             Rib
                                                                               Controller




  Connector                                                   Terminal
                                  Rib




  Rib

             Put connectors and
             lead wires between
             the ribs.
                                                                                                                  P 16 / 17
Wiring    diagram

                             Wiring around the switch and switch unit
   Controller's
                                        Controller's
   lead wire (blue)
                                        lead wire (gray)
                                        Pass controller's lead wire (gray)
                                        and the same of (blue) under
                                        switch unit.
                                           Switch unit

                                                                 Controller's lead wires (blue and gray)
         Connector                                               to LED circuit

                                              Switch
                                              unit                                            Do not slack the following
 Put the following                                                                            controller's lead wires.
                                                                   Gear case                  * (blue)
 parts in this space.                                                                                       to LED circuit
 * Connectors                                                                                 * (gray)
 * Extra of controller's
   lead wire (purple)
 * Extra of controller's
   lead wire (yellow)


                                                                                               Do not slack the following
       Rib                                                                                     controller's lead wires.
                                                                   Motor
                                                                                               * (blue)
                                                                   (Yoke)                                    to LED circuit
                                                                                               * (gray)
 Pass the following
                                             Motor                                             * (yellow)
 controller's lead                                                                                             to switch unit
                                             bracket                                           * (purple)
 wires between the ribs.
 * (purple)
                 to Switch unit
 * (yellow)
 * (gray)
               to LED circuit
 * (blue)


                                                                Switch
                                                                                                     Pass the lead wires
                                                                                                     between the rib and
                                                                                                     endbell.
                                                                                                       Endbell
                Pass the lead wires
                between the ribs.




                                  Rib

                                                                                                      Rib




                                                   Rib
                                          Pass the lead wires
                                          between the ribs.
                                                                                                P 17 / 17

Wiring   diagram
                                 Wiring in the light holder


                                                              LED circuit
                                                     Connector




                                                                                     Rib
          Pass the lead wires under
                                                                      The extra of lead wires and
          the rib.
                                                                      connector have to be put in
                                Rib                                   this space.
                                                                      But be careful, not to put the lead
                                                                      wires on the ribs or LED circuit,
                                                                      when putting them.




                             Light holder




                          Rib




         Pass the lead wires under
         the rib.




                                                                 Switch unit



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