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BFL300F-TE


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T      ECHNICAL INFORMATION
   Models No.             BFL300F, BFL400F, BFL401F
                                                                                                           NEW TOOL
                                                                                                             P 1 / 15

   Description            Cordless Angle Screwdriver 14.4V                                  L

CONCEPT AND MAIN APPLICATIONS                                                                                          H

   Models BFL300F and BFL400F have been developed
   as specialist tools for industrial assembly applications,
   featuring high torque capacity of 30N.m (BFL300F)/                                                         W
   40N.m (BFL400F).
   Their brief advantages are;                                                  HH
   *High precision fastening
   *DC brushless motor for increased no load speed                                    CH             *Battery is optional.
   *14.4V, 2.7Ah Ni-MH battery equipped with new type
    battery cells for more efficient energy supply to motor                     Dimensions: mm (")
                                                               Model No.            BFL300F     BFL400F/ BFL401F
   Model BFL401F is a sister tool designed for Italy.          Length (L)            506 (20)      510 (20-1/16)
   These models do not include battery and charger.            Width (W)            73 (2-7/8)       73 (2-7/8)
                                                               Height (H)          104 (4-1/8)      104 (4-1/8)
                                                               Head height (HH)   31.5 (1-1/4)      34 (1-5/16)
                                                               Center height (CH)    16 (5/8)       18 (11/16)




 Specification
    Model No.                                      BFL300F                BFL400F/ BFL401F
       Voltage: V                                                 14.4
    Battery




       Capacity: Ah                                                2.7
       Cell                                                      Ni-MH
    Capacity                                            9.5mm (3/8") Square drive*
                           Hard joint               16 - 30                      25 - 40
    Fastening torque: N.m
                           Soft joint               16 - 30                      25 - 40
    No load speed: min.-1=rpm                        400                          260
    Net weight: kg (lbs)                           2.3 (5.1)                    2.4 (5.3)
    *Note: 12.7mm (1/2") with optional Spindle G complete


 Standard equipment
   No (however, with Protector for some countries, and with Torque adjust tool for some countries)

 Optional     accessories
   Ni-MH battery BH1427
   Chargers DC24SA, DC14SA, DC14SC
   Automatic refreshing adapter ADP03
   Switch lever set (paddle switch)
   Spindle G complete (12.7mm square drive)
   Protectors Red, Blue, Yellow, Clear
   Torque adjust tool
                                                                                                                              P 2 / 15
Features                      and benefits

                            High Precision Fastening                                    Indication Lamp and Buzzer
                                                                              Inform user of;
   Plus or minus 10%, Plus or minus 3 sigma,
                                                                              *Complete fastening = with Green light on plus beeps
   Cm value of 1.67 or more
                                                                              *Incomplete fastening = with Red light on plus beeps
   Uses Machine Screws to                                                     *Remaining battery power is getting little
   Fasten Housing for Easy Repair.                                                                  = with Red light on plus beeps
                                                                              *Remaining battery power is too little to fasten screw
                     Torque Adjusting System                                   to preset torque = with Red light on plus beeps; at the
                                                                                                  same time, power supply is auto-
               Optimum for Industrial Assembly Lines
                                                                                                  matically shut off to prevent in-
   Impossible to change fastening torque without optional                                         complete fastening.
   torque adjust grip that might be supplied to an assembly
   line manager for better control of fastening torque
                                                                                                          Auto Stop System
          Extra-Rigid,                                                                             By sensing battery power drop
   Aluminum-Alloy Angle Head                                                                       (See the description in "Indication
                                                                                                   Lamp and Buzzer".)
   Designed as compact as possible
   for high maneuverability                                                                              Anti-Slip Dimpled Grip

                                                                                                      DC Brushless Motor
                                                                                                  Provides higher no loaded speed for
                                                                                                  powerful and quick screwdriving.

                                                                                                                14.4V, 2.7Ah
                                                                                                               Ni-MH Battery
                                                                                                         Equipped with new type cell
         9.5mm (3/8")                                                      Easy-to-Operate,              employed for more efficient
         Square Drive                                                                                    energy supply to motor
                                                                           Push Button Type
                                                                                                         Remark:
   Optional 12.7mm (1/2")                                                 F/R Change Switch              Use of batteries other than
   is also available.                                                                                    BH1427 will result in lower
                                                                      On-Off Switch                      than expected fastening torque.
                             Built-in LED Job Light
                                                                 with Practical Advantages                Convenient Options
   Turns on automatically
   when the switch trigger                                    *With soft start feature for minimum
                                                                                                   *Protector covers the angle head
   is pulled, and keeps on                                     startup return torque
                                                                                                    to protect the surface of car body
   illuminating work area                                     *Provides one second start-delay
                                                                                                    from scratches.
   till 10 seconds pass after                                  between fastening cycles to prevent
                                                                                                   *Switch lever set converts the
   the switch trigger is                                       overtightening.
                                                                                                    trigger switch to paddle switch.
   released.


     Evaluation of Makita cordless angle screwdrivers (BFL series models)
     from the viewpoint of fastening capacity
                            1,000
                                                                                             : 9.6V DC brush motor
                                                                                             : 12V DC brush motor
                             800
     No load speed: min-1




                                     BFL081F                                                 : 14.4V DC brushless motor

                             600
                                     BFL080F                          BFL300F
                                                 BFL121F              (30N.m)
                             400
                                             BFL120F
                             200                                                     BFL400F, BFL401F
                                                  BFL200F
                                                                                         (40N.m)

                                0       5        10        15        20        25          30       35         40        45
                                                           Fastening torque on soft joint: N.m
                                                                                                                                              P 3 / 15
  Comparison of products

                            Model No.                      Makita                                    A                         B                  C
                                                          BFL400F
Specifications                           BFL300F                         BFL200F          A1                A2                 B1                 C
                                                          BFL401F
             Voltage: V                    14.4             14.4               12         14.4             14.4             14.4 / 12             12
Battery




                                                                             *2.0                                          2.0 w/14.4V
             Capacity: Ah                   2.7              2.7                          2.4               2.4                                   2.0
                                                                            **3.3                                        2.0 (1.4) w/12V
    Cell                                 Ni-MH             Ni-MH            Ni-MH        Ni-Cd             Ni-Cd            Ni-Cd             Ni-Cd
Type of DC motor                        Brushless         Brushless          Brush        N/A               N/A              N/A             Brushless
Fastening Hard joint: N.m                16 - 30           25 - 40           8 - 20      8 - 30            7 - 23           15 - 28
                                                                                                                                            *** 5.5 - 16
torque    Soft joint: N.m                16 - 30           25 - 40           8 - 18      8 - 28            7 - 20           15 - 28
                                                                                                                          260 w/14.4V
No load speed: min.-1=rpm.                  400             260                 220       220               320                                 260
                                                                                                                           210 w/12V
Head height: mm [ " ]                   31.5 [1-1/4] 34 [1-5/16] 28.5 [1-1/8]             N/A               N/A              N/A            41 [1-5/8]
Center height: mm [ " ]                   16 [5/8]   18 [11/16] 13.5 [1/2]                N/A               N/A              N/A            14 [9/16]
Job light                               Yes (LED) Yes (LED) Yes (LED)                  Yes (LED)         Yes (LED)            No            Yes (LED)
Square drive: mm [ " ]                   9.5 [3/8]     9.5 [3/8]  9.5 [3/8]             9.5 [3/8]         9.5 [3/8]        9.5 [3/8]         9.5 [3/8]
                                                                   * 430
               Length: mm                   506           510       [17]                                                                       452.5
                                                                                          N/A               N/A               N/A
                       ["]                  [20]      [20-1/16]   ** 454                                                                      [17-3/4]
Dimensions




                                                                   [17-7/8]
               Width: mm                     73            73         71                                                                        74
                                                                                          N/A               N/A               N/A
                      ["]                 [2-7/8]       [2-7/8]   [2-13/16]                                                                  [2-15/16]
               Height: mm                   104              104              92                                                                  76
                                                                                          N/A               N/A               N/A
                       ["]                [4-1/8]          [4-1/8]          [3-5/8]                                                               [3]
                                                                             *1.7                                         2.5
                                                                                                                               w/14.4V
                                            2.3              2.4             [3.5]         2.4              2.4          [5.5]                  2.1
                             Catalog
                                           [5.1]            [5.3]           **2.0         [5.3]            [5.3]          2.6                  [4.6]
                                                                                                                               w/ 12V
Net weight: kg                                                               [4.4]                                       [5.7]
           [lbs]                                                             *1.7
                                            2.3              2.4             [3.5]                                                              2.1
                             Measured                                                     N/A               N/A               N/A
                                           [5.1]            [5.3]                                                                              [4.6]
                                                                            **2.0
                                                                             [4.4]
    * Data with battery BH1220, 12V/ 2.0Ah                  *** It is not clear whether "5.5 - 16" means the
   ** Data with battery BH1233, 12V/ 3.3Ah                         value on hard joint or soft joint.


                            Model No.                                                      B
                                            a; B2
                                                                       B4                 B5                        B6                       B7
Specifications                              b; B3
Fastening Hard joint: N.m
torque      Soft joint: N.m                 20 - 40                  20 - 40            18 - 32                   15 - 29                  14 - 28
No load speed: min.-1=rpm.                    430                     420                520                       550                      350
                                        a; 34.5 [1-3/8]
Head height: mm [ " ]                                           34.5 [1-3/8]          34.5 [1-3/8]           34.5 [1-3/8]               29.5 [1-3/8]
                                         b; 41 [1-5/8]
                                         a; 18 [11/16]
Center height: mm [ " ]                                            18 [11/16]          13.5 [1/2]             13.5 [1/2]                 13.5 [1/2]
                                         b; 20 [13/16]
                                          a; 9.5 [3/8]
  Square drive: mm [ " ]                                            9.5 [3/8]          9.5 [3/8]              9.5 [3/8]                    9.5 [3/8]
                                          b;12.7 [1/2]
                                        a; 436 [17-1/8]
  Overall length: mm [ " ]                                     400 [15-3/4]           385 [15-1/8]           385 [15-1/8]               350 [13-3/4]
                                        b; 453 [17-7/8]
                                           a; 2.0 [4.4]
Net weight: kg Catalog                                              1.8 [4.0]          1.6 [3.5]              1.6 [3.5]                    1.4 [3.1]
                                           b; 2.2 [4.9]
           [lbs]
                 Measured                     N/A                     N/A                N/A                       N/A                       N/A
                                                                                                                            P 4 / 15

    Repair
Warning: Always be sure to disconnect battery cartridge from the machine before starting repair.
   Note: See the instruction manual for safety instructions, safety rules and operating instructions.
                    -- Contents --                                                                             -- Page --
[1] Necessary Repair Tools ..................................................................................... III - 1
[2] Grease and Adhesive ......................................................................................... III - 1
[3] Disassembling/ Assembling .............................................................................. III - 2
   [3] -1. Disassembling/ Assembling of Job Light Section ................................... III - 2, 3
   [3] -2. Disassembling/ Assembling of Bearing Retainer .................................... III - 3
   [3] -3. Disassembling/ Assembling/ Adjustment of Angle Head Section ........... III - 3, 4
   [3] -4. Disassembling/ Assembling of Clutch Case Section ............................... III - 4, 5
   [3] -5. Disassembling/ Assembling of Clutch Section ........................................ III - 5
   [3] -6. Disassembling/ Assembling of Gear Case Section .................................. III - 5 -7
   [3] -7. Disassembling/ Assembling of Switch Section ........................................ III - 7, 8
[1] NECESSARY REPAIR TOOLS
  (Code No.)        (Tool Name)                              (Code No.)          (Tool Name)
   1R004     Retaining Ring Pliers ST-2                       1R223           Torque Wrench Shaft 20-90N.m
   1R005     Retaining Ring Pliers RT-2N                      1R269           Bearing Extractor
   1R006     Retaining Ring Pliers RT-2E                      1R291           Retaining Ring S and R Pliers
   1R008     Tips for Retaining Ring Pliers                   1R341           Spanner Head
   1R033     Bearing setting Plate 10.2                       134844-7        Socket 27-50 Ass'y
   1R219     Torque Wrench Shaft 7-23N.m                      134848-9        Socket 27-50 Ass'y
   1R220     Ratchet Head 9.5                                 765025-8        Torque Adjust Tool
   1R222     Socket Adapter
[2] LUBRICATION AND ADHESIVE
See the parts breakdown below.
Apply 2.0g of Makita Grease N. No.2 to the portions designated with the mark of                  .
Apply Makita seal lubricant to the portions designated with the mark of    .
Apply Loc-Tite 603 to the portions designated with the mark of      .
Fig. 1

                          10                          21 22

                                                                                                                       31




                                                                                       48                            51     52   53
                                       39 40                     43           45

                63
                     64




  The portions to lubricate with Makita                  The portions to lubricate with Makita Grease N No.2
  Seal Lubricant No. 101                                 48. Three gear shafts of Carrier Complete (A)
  10. Gear room of Angle Head Complete                   51. Spur Gear 13 (3 pcs)
  21. Pin 3 (5 pcs)                                      52. Spur Gear 20 Complete
  22. Teeth of Spur Gear 14                              53. Spur Gear 15 (3 pcs)
  31. Hole on Spur Gear 21
  39. Threads on Spindle                                 The portions to apply Loc-Tite 603
  40. Steel Ball 5.0 (3 pcs)                             36. Threaded portion of Bearing Retainer 15-26
  43. Steel Ball 4 (3 pcs)
  45. steel ball 3 (13 pcs)
  63. O Ring 15
                                                                                                                       P 5 / 15
[3] DISASSEMBLING/ ASSEMBLING
[3] -1. Disassembling/ Assembling of Job Light Section
DISASSEMBLING
*Shown in Fig. 2 are the parts of Job light section.
1) Remove Lead cover (on which Ring spring 36 is installed) and Ring spring 29 using a slotted screwdriver. (Figs. 3, 4)
2) Remove Light covers (R) and (L) while pushing the portion designated with the gray circle to unlock the tab on
   Light cover (R) from the slot in (L). (Fig. 5)
3) Separate Switch cover from the tool by removing two M4x8 Pan head screws.
4) Remove Lead wires and LED circuit from Lead wire holders and Light cover (R), and disconnect Connector. (Fig. 6)
Fig. 2

            Light cover (L)               Pan head screw M4x8         Pan head screw M4x8
                                          (for fixing Ring 38)        (for fixing Switch cover)




    Light cover (R) Ring spring 29         Lead cover        Switch cover

Fig. 3                                                       Fig. 4                               Fig. 5
  Push the end face of Lead cover using a slotted
  screwdriver till it is lifted up as illustrated to left                     Ring spring 29
                                                                                                   Push here.
  below. Now Lead cover can be removed by pulling                                                                 tab
  in the direction o the arrow as illustrated to right.




ASSEMBLING
1) Fix Lead wires securely with Lead wire holders, and then install LED circuit on Light cover (R).
  At this time, put the sag of Lead wires in place as illustrated to right in Fig. 6.
2) Push the tab on Light cover into the cut in Housing before fastening screws. And then fasten Switch cover with two
   M4x8 Pan head screws. Be careful not to pinch the Lead wires at this time. (Figs. 2, 7)
3) Install Light covers (R) and (L) while locking the tab on Light cover (R) in the slot in (L), then Ring spring 29. (Fig. 5)
   Ring spring 29 can be easily installed by fixing one end on the groove in Light cover, then pushing toward Light cover
   while expanding the other end. (Fig. 8)
4) Being careful not to pinch the Lead wires from LED circuit, install Lead cover (on which Ring spring 36 is installed)
   as illustrated in Fig. 9.
Fig. 6                                                                                    Fig. 7


  LED circuit          Lead wire holders                Put the sag of Lead wires           Switch cover         tab
                                                        in this portion.
                                                                                                                  P 6 / 15
[3] -1. Disassembling/ Assembling of Job Light Section (cont.)
Fig. 8                                         Fig. 9
                                                                           Lead cover


                                                                           Ring spring 36
                                                                           Lead wire

 Ring spring 29


[3] -2. Disassembling/ Assembling of Bearing Retainer
                                                                                    Fig. 10
DISASSEMBLING
Turn Bearing retainer clockwise using a 27mm spanner for BFL300F/ 32mm
                                                                                                          Bearing retainer
spanner for BFL400F and BFL401F. Now Bearing retainer can be removed
by pushing it down as illustrated in Fig. 10.

ASSEMBLING
1) After applying Makita seal lubricant No.101 to O ring 15, put O ring 15 and
   Bearing retainer in place on Spindle complete.
2) Put 2g of Makita seal lubricant No.101 in the gear room of Angle head complete.
   At this time, be careful not to put the grease on the threaded portion of Angle head complete.
3) Apply Loc Tite 603 to the threaded portion of Bearing retainer, and screw it into Angle head complete.
   At this time, remember to put Flat washer 5 in place.
4) Fasten Bearing retainer to the recommended torque of 30 - 50N.m by turning counterclockwise with the following tools;
   1R219, 1R220, 1R222, 134844-7 (for BFL300F), 134848-9 (for BFL400F/ BFL401F)

[3] -3. Disassembling/ Assembling/ Adjustment of Angle Head Section
DISASSEMBLING
*Shown in Fig. 11 are the parts of Angle head section.
Fig. 11


                                 Spiral bevel gear 9 section                            Carrier section
             10
                                                                                       21 22
                            11        12   13 14        15 16       17    18       19 20           23       24    25




  10) Angle head complete    15) Ball bearing 6900LLB          20) Flat washer 14      25) Retaining ring R-32
  11) Spiral bevel gear 9    16) Retaining ring S-10           21) Pin 3 (5pcs)
  12) Needle bearing 1212    17) Retaining ring R-22           22) Spur gear 14 (5pcs)
  13) Thin washer 12         18) Internal gear 50              23) Carrier
  14) Spacer                 19) Retaining ring S-14           24) Flat washer 26

1) Remove Light covers (R) and (L), Ring spring 29, Lead cover and Switch cover. (Refer to [3] -1.)
2) Fix Angle head by clamping its two flats using adjustable wrench or vise, and remove Hex nut M36-41 by turning
   in the direction of the arrow with 1R223 and 1R341. (Figs. 12, 13)
  Caution: When clamping Bearing retainer, be very careful not to deform it by overtightening.
3) Remove Angle head complete by turning counterclockwise.
4) Remove Retaining ring R-32 using 1R006 or the like, then Flat washer 26, Internal gear 50 and Carrier section.
5) Remove Retaining ring S-14 from Carrier section using 1R291 or the like. Now the following parts can be replaced;
   Flat washer 14, Pin 3 (5pcs), Spur gear 14 (5pcs)
   Note: Pin 3 can be pulled out easily by using a magnet.
6) Remove Retaining ring R-22 located inside Angle head complete using 1R005 or the like.
7) Remove Spiral bevel gear 9 section by hitting the end face of Angle head complete. (Fig. 14)
8) Remove Retaining ring S-14 from Spiral bevel gear 9 section using 1R004, 1R008 or the like.
   Now the following parts can be replaced by removing Ball bearing 6900LLB with 1R269 or the like:
   Spiral bevel gear 9, Spacer, Thin washer 12, Needle bearing 1212
                                                                                                                P 7 / 15
[3] -3. Disassembling/ Assembling/ Adjustment of Angle Head Section (cont.)
Fig. 12                        Fig. 13                                             Fig. 14

          two flats                  No.1R223




                                                      No.1R341

                                                       Adjustable wrench

    Angle head complete


ASSEMBLING
1) Assemble Needle bearing 1212, Thin washer 12 and Spacer to Spiral        Fig. 15
   bevel gear 9.
   Caution: Spacer is not reversible when assembled to Spiral bevel gear 9.     protrusion            matching hole
              Be sure to place as illustrated in Fig. 11.
2) Press-fit Ball bearing 6900LLB to Spiral bevel gear 9 using arbor press
   and 1R033. Assemble Retaining ring S-14 to Spiral bevel gear 9
   to complete assembling of Spiral bevel gear 9 section.
   And then insert Spiral bevel gear 9 section into Angle head complete.
3) Assemble Retaining ring R-22 to Spiral bevel gear 9.
4) Put Internal gear 50 in Angle head complete so that the protrusions on
   Internal gear 50 fit in the matching holes on Angle head complete.         Internal gear 50    Angle head complete
   (Fig. 15)
5) Assemble Spur gear 14 and Pin 3 (5 pcs each) to Carrier, and then Thin washer 14 and Retaining ring S-14 to complete
   Carrier section.
6) Insert Carrier section into Angle head complete, and apply 1.5g of Makita seal lubricant No.101 to Spur gear 14.
7) Install Flat washer 26 and Retaining ring R-32.
 ADJUSTMENT
1) Fasten Angle head complete and Hex nut M36-41 to Clutch case section to the full by hand.
2) Turn Angle head complete counterclockwise to adjust to a desired angle.
3) Being very careful not to turn Angle head complete, fix it securely by turning Hex nut M36-41 clockwise with 1R223
   and 1R341 to the recommended torque of 30 -50N.m.
4) Make sure that Lead wires are fixed in place with Lead wire holders as illustrated in Fig. 6.
   Then, being careful not to pinch Lead wires, install Lead cover.

[3] -4. Disassembling/ Assembling of Clutch Case Section
DISASSEMBLING                                        Fig. 16
*Shown in Fig. 16 are the parts of Clutch case                 28          29 30       31     32 33 34     35
 section.
1) Remove Angle head section. (Refer to [3]-1, 3.)
2) Remove Compression spring 2 and Switch lever.
3) Clutch case, Clutch assembly and Compression
   spring 5 can be removed by removing four
   M4x22 Pan head screws.
4) Remove Retaining ring R-26 using 1R006                      69   70 71
   or the like.
5) Push out Spur gear 21, and then, after removing
   Flat washer 21 using slotted screwdriver or
   the like, push out Ball bearing 6803ZZ.
6) Remove Retaining ring S-10 using 1R004 and          28) Clutch case                 34) Retaining ring R-26
   1R008 or the like, then Ball bearing 6000DDW        29) Ball bearing 6803ZZ         35) Compression spring 5
    using 1R269 or the like.                           30) Flat washer 21              69) P.H. Screw M4x22 (4pcs)
    Now Spur gear 21 can be replaced.                  31) Spur gear 21                70) Compression spring 2
7) Remove Hex nut M36-41 by turning                    32) Ball bearing 6000DDW        71) Switch lever
    counterclockwise. Remove Ring 38, and now          33) Retaining ring S-10
    Clutch case can be replaced.
                                                                                                                         P 8 / 15
[3] -4. Disassembling/ Assembling of Clutch Case Section (cont.)
ASSEMBLING
1) Press-fit Ball bearing 6000DDW to Spur gear 21 using arbor press and 1R033 or the like,
   then install Retaining ring S-10 on Spur gear 21.
2) Into Clutch case, insert first Ball bearing 6803ZZ, next Flat washer 21, and third Spur gear 21.
   Then install Retaining ring R-26.
   Remark: Remember to place Compression spring 5 between Clutch case and Clutch assembly.
3) Put an appropriate amount of Makita seal lubricant in the hole on Spur gear 21. (Fig. 1)

[3] -5. Disassembling/ Assembling of Clutch Section
Note: When repairing Clutch section, it is recommended to entirely replace Clutch assembly with fresh one.
      However, if required to replace component parts of Clutch assembly, follow the disassembling/assembling
      procedure described below
DISASSEMBLING                                                         Fig. 17
1) Remove Clutch case section, and take Clutch section out of             Adjust ring complete    Lock nut M12
   the machine. (Refer to [3]-1, 3, 4.)
2) Insert Torque adjust toll into the hole of Adjust ring complete,
   and turn it counterclockwise to remove Lock nut M12.                   Flat washer
   Decrease in the pressure of Compression spring 19 allows
   you to remove Lock nut M12 by turning it clockwise by                  Cam D
   hand. (Fig. 17)
3) Remove Adjust ring complete, Flat washer and Compression
   spring 19 from Spindle.
                                                                          Cam A
4) While shifting the positions of Cam A and Cam D, replace
   Steel ball 3.0 (13 pcs.), Steel ball 4.0 (3 pcs.)
                                                                          Compression spring 19        Turn Torque adjust tool
   and Steel ball 5.0 (3 pcs.).
   Steel balls can be removed easily by using a magnet.                                                counterclockwise.


ASSEMBLING                                                      Fig. 18

1) Apply Makita seal lubricant No. 101 to Steel ball 5.0           Steel ball 3.0 (13 pcs)                 Steel ball 5.0 (3 pcs)
   (3 pcs.), Steel ball 4.0 (3 pcs.) and Steel ball 3.0
   (13 pcs.), and set these Steel balls in place on the Cams.                             Cam A
   (Fig. 18)
2) Apply Makita seal lubricant No. 101 to the male threads
   on Spindle, and then assemble Compression spring 19,
   Flat washer and Adjust ring complete to Spindle,
   and then secure Lock nut M12 to Spindle by turning it
   counterclockwise using Torque adjust tool, etc.
                                                                                         Cam D


                                                                                  Threads on Spindle       Steel ball 4.0 (3 pcs)



[3] -6. Disassembling/ Assembling of Gear case Section
DISASSEMBLING
1) Remove Switch lever, Switch cover and Compression spring 2. (Refer to [3] -1.)
2) Remove four M4x22 Pan head screws to separate Clutch case from the machine.
3) Remove seven M3x20 Pan head screws to separate Housing (L) from (R).
4) Remove switch unit from Gear case.
5) Separate Gear case section from Motor control unit by lifting up them, then turning
   Motor bracket counterclockwise. (Fig. 19)
6) Pull off Motor bracket from Rotor, and then pull off Rotor from Motor control unit.
7) Remove Lock washer located in Gear case by turning counterclockwise with pliers
   or slotted screwdriver. (Fig. 20)
8) Remove Spur gears, Internal gear, Carrier complete and Ball bearing 6805LLB.
                                                                                                                      P 9 / 15
[3] -6. Disassembling/ Assembling of Gear Case Section (cont.)
Fig. 19                                                         Fig. 20
     Gear case section                                                       Lock washer
                              Motor bracket
                                        Motor control unit

                                                                                                          Gear case section




                                                                        Turn Lock washer counterclockwise using pliers
      Turn Motor bracket counterclockwise, and then                     or slotted screwdriver, and
      Separate Gear case section from Motor control unit.               Remove from Gear case section.


ASSEMBLING
1) After applying Makita grease N No.2 to teeth of all Spur gears, shafts of Carrier complete and shafts of Spur gear 20
   complete, assemble Ball bearing 6805LLB and Carrier complete (A) to Gear case. (Fig. 1)
   And then assemble Internal gear 47 and Spur gears from the opposite side.
2) Install Rotor on Motor control unit as described below;
   Fix Motor control unit on table or the like, and insert Rotor slowly into Motor control unit till it touches the surface of
   the table. Then lift up Motor control unit gradually till it stops. (Fig. 21)
   Caution: 1. Because Rotor is a strong magnet, be sure to remove metal chips or debris from it before installation,
                 and be very careful not to pinch your fingers between Rotor and metal parts, etc.
              2. Be careful not to shock the printed wiring board of Motor control unit.
3) Install Lock washer on Gear case. Then put Motor bracket on Gear case, and turn it clockwise to lock in place.
4) Assemble Gear case section and Motor control unit to Housing (R) so that the lead wires of Motor control unit and the
   Switch unit installation portion on Gear case face the side of the LED - Trigger switch line. (Fig. 22)
   When assembling, fit the boss on Housing (R) in the notch in Motor control unit. (Fig. 23)
Fig. 21                                                   Fig. 22
                                                                        Gear case              Motor control unit




      Fix Motor control unit, and insert Rotor.                     Switch unit
      Lift up Motor control unit till it stops.                     installation portion             Lead wires


5) Set Switch unit in place on Gear case.                             Fig. 23
6) Assemble the following parts to Housing (R) in numerical                                  Motor control unit
   order:
    1. Controller of Motor control unit
    2. Terminal                                                         notch
    3. LED circuit
    4. Assembly of Gear case section and Motor control unit
   Put lead wires in place while taking care not ot pinch them.
   After putting Switch section in place, install Plate and Lens.
   Then fasten Housing (L) to (R) with seven M3x20 Pan head
   screws. (Fig. 24)
   Caution: When disconnecting connectors, do not pull lead
              wires. (Fig. 25)

                                                                             boss



                                                                                             Housing (R)
                                                                                                                         P 10/ 15
[3] -6. Disassembling/ Assembling of Gear Case Section (cont.)
Fig. 24

                                                                                       Fix lead wires with lead wire holders.
                                                Plate

                                                               Lens




     Fix lead wires with lead wire holders.




                                                                                         Terminal


Fig. 25

                                                                                             Color of Lead Wires
                                                                                                 Blue, Black
                                                                                                 Yellow, White
                                                                                                 Yellow, Blue
                                                                                                 Purple, Yellow

          LED circuit            Switch unit in Trigger             Switch unit for              Red, White
                                                                    rotation reverse             Positive: Red, Negative: Black




      Switch unit for Clutch         Buzzer circuit                      Terminal

[3] -7. Disassembling/ Assembling of Switch Section
Although Switch section can be disassembled, you can also use Switch assembly to entirely replace Switch section.
DISASSEMBLING                                             Fig. 26
1) Remove Clutch case section and Housing (L).                                                 ribs
   (Refer to [3] -1, 6.)
2) Remove Switch unit in Trigger while expanding
   the ribs. (Fig. 26)
3) Switch unit for rotation reverse can be replaced by
   removing PT3x16 Tapping screw, then removing
   Cover.
   Now the following parts can also be replaced:
   F/R Change lever, Leaf spring, Switch lever (A),
   Compression spring (A)


                                                           Switch unit in Trigger
                                                                                                   P 11/ 15
[3] -7. Disassembling/ Assembling of Switch Section (cont.)
ASSEMBLING                                                         Fig. 28
Put Leaf spring in place on F/R Change lever, and Compression
spring 4 on Switch lever (A).                                                protrusion on F/R Change lever
Put F/R Change lever, Switch lever and Switch unit for rotation
reverse in place. At this time, fit the protrusion on F/R Change
lever in Switch lever (A). (Fig. 27)
Then, while pushing these parts with Cover, fasten with PT3x16
Tapping screw.

                                                                                           Switch lever (A)
                                                                                            P 12/ 15
    Circuit      diagram
Fig. 28



                                          Motor control unit



          Terminal                                                       Main switch
                                Stator                           Switch unit B
                                                                               Switch unit A
                                                                 (for rotation
                                                                               (for Trigger)
                                                                    reverse)




                                             Controller




                                Buzzer                          LED PWB
                                circuit                        (for display)



                                                                          Switch unit C
                                                                           (for clutch)
                                                                                            LED
                                                                                           circuit
            Color index of lead wires' sheath                                             (for job
                                                                                            light)
            Black
            White
            Red
            Yellow
            Orange
            Blue

                       = Tape

                       = Connector
                                                                                             P 13/ 15
    Wiring      diagram
[1] Wiring Around Controller
Fig. 29


                         rib (A)
                                                                      Route the lead wires (orange,
                                                                      white, blue) from Controller
                                                                      to Stator between the two pins.
   Route the lead wires from
   Switch unit (for rotation
   reverse) between rib (A)
   and rib (C).
                                                                             pin
                         rib (B)       Switch
                                                                       Place Connectors and the sag
                                                                       of lead wires in the space
   Route the lead wires from                                           between ribs (A)- (B)- (C)
   Switch unit (for Trigger)                                           and pins- rib (D)- boss.
   between rib (B) and rib (C).
                                                                             rib (D)
                         rib (C)
                                                                             Connector
                                                                             boss
                                                     Controller


   Put the lead wires from                                               Put Connector and the lead
   Controller to Buzzer on                                               wires from Controller to
   the groove in Controller.                                             Buzzer between the ribs
                                                       Buzzer            on Controller.
                                                       circuit
                                                                             Connector
                         groove
                                                                             rib



                                                                             Terminal




             Install Receptacles on                               Receptacles
             Terminal as illustrated   Lead wire (black)
             to right.
                                         Lead wire (red)

                                                                  Terminal
                                                                                                  P 14/ 15
    Wiring      diagram
[2] Wiring Around Stator
Fig. 30




                            Connector (to LED circuit)             Switch unit (for Clutch)




                      Place Connectors and the sag
                      of lead wires in the space
                      between rib (E) and the inside
                      wall of Housing.


                      inside wall of Housing                     Connector

   Route the following lead wires from Controller
   between rib (E) and the inside wall of Housing;                        rib (E)
   *wires to LED circuit
   *wires to switch unit (for Clutch)
   At this time, place the lead wires so that the tape
   is positioned beside Printed wiring board.                       Printed wiring board

                                               tape                 pin

                        Route the three lead wires
                        (orange, white, blue) from
                                                                          Stator
                        Controller to Stator between
                        the pin and Stator.




                               lead wire holder


   First, put the following lead wires from Controller
   in place;
   *wires to LED circuit
   *wires to switch unit (for Clutch)
   Then, with the lead wire holder, fix the lead
   wires (orange, white, blue) from Controller to
   Stator.                                               rib (F)          rib (G)


                                                         Route the six lead wires (orange, black, white,
                                                         yellow, blue, red) from Controller to Stator
                                                         between rib (F) and rib (G).
                                                                                        P 15/ 15
    Wiring         diagram
[3] Wiring the Lead Wires from LED Circuit on Lead Holder
Fig. 31



                                                       LED circuit
          Make the lead wires so that
          they cannot be pulled to
          disconnect LED circuit from
          Controller when Switch
          cover is installed.




                                                              tab
                                   tab

          Hook the lead wires
                                                              Route the lead wires between
          on the five tabs of
                                                              rib (H) and rib (I), and then
          Lead holder.
                                                              rib (I) and rib (J).
          Remark:
          Do not place the lead
          wires over the tabs.                               rib (H)
                                                             rib (I)
                                                             rib (J)

                                   tab


          Route the lead wires
          under the pin.

                                  pin
                                                              Put Connector and the sag
          Route the lead wires                                of the lead wires in the space
          beside rib (K) and                                  between Housing and rib (L).
          Switch unit (for Clutch).

                                  rib (K)                     rib (L)
          Switch unit (for Clutch)                            Connector



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