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JR3070CT-TE


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T    ECHNICAL INFORMATION
    Models No.             JR3070CT
                                                                                                    PRODUCT
                                                                                                      P 1 / 18

    Description            Recipro Saw

CONCEPT AND MAIN APPLICATIONS                                                              L

   Model JR3070CT has been developed as the highest specification
   model in Makita Recipro Saws.
   Features electronic control and orbital mechanism for extra-high        H
   cutting efficiency while ensuring low vibration performance with
   our innovative AVT (Anti-Vibration Technology).
   Additionally, provides more control and comfort with toolless                            W
   blade change, toolless shoe adjustment and rubberized soft grip.
                                                                                          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                  14.5           50/60              1,510             650            1,600
         120                   15            50/60              1,700             950            1,600
         220                   7.2           50/60              1,510             650            1,600
         230                   6.9           50/60              1,510             650            1,600
         240                   6.6           50/60              1,510             650            1,600

   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)                                      4.4 (9.7)
                                                        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)
   Steel 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.                     JR3070T    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
  AVT (Anti-Vibration Technology)                                      and our predecessor models in class.
                                                                       (See the comparison charts on page 4.)
 Use of counterweight mechanism
 ensures low vibration performance.         *Orbital Mechanism
                                                 For high speed             Electronic Constant Speed Control
  *Toolless Blade Change                         wood cutting
                                                                       Minimizes reciprocating speed loss when loaded,
 Simply insert the blade for                                           ensuring high cutting efficiency.
 installation. Removal can
 also be done with one touch.
                                                                              *Large Variable Speed Trigger Switch
                                                                                   Easy to operate even with gloved hand




                                                                                         *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.
                                                                                   Variable Speed Preset Dial

      *Reliable, Dust and Drip-Proof Tool Head Mechanism                        Simply by turning the dial, an optimum
                                                                                reciprocating speed range can be variably
 1. Front side of the slider is protected against saw dust by;                  preselected to the material.
   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 JR3060T
                                                                                                               P 3 / 18
Comparison       of products

  Specification Comparison

                            Model No.                       Makita                      Competitor A     Competitor B
  Specifications                             JR3070CT                 JR3020              Model A          Model B
  Rated amperage for North America: A            15                     9.3                 11              11.8
  Continuous rating input: W                  a) 1,510                 1,020               N/A              N/A
  Strokes per min: spm.= min.-1               0 - 2,800               0 - 2,500          0 - 3,200         0 - 2,900
  Length of Stroke: mm (")                    32 (1-1/4)             30 (1-3/16)         32 (1-1/4)        32 (1-1/4)
  Orbital mechanism                              Yes                     Yes                Yes               Yes
  Variable speed trigger switch                  Yes                     Yes                Yes               No
  Electronic constant speed control              Yes                     No                 No                No
  Variable speed control dial                    Yes           No (by trigger stroke)       Yes               Yes
                      Blade change               Yes                    No                  Yes               Yes
  Toolless system
                      Shoe adjustment            Yes                     No                 Yes              Yes
  Clutch                                         Yes                     No                 Yes               No
  Counterweight mechanism                        Yes                     No                 Yes              Yes
  Soft grip                                      Yes                     No                  No              Yes
                      No load                     10                     16                  4.2              10
  Vibration: m/s2
                      b) Loaded                   10                     23                  21               17
  Double insulation                              Yes                    Yes                 Yes              Yes
  Power supply cord: m (ft)                  c) 2.5 (8.2)             2.5 (8.2)           3.0 (9.8)        2.5 (8.2)
                            Length          485 (19-1/8)          463 (18-1/4)          468 (18-1/2)      448 (17-5/8)
  Dimensions: mm (")        Width             99 (3-7/8)            92 (3-5/8)          94 (3-11/16)     100 (3-15/16)
                            Height           181 (7-1/8)           168 (6-5/8)           172 (6-3/4)       180 (7-1/8)
  Net weight: kg (lbs)                         4.4 (9.7)             3.8 (8.4)            4.0 (8.9)         3.8 (8.4)
                  Blade                     Yes, d) 3 pcs          Yes, 3 pcs            Yes, 2 pcs         Yes, 1 pc
  Standard
  equipment       Plastic carrying case       e) Yes                   Yes                  Yes               Yes
                  Hex wrench                      No                   Yes                   No                No
 a) 120V areas: 1700W
 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
 e) North America: with Steel carrying case
                                                                                                              P 4 / 18
Comparison      of products

 Performance Comparison
 Note:
 1) Numbers in the charts below are relative values when the capacity of Model A 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 JR3070CT*                  135                                               150
   Makita JR3020*                    70                                                105
   Competitor A Mod. A*              100                                               100
   Competitor B Mod. B                                                      No blade for wood cutting
                                     85                                     is supplied with the tool.




 [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.22              B) With the Blade Supplied with Each Model
                                 slow                fast                       slow                  fast

   Makita JR3070CT*                  110                                               200
   Makita JR3020*                    100                                               135
   Competitor A Mod. A*              100                                               100

   Competitor B Mod. B               90                                                165
                                                                                                                  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
    1R254      Torque wrench shaft 2-6N.m               Tightening torx socket head screw M5x14



 [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
     47       Counterweight           Surface that contacts Crank cam complete
     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

                                                                      Counter weight

                   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

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




                                                               Torque limiter
                                                               complete




 5) Unscrew four M5x14 torx socket head screws (adhesive-coated) using Torx Driver T25H120 (No.1R327),
    and then remove guide plate 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

    Torx socket head                 Torx Driver T25H120
    screw M5x14                      (No.1R327)
    (adhesive-coated)                                                                               Round bar
                                                                                                    for arbor 20-100
                                                                                                    (No.1R247)




           Guide plate

                                                                            Ball bearing
                                                                            6003LLB
     Ball bearing 6003LLB


 ASSEMBLING
                                                                       Fig. 27
 Do the reverse of the disassembling steps.
 Note:                                                                    Counter weight
                                                                                              Projections
 1) Tighten torx socket head screw M5x14 with Torque wrench shaft
    2-6N.m (No.1R254) to the recommended torque of 2.9-5.9N.m                                         Motor housing
    (30-60 kgf.cm).
  2) Counterweight is not reversible when assembled to gear housing.
    As illustrated in Fig. 27, be sure to place it so that the two
    protrusions faces towards the direction of motor housing.
 3) 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).

                                                                           Gear housing
                                                                                                                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. 28)
 4) By removing three M5x8 hex socket head bolts, armature can be separated from gear housing. (Fig. 29)

 Fig. 28                                                      Fig. 29

                                                                   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. 30
    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. 30)
 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. 30)
                                                              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. 30)
                                                                                                         P 16/ 18
Circuit    diagram

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


    When Choke Coils Are Used
                                                                            Insulated connector


                                                                                                      Heat-shrink
                                                               Speed control dial
     Noise                                                                                            tube
     suppressor                                                Fasten this connector
                                                               to the field core with
                                                               a screw.
   Connector
                                                                               Insulated
                                                                               connector
                                               Controller
                  Switch
                                                             Pick up coil
                                                                                                  Field
                                                                                                  (view from
                                                                                                  commutator side)




                                       Noise suppressor
    Power supply cord                                              Choke coil              Insulated connector
                                             Insulated connector



    When Choke Coil Is Not Used
                                                  If noise suppressor is used,
                                                  connect it with No.2 and No.4
                                                  terminal of the switch.
            Noise
            suppressor                                          Speed control dial


                                                                    Insulated connector
   Connector


                                                Controller
                   Switch
                                                             Pick up coil
                                                                                                   Field
                                                                                                   (view from
                                                                                                   commutator side)




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

                                                                     Pick up coil
                                                                     Put pick up coil here
                                                                     after mounting sleeve on it.


  Route the following lead wires                                                          Route the connecting lead wire
  through this opening:                                                                   (clear) through this opening.
  Field lead wire (black)
  Field lead wire (white)                                                                       Connecting lead wire (clear),
                                                                                                from field core
                     Field lead wire                                                                    Lead wire (clear)
                             (black)                                                                    from noise suppressor
                     Field lead wire
                             (white)

                       Lead wire (orange)
Two lead wires         from choke coil to
used if choke coil     brush holder
                                                                                 Lead wire (black)
is used                Field lead wire
                                                                                 from controller
                              (orange)
                                                                 Lead wire (white)
  If choke coils are used, route the following                   from controller
  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

                                       Secure connecting lead wire (clear)
                                       to field core with the screw with which
                                       field is secured to motor housing.



                                                     Heat-shrink tube




                                                 Connecting lead wire (clear)



 [Protecting the Interconnecting Lead Wire with Heat-Shrink Tube]
 In case that noise suppressor is used, protect the lead wire that interconnects between noise suppressor and
 field core using polyolefin heat-shrink tube. Be sure to cover the crimped portion as illustrated below.

                     [Before shrinkage]                                               [After shrinkage]
     crimped portion       Polyolefin heat-shrink tube                                   Polyolefin heat-shrink tube
                           (before shrinkage)                                            (after shrinkage)




     Non-insulated     Lead wire (clear) that interconnects
     terminal          between noise suppressor and
                       field core
                                                                                                                 P 18/ 18

Wiring     diagram

[2] Wiring in Handle


                                                                                    Be sure that the lead wires from
                                                                                    the opening of motor housing
                                                                                    holder are tight in this portion.




  Route the lead wires to
  switch under the switch.
                                       Switch



  If rubber band is used,                                  Controller
  hold the parts with it.
                                                     Rubber band
    Noise suppressor

  If noise suppressors                           Speed control dial
  are used, put them here.                                                  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.



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