Service Manuals, User Guides, Schematic Diagrams or docs for : MAKITA JR3060T-TE

<< Back | Home

Most service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.




Image preview - the first page of the document
JR3060T-TE


>> Download JR3060T-TE documenatation <<

Text preview - extract from the document
T    ECHNICAL INFORMATION
    Models No.             JR3060T
                                                                                                      PRODUCT
                                                                                                        P 1 / 18

    Description            Recipro Saw

CONCEPT AND MAIN APPLICATIONS                                                                L

   Model JR3060T has been developed as a middle specification
   model between JR3050T and JR3070CT.
   Features orbital mechanism for high cutting efficiency.                   H
   Additionally, provides more control and comfort with toolless
   blade change, toolless shoe adjustment and rubberized soft grip.
                                                                                              W

                                                                                            Dimensions: mm (")
                                                                                      Length (L)     485 (19-1/8)
                                                                                      Width (W)        99 (3-7/8)
                                                                                      Height (H)      181 (7-1/8)


 Specification
                                                                   Continuous Rating (W)
      Voltage (V)         Current (A)       Cycle (Hz)                                        Max. Output(W)
                                                                  Input           Output
         110                  12              50/60               1,250             600            1,100
         120                  12              50/60               1,400             700            1,100
         220                  6.0             50/60               1,250             600            1,100
         230                  5.7             50/60               1,250             600            1,100
         240                  5.5             50/60               1,250             600            1,100

   Stroke per minute: min-1                                    0 - 2,800
   Length of Stroke: mm (")                                   32 (1-1/4)
                    *Wood: mm (")                              255 (10)
   Capacity
                    Pipe: dia. mm (")                         130 (5-1/8)
   Variable speed control                                         Yes
   Net weight: kg (lbs)                                        4.2 (9.3)
                                                          Europe: 4.0 (13.1)
   Power supply cord: m (ft)                              Australia: 2.0 (6.6)
                                                       Other countries: 2.5 (8.2)

   *when cutting with the supplied 300mm (11-3/4") length recipro saw blade.

 Standard equipment
   North America:                          All countries other than North America:
   Recipro saw blade (for Steel)           Recipro saw blades No.21 (for Steel)
   Recipro saw blade (for Composite)       Recipro saw blades No.22 (for Steel)
   Plastic carrying case                   Recipro saw blade No.23 (for Wood and Plywood)
                                           Plastic carrying case

  Note: The standard equipment for the tool shown above may differ by country.


 Optional      accessories
   Recipro saw blades No.21, 22, 24 (for Steel)
   Recipro saw blade No.23, 23B (for Wood and Plywood)
                                                                                                           P 2 / 18
Features    and benefits
 Main specification differences among the series models
  Model No.               JR3070CT         JR3060T      JR3050T
  Rated amperage for USA     15               12           9
  Electronic control         Yes             No           No
  Counterweight mechanism    Yes             No           No
  Orbital mechanism          Yes             Yes          No



     Extra-High Cutting Efficiency
 The cutting speed is higher than the competitions
 and our predecessor models in class.
 (See the comparison charts on next page.)


  *Toolless Blade Change                    *Orbital Mechanism               *Large Variable Speed Trigger Switch
                                                 For high speed
 Simply insert the blade for                                                     Easy to operate even with gloved hand
                                                 wood cutting
 installation. Removal can
 also be done with one touch.


                                                                                       *Rubberized Soft Grip
                                                                                    Provides more control and comfort.




 *Toolless Shoe Adjustment
                                            *Clutch protects both user and
 Shoe is adjustable to 5 positions          tool when the blade is jammed.
 by merely pushing a button.


      *Reliable, Dust and Drip-Proof Tool Head Mechanism
 1. Front side of the slider is protected against saw dust by;
   1) Air from the fan that sweeps away saw-dust
   2) X ring and Seal plate that seal out saw-dust from the gear room
 2. Gear room is also protected against water drops by a rubber seal ring
    on the matching surface between gear housing and gear housing cover.


 *The same advantage as JR3070CT
 Specification Comparison

                           Model No.                       Makita                           Competitor A                    Competitor B   Competitor C
 Specifications                              JR3060T                 JR3030T         Model A1          Model A2               Model B        Model C
                                                                                                                                                          Comparison



 Rated amperage for North America: A             12                     8              10                10                     9.5           11.5
 Continuous rating input: W                   a) 1,250                 900             N/A               N/A                   N/A            N/A
 Strokes per min: spm.= min.-1               0 - 2,800              0 - 2,600        0 - 2,800            0 - 3,200          0 - 2,800      0 - 2,600
 Length of Stroke: mm (")                   32 (1-1/4)              28 (1-1/8)       28 (1-1/8)           28 (1-1/8)         32 (1-1/4)     32 (1-1/4)
                                                                                                                                                          of products




 Orbital mechanism                              Yes                     No               No                   No                 No            Yes
 Variable speed trigger switch                  Yes                    Yes              Yes                  Yes                Yes            Yes
 Variable speed control dial                    No                      No               No                  Yes                 No             No
                     Blade change               Yes                    Yes              Yes                  Yes                Yes            Yes
 Toolless system
                     Shoe adjustment            Yes                    Yes              Yes                  Yes                Yes            Yes
 Clutch                                         Yes                     No              Yes                  Yes                 No             No
 Counterweight mechanism                        No                      No               No                  Yes                 No             No
 Soft grip                                      Yes                     No               No                   No                Yes            Yes
 Rotating handle                                No                      No               No                   No                 No            Yes
                     No load                     20                     18               26                   5.0                29             24
 Vibration: m/s2
                     b) Loaded                   20                     22               26                   18                 28             19
 Double insulation                              Yes                    Yes               No                   No                Yes            Yes
 Power supply cord: m (ft)                  c) 2.5 (8.2)             2.5 (8.2)        2.5 (8.2)            2.5 (8.2)          2.5 (8.2)      2.5 (8.2)
                           Length          485 (19-1/8)               483 (19)      460 (18-1/8)        447 (17-5/8)        440 (17-1/4)   485 (19-1/8)
 Dimensions: mm (")        Width             99 (3-7/8)              96 (3-3/4)       92 (3-5/8)        94 (3-11/16)           100 (4)      107 (4-1/4)
                           Height           181 (7-1/8)             164 (6-1/2)      168 (6-5/8)         172 (6-3/4)         180 (7-1/8)    166 (6-1/2)
 Net weight: kg (lbs)                         4.2 (9.3)               3.5 (7.7)        3.1 (7.0)          3.9 (8.7)           3.1 (6.9)      4.2 (9.3)
 Standard        Blade                     Yes, d) 3 pcs            Yes, 3 pcs       Yes, 2 pcs          Yes, 2 pcs           Yes, 1 pc     Yes, 6 pcs
 equipment       Plastic carrying case          Yes                     Yes              Yes                Yes                 Yes            Yes

a) 120V areas: 1400W
b) When cutting 2"x10" SPF timber
   Note: The vibration values appeared in the instruction manuals for European countries are different from these values.
c) Europe: 4.0m (13.1ft), Australia: 2.0m (6.6ft)
d) 2 pcs. for North America
                                                                                                                                                                        P 3 / 18
                                                                                                              P 4 / 18
Comparison      of products
 Performance Comparison
 Note:
 1) Numbers in the charts below are relative values when the capacity of Model A1 of the competitor A is indexed at 100.
 2) Models with asterisk are equipped with orbital mechanism.

 [1] Wood Cutting
  Test conditions:
  Cut a piece of 2"x10" SPF lumber with;
  A) an identical recipro saw blade (Makita blade No.23)
  B) the recipro saw blade supplied with each model
    (For testing JR3070CT, we used Makita blade Part No.723054-A, a standard accessory of the tool for North America.),
  and measured the time required to cut through the test material.

  Result: See the charts below.

                                  A) With Makita Blade No.23          B) With the Blade Supplied with Each Model
                                    slow                fast                   slow                  fast

   Makita JR3060T*                     155                                              130
   Makita JR3030T                      75                                               100
   Competitor A Mod. A1                100                                              100
   Competitor A Mod. A2                120                                              115

   Competitor B Mod. B                 110                                              100
   Competitor C Mod. C*                110                                              80




 [2] Metal Cutting
  Test conditions:
  Cut a 25mm diameter carbon steel pipe with;
  A) an identical recipro saw blade (Makita blade No.22),
  B) the blade supplied with each model,
    (For testing JR3070CT, we used Makita blade Part No.723066-A, a standard accessory of the tool for North America.),
  and measured the time required to cut through the test material.

  Result: See the charts below.

                                  A) With Makita Blade No.23          B) With the Blade Supplied with Each Model
                                    slow                fast                   slow                  fast

   Makita JR3060T*                     175                                            160
   Makita JR3030T                      95                                             75
   Competitor A Mod. A1                100                                            100
   Competitor A Mod. A2                190                                            200

   Competitor B Mod. B                 135                                            170
   Competitor C Mod. C*                110                                  No blade for metal cutting
                                                                            is supplied with the tool.
                                                                                                                  P 5 / 18
Repair
 CAUTION: Remove the saw blade from the machine for safety before repair/ maintenance !

 [1] NECESSARY REPAIRING TOOLS
  Code No.                  Description                                            Use for
    1R291      Retaining Ring S and R Pliers            Installing/removing Retaining rings S-18 and S-12
     ----      Recipro saw blade                        Inserting push plate into blade clamp section of slider
    1R327      Torx screwdriver T25H120                 Installing/removing Torx countersunk head screw
    1R314      Torx bit VT-25                           Installing/removing Torx countersunk head screw
    1R269      Bearing extractor (small)                Removing Ball bearing 6001DDW
    1R280      Round bar for arbor 6-50                 Removing pin 7
    1R247      Round bar for arbor 20-100               Removing Ball bearing 6003LLB
    1R245      Round bar for arbor 16-100               Removing torque limiter complete
    1R041      Vise plate                               Protecting crank cam complete, when fasten it with vise
    1R268      Spring pin extractor                     Removing shift button
    1R223      Torque wrench shaft 20-90N.m             Tightening torque limiter complete


 [2] LUBRICATION AND ADHESIVE APPLICATION
 [2] -1. LUBRICATION
 Blade Clamp Section
 Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect
 parts and product from unusual abrasion.

  Item No.       Description                                      Portion to lubricate

      64       Pin 3                  Surface which contacts Slider

                                      Head which contacts Driving sleeve
      66       Shoulder pin 5
                                      Surface which contacts Guide sleeve

   Fig. 1
                                                           Driving sleeve
                                                                    Pin 3
                                                                       Driving sleeve guide
                                Guide sleeve
                                                                             Sleeve

                                   Compression
                                   spring 6
                                                                                                               P 6 / 18
Repair
 [2] -1. LUBRICATION (cont.)
  Gear and Reciprocation Mechanisms

 Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect
 parts and product from unusual abrasion.

  Item No.         Description                                      Portion to lubricate
     20       Slider support          Inside surface where Slider reciprocates. Apply approx. 12g.
     24       Slider                  Whole surface
     26       Gear housing            Gear room where (37) Torque limiter rotates. Apply approx. 15g.
     27       Bearing complete        Circumference of Ball bearing portion which contacts (45) Crank cam complete
     37       Torque limiter          Teeth portion
     45       Crank cam complete      Boss on which (52) Needle bearing 710 is installed
     48       Ring 21B                Whole surface
     49       Bearing retainer B      Surface which contacts (48) Ring 21B
     52       Needle bearing 710      Outer surface of the outer ring which contacts the slider block of (24) Slider

   Fig. 2




                                                               Slider block


          Plane bearing 14A




                         Crank base complete




                                                                                                       Bearing box
                                                                                                        P 7 / 18
Repair
 [2] -2. ADHESIVE APPLICATION
 Apply adhesive to the following screws to prevent them from loosening.

   Item No.                    Description                                       Apply for
      (15)      Pan head screw M5x16 (4 pcs)             Securing Gear housing cover
   (29) (42)    Hex socket head bolt M5x16 (4 pcs)       Tightening Plate A and B
      (39)      Countersunk head screw M6x16 (1 pc)      Securing Shoe guide
      (44)      Hex socket head bolt M6x14 (1 pc)        Securing Crank cam complete to Crank base complete
      (51)      Pan head screw M5x16 (4 pcs)             Securing Bearing retainer B

    Fig. 3




               Gear housing cover


                                                                     Slider support complete
                           Slider
                                                                   Bearing complete
                      Plane bearing A
                                Plate A

                                                                    Plate B


                                                                      Crank cam complete


                                                                      Ring 21B
                   Bearing retainer B                                 Crank base complete


                  Shoe guide
                                                                                                                          P 8 / 18
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -1. Disassembling/ Assembling Blade Clamp Section
 DISASSEMBLING                                                              Fig. 4

 1) Remove shoe. If the blade clamp section is positioned inside                                   Blade clamp section
    gear housing, pull it out of gear housing. (Fig. 4)
 2) After removing protector, remove retaining ring S-18 with
    Retaining Ring S and R Pliers (No.1R291).
    Then remove the following parts:
      Driving sleeve, Shoulder pin 5, Compression spring 6,
      Pin 3 (of 6mm length), Guide sleeve, Driving sleeve guide
    Now sleeve appears. (Fig. 5)                                                Shoe

 Fig. 5

             Protector                                                                                   Shoulder pin 5
                   Retaining ring S-18                                                                   Compression spring 6
                                                          Driving sleeve                                 Driving sleeve guide

                                                               Pin 3
                                                     (of 6mm length)
                                                                           Guide sleeve

                                                                                          Sleeve

 3) Because sleeve is locked, release it         Fig. 6
    by pulling in the direction of the blade
    installation side. (Fig. 6)                           [Sleeve Locked]                      [Sleeve Released]
                                                    Pin 3 (of 19.8mm length)                       (Pull in the direction of
                                                                                                   the blade installation side.)
                                                   Sleeve

                                                   groove

                                                                                                        Pin 3 is positioned
                                                                                                        at the lower end of
                                                                                                        the groove on sleeve
                                                                                                        when sleeve is released.


 4) While putting your finger on the top of slider to close the slit of slider, remove pin 3 (of 19.8mm length) by pushing
    with a thin bar. (Fig. 7)
    Note: Be sure to put your finger on the top of slider or push plate will pop out from the slit of slider.
 5) Remove sleeve and torsion spring 17 from slider, then take push plate and compression spring 2 out of the slit of
    slider. (Fig. 8)
 Fig. 7                                            Fig. 8

                                 Slider
                                                      Sleeve                                Push plate
                                      thin bar
                                                      Torsion                              Compression
                                                      spring 17                            spring 2




                                      Sleeve              Slider

                           Pin 3
                           (of 19.8mm length)
                                                                                                                   P 9 / 18
Repair
 [3] -1. Disassembling/ Assembling Blade Clamp Section (cont.)
 ASSEMBLING
 1) Assemble torsion spring 17 to slider as illustrated in Fig. 9.
    Important: Be sure that torsion spring 17 is not reversible when assemble to slider.
                 Follow the instruction described in Fig. 9.
 2) Insert compression spring 2 into the slit of slider.
 3) Install sleeve on slider and lock pin 3 temporarily by turning sleeve clockwise. (Fig. 10)
 Fig. 9                                                                          Fig. 10


     Torsion spring 17                          This end has to
                                                be positioned                                                    Slider
     Insert this end                            on the cap side.                   Pin 3
     into the slit of                                                              (of 19.8mm length)
     slider.                                                                                                       Sleeve

                                                   Cap

   Shift button                                     [Side view of cap]



           Slider                                 Cap has an insert hole
                                                  for shift button.



 4) Mount guide sleeve temporarily, and put push plate into the slit of slider as illustrated to left in Fig. 11.
    Important: Be sure that push plate is not reversible when installed.
    While pushing push plate straight into slider with recipro saw blade, insert pin 3 (of 19.8mm length) through the hole
    of push plate as illustrated to right in Fig. 11. And then remove guide sleeve.
    Note: Guide sleeve is used as a jig, not assembled to slider yet in this step.
 Fig. 11


      This projection must                                                           While pushing recipro saw blade,
      face the blade side.

                                            Push plate
                                                                               Recipro saw blade



                                                                                    Pin 3
                                                                         (of 19.8mm length)
          Guide sleeve

                                                                    insert pin 3 through
                                                                    the hole of push plate.
                                                                                                                          P 10 /18
Repair
 [3] -1. Disassembling/ Assembling Blade Clamp Section (cont.)
 5) While fitting the two projections of driving sleeve in the concavities of sleeve, push driving sleeve into gear housing.
    At this time, turn driving sleeve clockwise so that the protruding portion of driving sleeve cannot be interfered by
    gear housing. After driving sleeve is pushed into gear housing to the full, turn driving sleeve clockwise to lock pin 3
    in place. (Fig. 12)
    Note: Driving sleeve is used as a jig to lock pin 3 in place, not assembled to slider in this step.
 6) Remove driving sleeve.
 Fig. 12

                                                                                                         Driving sleeve
           Driving sleeve                                      Concavities
                            Sleeve




       Projections                                                                      Sleeve


 7) Assemble the following parts to slider (Refer to Fig. 5.):
    Driving sleeve guide, Guide sleeve, Pin 3 (of 6mm length), Shoulder pin 5, Compression spring 6
 8) Put driving sleeve over guide sleeve and secure it with retaining ring S-18 using 1R291. Then cover driving sleeve
    with protector. (When installing driving sleeve, fit its projections in the concavities of sleeve and driving sleeve guide.)

 [3] -2. Replacing Shift Button and Cap
 DISASSEMBLING                                                     Fig. 13

 Shift button can be removed from gear housing cover by                                   Shift button
 inserting a thin bar into the hole of cap and push the bar.
 (Fig. 13)                                                                                                    Cap

                                                                                                                    thin bar




 ASSEMBLING                                                        Fig. 14
 1) Replace cap by new one because removal of shift button
    damages the inside surface of cap.                                       Slider
 2) From shift button, remove all the plastic dust scraped off
    the removed cap. Insert shift button through the holes in
    the both sides of gear housing cover.
   And then press-fit shift button in the new cap by hand.
    Important:                                                                                                      Shift button
    Be sure to assemble shift button to gear housing cover            Cap
    so that the two notches of shift button face the side
    opposite to slider as illustrated in Fig. 14.




                                                                               These notches of shift button must
                                                                               face the side opposite to slider.
                                                                                                               P 11/ 18
Repair
 [3] -3. Disassembling/ Assembling Slider
    DISASSEMBLING
   1) After removing shoe and insulation cover, remove the blade clamp section. (Refer to [3]-1.)
   2) Separate gear housing cover from gear housing by removing four M5x16 pan head screws (adhesive). (Fig. 15)
   3) Remove stop ring E-6, and then take off lever 20 from gear housing cover. (Fig. 15)
   4) Remove another stop ring E-6 from the end of pin 7 as illustrated above in Fig. 16.
      Applying Round bar for arbor 6-50 (No.1R280 ) to the same end of pin 7, push it with arbor press.
      Now pin 7 can be removed from gear housing cover as illustrated below in Fig. 16.
   5) Separate slider section (slider support, seal plate 14, plane bearing 14A, slider, slide plate, bearing complete,
      plates A and B) from gear housing cover. (Fig. 17)
   6) Remove plates A and B by unscrewing four M5x16 hex socket head bolts. ( Fig. 18)

   Fig. 15                                                             Fig. 16

     Pan head screw M5x16                  Pan head screw M5x16               Stop ring E-6         Gear housing cover
     (adhesive-coated)                     (adhesive-coated)



                                                     Stop ring E-6


      Plate C
                                                                                   Pin 7
    Lever 20
                                                                                                 Round bar for arbor
                                                 Gear housing cover                              6-50 (No.1R280)




             Gear housing

                                                                             Pin 7                Gear housing cover


   Fig. 17                                                             Fig. 18


                                        Gear housing cover
                                                                          Plate A securing        Hex socket head
                                                                          Plane bearing 14A       bolt M5x16




          Slider                           Compression spring 5
                                                                          Slider
             Slider support                                                                                    Bearing
                                                                                                               complete
                              Slider section                             Slider support    Plate B securing
                                                                                           Bearing complete
         Be careful not to lose the two compression springs
         illustrated above because they are important parts for
         orbital mechanism.
                                                                                                                    P 12/ 18
Repair
 [3] -3. Disassembling/ Assembling Slider
 DISASSEMBLING

 7) While raising the end of bearing complete side, remove slider from slider support by pulling in the direction
    of the arrow. (Fig. 19)
 8) Remove X ring 14 from slider support. (Fig. 19)
 Fig. 19

    Bearing complete              Plane bearing 14A
                         Slider
                                                                                                                X ring 14




                                  Slider support



 ASSEMBLING
 1) Install X ring 14 on slider support. (Refer to Fig. 19.)
 2) Put bearing complete on the motor side-end of slider, and plane bearing 14A on the blade side-end of slider. (Fig. 20)
    Important: Bearing complete and plane bearing 14A are both not reversible when assembled to slider.
                 Be sure to place them so that the rib on bearing complete/ plane bearing 14A faces toward the motor side.
 Fig. 20

                         Motor side                                                        Blade side
             Bearing complete                          Slider block       Slider            Plane bearing 14A




            rib                                                                                     rib


 3) Mount slider to slider support. (Refer to Fig. 19.)
 4) Fasten plate A and plate B to slider support as illustrated to left in Fig. 21.
 5) Mount compression spring 5 (2 pcs) to slider support as illustrated to right in Fig. 21.
 Fig. 21

        Slider support
                                                                                        Compression spring 5




           Plate A securing                    Plate B securing                    Slider support
           plane bearing 14A                   bearing complete
                                                                                                                P 13/ 18
Repair
 [3] -3. Disassembling/ Assembling Slider (cont.)
 ASSEMBLING
 6) Assemble slider support to gear housing cover complete as illustrated in Fig. 22.
 Fig. 22

           Insert pin 7 through gear housing                  Slider
           cover complete and slider support                             Stop ring E-6
           from the same side of lever 20.
                                                                              Slider support
                                                                                     Stop ring E-6


                                   Pin 7
                                                                                    Compression spring 5
                   Gear housing cover complete

           While pressing slider support toward                                      Make sure that two O rings are
           the direction designated with the                                         assembled to lever 20 before
           black arrow, insert lever 20 through                                      assembling the lever to gear
           gear housing cover complete.                                  Plate C     housing cover complete.
                                                                       Lever 20


 [3] -4. Replacing Torque Limiter Complete
 DISASSEMBLING
 1) After removing insulation cover and shoe, separate gear housing cover complete from gear housing. (Fig. 15)
    It is not necessary to remove lever 20 and pin 7.
 2) Remove bearing box from gear housing by unscrewing three M5x16 pan head screws (adhesive-coated),
    then the hexagon hole of torque limiter will be visible. (Fig. 23)
 3) Secure crank cam complete in vise, then insert hex wrench into the hexagon hole. By turning the hex wrench
     counterclockwise, torque limiter can be disconnected from crank base complete of the crank section. (Fig. 24)
    CAUTION:
    Never use impact driver for turning the hexagonal hole of torque limiter or you may alter the factory-adjusted
    torque setting.
 4) Separate crank cam complete and crank base complete from torque limiter.

 Fig. 23                                                     Fig. 24

                                                               Turn counterclockwise for loosening.
  Pan head screw M5x16
  (adhesive-coated)

             Bearing box

     Hexagon hole
     of torque limiter                                         Vise plate
                                                               (No.1R041)
           Gear housing



                                                              Crank cam complete
                                                                                    Vise plate
                                                                                    (No.1R041)
                                   Crank cam complete
                                                                             Note: Use Vise Plate (Copper) (No.1R041)
                                                                                   to protect crank cam complete.
                                                                                                              P 14/ 18
Repair
 [3] -4. Replacing Torque Limiter Complete
 DISASSEMBLING

 4) After separating crank section from torque limiter complete, remove torque limiter complete from gear housing
    by pressing down with arbor press and Round bar for arbor 16-100 (No.1R245). (Fig. 25)
 Fig. 25

                                    Torque limiter
  Crank section                     complete
                                                                                                  Round bar
                                                                                                  for arbor 16-100
                                                                                                  (No.1R245)




                                                               Torque limiter
                                                               complete




 5) Unscrew four M5x16 pan head screws (adhesive-coated), and then remove bearing retainer B from gear housing.
    Turn over the tool, and now ball bearing 6003LLB can be removed from gear housing by pressing down with
    arbor press and Round bar for arbor 20-100 (No.1R247). (Fig. 26)
 Fig. 26

    Pan head screw M5x16
    (adhesive-coated)

                                                                                                    Round bar
                                                                                                    for arbor 20-100
                                                                                                    (No.1R247)


   Bearing retainer B



                  Ball bearing
                  6003LLB                                                  Ball bearing
                                                                           6003LLB



 ASSEMBLING
 Do the reverse of the disassembling steps.
 Note:
 When fastening torque limiter complete, tighten with Torque wrench shaft 20-90N.m (No.1R223)
 to the recommended torque of 29.4-39.2N.m (300-400 kgf.cm).
                                                                                                                P 15/ 18
Repair
 [3] -5. Replacing Armature
 DISASSEMBLING

 1) After removing insulation cover and shoe, separate gear housing cover complete from gear housing. (Fig. 15)
    It is not necessary to remove lever 20 and pin 7.
 2) Remove carbon brush. Separate motor housing from gear housing by removing four 5x35 tapping screws that fasten
    gear housing to motor housing.
 3) Remove baffle plate. (Fig. 27)
 4) By removing three M5x8 hex socket head bolts, armature can be separated from gear housing. (Fig. 28)

 Fig. 27                                                      Fig. 28

                                                                   Hex socket head bolt M5x8
                                                                   (adhesive-coated)
        Gear housing                         Baffle plate
                                                                                                       Armature




                                                                    Hex socket head bolt M5x8
                                                                    (adhesive-coated)

 5) Remove retaining ring S-12 with Retaining Ring          Fig. 29
    S and R Pliers (No.1R291).
    Now the flat washer 12 on the gear housing side           Flat washer 12
                                                              (Gear housing side)        Bearing retainer A   Armature
    can be removed. (Fig. 29)
 6) By removing ball bearing 6001DDW with
    Bearing Extractor, small (No.1R269), the flat washer 12
    on the fan side and bearing retainer A can be removed
    from armature. (Fig. 29)
                                                              Retaining
                                                              ring S-12
                                                                       Ball bearing      Flat washer 12 (Fan side)
                                                                       6001DDW


 ASSEMBLING

 Do the reverse of the disassembling steps.
 Note:
 Do not forger to put flat washer 12 (2 pcs) in place. (Fig. 29)
                                                                                                        P 16/ 18
Circuit    diagram

                   Color index of lead wires' sheath
   Black                              Orange
   White                              Purple
   Red                                Clear


    When Choke Coils Are Used
                                                                                    Choke coil


    Noise
    suppressor                                              Insulated connector


  Connector


                                               Controller
                 Switch

                                                                                                 Field
                                                                                               (view from
                                                                                               commutator side)




                                      Noise suppressor
    Power supply cord                                             Choke coil
                                                 Insulated connector              Insulated connector




    When Choke Coil Is Not Used

      Noise                                   If noise suppressor is used,
      suppressor                              connect it with No.2 and No.4
                                              terminal of the switch.

                                                            Insulated connector
     Connector




                                               Controller
                 Switch

                                                                                                Field
                                                                                                (view from
                                                                                                commutator side)




   Power supply cord
                                                                                                         P 17 /18
Wiring     diagram
[1] Wiring in Motor Housing



                                                              If choke coils are used, route the following
                                                              lead wires through this opening:
                                                              Field lead wire (purple)
                                                              Lead wire (purple) from choke coil to brush holder

                                                                                    If choke coils are used,
   Route the following lead wires                                                   fix the lead wires from this
   through this opening:                                                            opening with the lead wire
   Field lead wire (black)                                                          holder, and be sure that they
   Field lead wire (white)                                                          are tight in this portion.
                      Field lead wire
                                                                                      Lead wire (purple) from
                              (black)
                                                                                      choke coil to brush holder
                      Field lead wire
                              (white)

                                                                                        Field lead wire (purple)
                        Lead wire (orange)
 Two lead wires         from choke coil to
 used if choke coil     brush holder                    Lead wire
 is used                Field lead wire                 holder
                               (orange)


   If choke coils are used, route the following
   lead wires through this opening as well as
   Field lead wires (black, white):
   Field lead wire (orange)
   Lead wire (orange) from choke coil to brush holder
                                                                                                                  P 18/ 18

Wiring    diagram

[2] Wiring in Handle


                                                           If choke coil is used,     Be sure that the lead wires from
                                                           put it here.               the opening of motor housing
                                                                Choke coil            holder are tight in this portion.




  Route the lead wires to
  switch under the switch.
                                      Switch                        Rib



  If rubber band is used,
                                                     Rote lead wires
  hold the parts with it.
                                                     from choke coil
                                                     between ribs.
    Noise suppressor                                 Rubber band

  If noise suppressors                                Controller
  are used, put them here.                                                    Rib

                                                   Rib                                                       Lead wire
                                                                                                             holder



                                                                                                Fix lead wires with
                                                                                                lead wire holder.
                                                                 Choke coil
                                                             If choke coil is used,      Do not route the lead wires
                             Do not route the lead wires     put it here.                over the ribs.
                             over the rib.



                      When choke coils are used,
                      put the vinyl tube on choke coils,
                      and fix it with two ribs as illustrated
                      to right.




                                                                                                      Vinyl tube

                                                                 rib



◦ Jabse Service Manual Search 2022 ◦ Jabse PravopisonTap.bg ◦ Other service manual resources online : FixyaeServiceinfo