Service Manuals, User Guides, Schematic Diagrams or docs for : MAKITA UH5540-TE
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T ECHNICAL INFORMATION
Model No. UH4540 / UH5540 / UH6540 W
PRODUCT
P 1 / 11
Description 450mm / 550mm / 650mm / Hedge Trimmers L1
CONCEPT AND MAIN APPLICATIONS
The above products are new hedge trimmer series models L2
with higher power and durability for professional use.
Their brief features and benefits are H
* Carbon brushes can be changed without dismounting
housing.
* Shear blade with stabilized sliding action
* Easy to cut hedge side with the sub grip
Dimensions : mm ( " )
Model No. UH4540 UH5540 UH6540
Length ( L2 ) 830 (32-3/4) 930 (36-5/8) 1,030 (40-1/2)
Length ( L1 ) 470 (18-1/2)
Height ( H ) 200 (7-7/8)
Width ( W ) 220 (8-5/8)
Specification
Continuous Rating (W)
Voltage (V) Current (A) Cycle (Hz) Max. Output(W)
Input Output
230 2.7 50 / 60 600 370 500
Model No. UH4540 UH5540 UH6540
Specifications
Blade length : mm 450 550 650
(") (17-3/4) (21-5/8) (25-1/2)
No load speed : (min -1= spm) 1,500
Length of stroke : mm 18
(") (11/16)
Blade pitch : mm 28
(") (1-1/8)
Clutch Yes
Externally accessible brushes Yes
Protection from electric shock by double insulation
Net weight 3.8 4.0 4.1
including blade: Kg (lbs) (8.4) (8.8) (9.1)
Cord length : m ( ft ) 0.3 (0.98)
Standard equipment
* Blade cover ............................................. 1 pc.
* Hook complete ........................................ 1 pc.
< Note > The standard equipment for the tool shown may differ from country to country.
Optional accessories
* Blade cover * Hook complete
* Shear blade assembly
Features and benefits P 2 / 11
UH4540 / UH5540 / UH6540
Easy to change carbon brushes.
No need to dismount whole of housing.
For changing, you can only remove
top cover.
Durable gear unit equipped
with ball bearings on both
sides of gear shaft Palm fitting front
grip and handle
Double-sided, Easy to trim hedge side with
Double Reciprocating Blades the palm fitting sub grip
for Sharp Trimming
Firmly stabilized sliding action
Mechanic Brake Feature of shear blade by thickening
stops the machine within the sliding portion of crank and
0.2 sec. for Absolute Safety shear blade's shank.
New type Two-hand Operation Switch.
Three switches are installed; in handle,
front grip and sub grip.
Branch catcher equipped
The blades start moving only when
on the top of shear blade,
any pair of these three switches are pressed.
prevents the accidental shock,
and the change of gear unit.
Comparison of products
Model No. MAKITA Competitor A
Specifications UH4540 / UH5540 / UH6540 UH4520 / UH5520 / UH7020 Model A1 /Model A2 /Model A3
450 450 550
UH4540 UH4520 Model A1
(17-3/4) (17-3/4) (21-5/8)
Cutting width : mm 550 550 650
UH5540 UH5520 Model A2
(") (21-5/8) (21-5/8) (25-1/2)
650 700 750
UH6540 UH7020 Model A3
(25-1/2) (27-1/2) (29-1/2)
Power input : W 600 550 600
No load speed : (min -1= spm) 1,500 1,500 1,350
Blade pitch : mm ( " ) 28 (1-1/8) 31 (1-1/4) 26 (1 )
Length of stroke : mm 18 21 18
(") (11/16) (13/16) (11/16)
* Max. cutting diameter of branch 15 11 13
with one stroke : mm ( " ) (9/16) (7/16) (1/2)
Vibration in no load operation 2.1 m/s2 (UH6540) 1.6 m/s2 (UH4520) 2.1 m/s2 (Model A2)
Noise level in no load operation 84 dB (UH6540) 91 dB (UH4520) 85 dB (Model A2)
Clutch Yes Yes Yes
Reduction gears one gear one gear two gears
Brake system mechanic mechanic mechanic
Externally accessible brushes Yes No Yes
Length : mm ( " ) 470 (18-1/2) 410 (16-1/8) 500 (19-3/4)
Dimensions Width : mm ( " ) 220 (8-5/8) 215 (8-1/2) 210 (8-1/4)
Height : mm ( " ) 200 (7-7/8) 190 (7-1/2) 200 (7-7/8)
Net weight including UH4540 3.89 UH4520 3.80 Model A1 4.08
shear blades (8.74) (8.38) (8.99)
(measured by us) : Kg 4.04 4.00 4.23
UH5540 UH5520 Model A2
(lbs) (9.07) (8.82) (9.33)
4.16 4.2 4.43
UH6540 (9.34) UH7020 (9.26) Model A3 (9.77)
* Max. cutting diameter of branch with one stroke : measured by MAKITA, The figures may be different from
materials to materials.
Repair P 3 / 11
< 1 > Lubrication
Apply MAKITA grease N. No.2 to the following portions marked with black triangle to protect
parts and product from unusual abrasion. See Fig. 1.
Helical gear
Pin 5
Lock spring 18 (Switch rod)
Inner sleeve
Pin holder
Gear complete Spacer
Crank
Fig. 1
Lubricant to be applied
Parts' name Portion to be lubricated Volume of lubricant
Helical gear Teeth portion 3.5 g
2.9 g
MAKITA grease N No.2 Lock spring 18 Whole of its inside
Inner sleeve whole of its outside 0.5 g
Crank Portion where contacts with blade shank 3.0 g
Pin 5 (Switch rod) Portion where contacts with pin holder 0.1 g
< 2 > Disassembling shear blade
1. Disassemble under cover by unscrewing 2 pcs. of tapping screws 4 x 16. See Fig. 2.
2. Disassemble gear housing cover by unscrewing 2 pcs. of tapping screws 4 x 16. See Fig. 2.
Gear housing cover
2 pcs. of
Tapping
screws 4 x 16
Fig. 2
Under cover
2 pcs. of
Tapping
screws 4 x 16
Repair P 4 / 11
3. Unscrewing 2 pcs. of pan head screws M5 x 25 as illustrated in Fig. 3.
These pan head screws M5 x 25 are the adhesive screws. It is recommended to unscrew
with the impact driver.
4. Align the both elliptic holes of shear blades A and B with crank, by turning spindle portion anti-clockwise
with screwdriver inserted into the spindle's slit. See Fig. 4.
5. Then, shear blades can be disassembled from housing. See Fig. 5.
Pan head screws
M5 x 25
The slit of spindle
for inserting screwdriver
Crank
Shear blade A
Shear blade B
Crank, aligned
with the holes of
Fig. 3 shear blades A and B. Fig. 4 Fig. 5
< 3 > Assembling shear blade
1. Turn crank to the position where it crosses the joint of housing R and L in right angle as illustrated in Fig. 6.
2. Align the elliptic hole of shear blades A with the same of shear blade B as illustrated in Fig. 7.
3. Assemble shear blades with aligning the screw holes of shear blades with the same of gear housing as illustrated
in Fig. 8.
4. Fasten shear blades with 2 pcs. of pan head screws M5 x 25 as illustrated in Fig. 9.
These pan head screws M5 x 25 are the adhesive screws. Do not use the used ones.
Always fasten with fresh adhesive screws.
Pan head screws
Joint of M5 x 25
housing R and L
Gear Gear
housing housing
Crank
Align the elliptic holes
each other.
Fig. 7
Fig. 6 Fig. 8
Repair P 5 / 11
5. Fasten gear housing cover with 2 pcs. of tapping screws 4 x 16. And then, fasten gear housing cover with 2 pcs.
of tapping screws 4 x 16 as illustrated in Fig.10.
Gear housing cover
2 pcs. of
Tapping
screws 4 x 16 Fig.10
Under cover
2 pcs. of
Tapping
screws 4 x 16
< 4 > Disassembling gear section (Crank section)
1. Disassemble shear blades as mentioned in "< 2 > Disassembling shear blade" at page 3 and 4.
2. Slightly hit the edge of gear housing with plastic hammer. Then, gear section (crank section) can be separated
from gear housing. See Fig. 11.
3. Disassemble ball bearing 608ZZ with No.1R269 "Bearing extractor", and stop ring E-7. See Fig. 12.
Ball bearing 608ZZ
Stop ring E-7
Gear
housing
Gear
Crank
Fig. 12
Fig. 11
4. Pull with turning gear assembly anti-clockwise, and pull crank section with turning clockwise.
Then, crank section can be separated from gear assembly as illustrated in Fig. 13.
Holder It is impossible to separate these parts each other by
Gear assembly turning them reverse direction.
(including holder)
Crank section
Fig. 13
Repair P 6 / 11
5. Put holder on lock spring 18 aligning its hole with the tail of lock spring 18.
Turning lock spring 18 with holder anti-clockwise and turning crank section clockwise, pull them as illustrated
in Fig. 14.
Holder Tail of Holder
lock spring 18
Lock spring 18 It is impossible to separate these parts
each other by turning them reverse
direction.
Crank section
Fig. 14
6. Disassemble ball bearing 6000ZZ with No.1R269 "bearing extractor", and flat washer 10.
And then, disassemble spindle by pressing with arbor press. The crank section can be disassembled
in crank complete, spacer and inner sleeve as illustrated in Fig. 15.
Inner sleeve
Spacer
Flat washer 10
Ball bearing 6000ZZ Spindle
Crank complete
Fig. 15
< 5 > Assembling gear section (Crank section)
1. Assemble inner sleeve spacer, crank complete and spindle as illustrated in Fig. Fig. 16.
And apply MAKITA grease N. No.2 to the out side of inner sleeve. See Fig. 16.
Assemble spindle by pressing
with arbor press.
Spindle
Crank complete
Apply 0.5 g of MAKITA grease N. No.2 to
Spacer the out side of inner sleeve.
Inner sleeve
Fig. 16
2. Assemble gear assembly by pressing. And apply 2.9g of MAKITA grease N.No.2 in the gear hole.
Put holder on lock spring 18 aligning its hole with the tail of lock spring 18, and press lock spring 18 together
with holder, into the gear hole. See Fig. 17.
Put holder on lock spring 18
aligning its hole with the tail
Assemble gear assembly by of lock spring 18.
pressing.
Press lock spring 18 together
with holder, into the gear hole.
Holder
Lock spring 18
Apply 2.9g of MAKITA grease
N.No.2 in the gear hole.
Fig. 17
Repair P 7 / 11
3. Assemble stop ring E-7, and assemble ball bearing 608ZZ by pressing as illustrated in Fig. 18.
4. Assemble flat washer 10, and assemble ball bearing 6000ZZ by pressing as illustrated in Fig. 19.
Ball bearing 608ZZ
Stop ring E-7
Flat washer 10
Ball bearing 6000ZZ
Fig. 18 Fig. 19
< 6 > Replacing carbon brush
1. Disassemble housing top cover by unscrewing 2 pcs. of tapping screws 4 x18. See Fig. 20.
2. Levering up carbon brushes with small slotted screwdriver, pull out them in the direction of shown with arrows.
See Fig. 21.
Pull out carbon brushes in
2 pcs. of the direction shown with
Housing top cover
Tapping screws 4 x18 the arrows.
Fig. 20
Fig. 21
3. After making sure that the fresh carbon brushes have been installed firmly to housing, assemble housing top cover
to housing by fastening with 2 pcs. of tapping screws 4 x 18.
< 7 > Disassembling housing
1. Loosen 2 pcs. of tapping screws CT5 x 30, and slide the front grip section to the direction shown with the arrow.
2. Disassemble housing top cover by unscrewing 2 pcs. of tapping screws 4 x18. See Fig. 22.
Housing top cover
2 pcs. of
Tapping screw CT5x30 Tapping screws 4 x18
Front grip section
Fig. 22
Tapping screw CT5x30
Repair P 8 / 11
3. Loosen 2 pcs. of tapping screws 4 x 16, and disassemble under cover. See Fig. 23.
4. Loosen 11 pcs. of tapping screws 4 x 18, and disassemble housing R from housing L. See Fig. 24.
Under cover
2 pcs. of
Tapping
screws 4 x 16
Fig. 23
11 pcs. of tapping screws 4 x 18
Fig. 24
< 7 > Disassembling armature
1. Disassemble shear blades as mentioned in "< 2 > Disassembling shear blade" at page 3 and 4.
2. Disassemble carbon brushes and brush holders as mentioned in "< 6 > Replacing carbon brush" at page 7.
3. Disassemble housing L and R as mentioned in "< 7 > Disassembling housing" at page 7 and 8.
4. Disassemble motor unit (gear housing, armature, field and lever) from housing as illustrated in Fig. 25.
And take off field together with lever from motor unit as illustrated in Fig. 26. Separate armature from
gear housing as illustrated in Fig. 27.
Field
Armature
Field
Gear housing Lever
Lever
Fig. 25
Fig. 26 Fig. 27
Repair P 9 /11
< 8 > Assembling armature
1. Assemble armature to gear housing as illustrated in Fig. 28.
2. Assemble field and lever to armature as illustrated in Fig. 29. Now the motor unit has been completed.
3. Assemble the motor unit to housing as illustrated in Fig.30.
Fig. 28
Fig. 29
Fig. 30
< Note in assembling >
Take care of the following 3 points, when assembling motor unit
to housing.
1 Field has to be precisely set in in the concave for field
assembling in housing.
2 This portion for assembling front grip has to be inserted
into the hole of housing.
3 The portions 3 have to be fitted into the housing's bosses
with screw holes.
Fig. 30A
4. After making sure the above 3 points, assemble another housing and fasten it with 11 pcs. of tapping screws 4 x 18.
See Fig. 31.
Fig. 31
Repair P 10 / 11
< 9 > Assembling switch section
1. Pas pin 5 through cap holder. See Fig. 32.
2. Assemble compression spring 8 and insulation cap to the top of pin 5. See Fig. 33.
When assembling insulation cap, bring the convex portion of cap holder into the slit of
insulation cap. See Fig. 33A.
Slit of insulation cap
Insulation cap
Compression
Pin 5 spring 8
Cap holder
Cap holder
Protrusion
Fig. 32 Fig. 33
Fig. 33A
3. Assemble lifter, pin holder and compression spring 5 to the lower side of cap holder. See Fig. 34.
Assemble stop ring E-4 to fix lifter, holder, and compression spring 5. See Fig. 35.
The protrusions have to
be faced to cap holder
Cap holder side.
Lifter
Lifter
Stop ring E-4
Pin holder This protruding portion
has to be faced to cap holder Fig. 35
Compression side.
spring 5
Pin holder
Fig. 34
4. Assemble the switch section to housing with pushing pin holder down as illustrated in Fig. 36.
And then, assemble push cap and pin 3 to pin holder as illustrated in Fig. 36.
5. After assembling the switch section to housing, make sure the matters mentioned in Fig. 36A.
< Note in assembling >
3 arms of lifter have to be located on lever, switch lever A and push cap respectively
as illustrated in Fig. 36A.
View from side A
Side A
Pin holder
Push cap
Pin 3
Lever
Arms of
lifter
Switch lever A
Gear housing Push cap
Fig. 36 Fig. 36A
Circuit diagram P 11 / 11
Color index of lead wires Noise suppressor
Black
White
See-through
COM
NO
Switch
to field core
Terminal block
Power supply cord
Line filter
Field
Wiring diagram Pass brush holders' lead wires under Housing L Brush holders'
the brush holders by bending them to lead wires (white)
the housing L side.
Brush
holder
Fix lead wires with lead holder.
Line filter
Pass field lead wires
through line filter, and
set the line filter in the
position illustrated.
Field lead wires
(Black)
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