Makita XRU09 Betriebsanleitung

REPAIR MANUAL

XRU09

P 2/ 19

Repair

Index

1 NECESSARY REPAIRING TOOL............................. 2

2 ROTOR, STATOR ASS’Y

2-1 Disassembling ......................................................... 3

2-2 Assembling .............................................................. 8

3 LOOP HANDLE SET, PIPE COMPLETE, GRIP SET, SWITCH LEVER, LOCK OFF LEVER

3-1 Disassembling ......................................................... 10

3-2 Assembling .............................................................. 12

4 CIRCUIT DIAGRAM ................................................. 15

5 WIRING DIAGRAM ................................................... 16

6 TROUBLE SHOOTING

6-1. Check list for Trouble shooting ........................... 18

6-2. Note for repairing ................................................. 19

6-3. Note for recognizing the short-circuit of

FET (Field Effect Transistor) on controller ....... 19

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

Code No. Description Use for

press-fitting Ball bearing 6001DDW

press-fitting Stator ass’y

press-fitting Rotor

Pipe ring (for Arbor press)1R023

Bearing setting pipe 16-8.21R026

Bearing setting pipe 18-10.2

Bearing setting pipe 20-12.2 removing Ball bearing 6001DDW/ press-fitting Rotor

Bearing setting pipe 28-20.2

Bearing setting plate 10.2

Gear extractor (large) removing Rotor

1R027

1R028

1R031

1R033

1R045

Bearing extractor removing Stator ass’y

removing Ball bearing 607ZZRound bar for Arbor 12-50

Retaining ring S and R pliers removing / assembling Retaining ring R-28

1R263

1R286

1R291

Ring 60 removing Stator ass’y1R350

1 NECESSARY REPAIRING TOOLS

P 3/ 19

(1) Remove Cutter blade / Tipped saw blade / Nylon cutting head / Plastic blade. (Figs. 2-1-1, 2-1-2 and 2-1-3)

2 ROTOR, STATOR ASS’Y

2-1 Disassembling

1. Hold Rotor by inserting Hex wrench into the side hole

of Motor housing.

Remove M10-17 Hex nut by turning it clockwise.

2. Remove Cup, Clamp washer, Cutter blade

and Receive washer A (48).

M10-17 Hex nut

Fig. 2-1-1

Fig. 2-1-2

Hex wrench to hold Rotor

Motor housing

Receive washer A

Cutter blade/Tipped saw blade

Clamp washer

Cup

< Cutter blade/ Tipped saw blade>

1. Hold Rotor by inserting Hex wrench into the side hole of Motor housing.

Remove Nylon cutting head by turning it clockwise.

2. Remove Guard and Receive washer.

Guard

Receive washer

Nylon cutting head

Hex wrench to hold Rotor

Motor housing

< Nylon cutting head>

Fig. 2-1-3

1. Hold Rotor by inserting Hex wrench into

the side hole of Motor housing.

Remove Plastic blade by turning it clockwise.

Plastic blade

Hex wrench

2. Remove Hex nut, Plastic blade and Receive washer.

Hex nut

Receive washer

< Plastic blade >

Plastic blade

Fig. 2-1-4

Fig. 2-1-5

M5x20 Hex socket

head bolts (2 pcs.)

M5x16 Hex socket head bolts with WR* (2 pcs.)

1. Disassemble Protector by loosening two

M5x20 Hex socket head bolts.

Note: No need to remove Hex socket

head bolts completely.

2. Disassemble Protector clamp by unscrewing

two M5x16 Hex socket head bolts with WR*.

Protector

Protector clamp

< Protector>

P 4/ 19

1. Loosen M5x25 Hex socket head bolt.

Remove three M5x20 Pan head screws.

2. Remove Top cover.

Top cover

M5x20 Pan head screw (3 pcs.)

M4x16 Pan head screw (2 pcs.) Controller B

5. Cut three Insulated connectors 5.5-SD

at the position marked with red lines.

Inner cover

M5x25 Hex

socket head bolt

3. Remove Controller B and Inner cover by unscrewing two M4x16 Pan head screws.

Note: Lead wires connected with Insulated connectors 5.5-SD

can be disconnected without cutting lead wires.

(Fig. 2-1-6 in page 5)

4. Disconnect the connectors of

Controller B.

Connectors of Controller B Insulated connectors 5.5-SD (3 pcs.)

(2) Remove Protector. (Fig. 2-1-4)And then, disassemble Motor housing section. (Fig. 2-1-5 as below and Fig. 2-1-6 in

page 5, Figs 2-1-7/ 2-1-8 in page 6, and Fig. 2-1-9 in page 7)

*W...Spring washer

R....Flat washer

P 5/ 19

Fig. 2-1-6

1. Cut the tip of

plastic portion.

2. Cut the skirt portion. 3. Cut the drum portion.

4. Remove Plastic cover.

5. Pull Lead wires slowly while

forming the sleeve to cylindrical

figure with water pump pliers.

P 6/ 19

Fig. 2-1-7

Fig. 2-1-8

1. Remove Strain relief by unscrewing

M4x16 Pan head screw.

2. Pull out Motor housing.

2. Put Motor housing on 1R350, and release

the press-fitting condition of Stator ass’y

and the shaft of Rotor slightly with 1R045.

4. Pull out Stator ass’y

from the shaft of Rotor.

3. Pry Stator ass’y with

two pieces of 1R263.

Shaft of Rotor

Stator ass’y

ﾄ

Stator ass’y

Strain relief

M4x16 Pan

head screw

Motor housing

Motor

housing

1R350

1R045 1R263

1. Loosely tighten with Receive washer A and Hex nut M10-17/ Hex nut M10-14 to prevent Rotor from falling out.

Loosely tighten Nylon cutting head instead of the hex nut if Nylon cutting head is used.

Rotor

Hex nut M10-17/ Hex nut M10-14

Receive washer A

Stator ass’y is

slid upward from

Shaft end of Rotor.

5. Press Ball bearing 607ZZ with 1R286 to remove it from Stator ass’y.

1R286

Stator ass’y

Ball bearing 607ZZ

P 7/ 19

2. Remove Retaining ring R-28 with 1R291. 3. Remove Ball bearing 6001DDW by pressing down 1R028.

1R291

Retaining ring R-28

Ball bearing

6001DDW

1R028

Fig. 2-1-9

Ring 14

Rotor

1. Remove Rotor and Ring 14 from Motor housing with 1R045.

Note: Hook the jaws of 1R045 to Motor housing and set the center shaft of 1R045 to the shaft of Rotor.

The jaws must not be touched to Rotor.

Motor housing

1R045

P 8/ 19

Fig. 2-2-2

Fig. 2-2-3

1. Mount Ball bearing 607ZZ

to Stator ass’y by hand.

2.Set Motor housing on 1R023

while avoiding its pin.

(1) If Stator lead wires are cut as shown in Fig. 2-1-5, strip the ends. (Fig. 2-2-1)

(2) Mount Ball bearings to Stator ass’y and Motor housing. (Fig. 2-2-2)

(3) Mount Retaining ring R-28 to secure Ball bearing 6001DDW with 1R291. Refer to Fig. 2-1-9 in page 7.

Assemble Rotor to Motor housing. (Fig. 2-2-3)

3. Assemble Ball bearing 6001DDW

by pressing down 1R031.

Ball bearing 6001DDW

Stator ass’y

1R023

1R031

Motor housing

Fig. 2-2-1

1. Remove sheathes

by 13mm from the tip.

2. Remove enamel with abrasive paper #100

by 11mm from the tip.

Note: It is necessary to remove enamel

to conduct electricity.

1. Place Ring 14 on the shaft of Rotor.

Note: No paint portion of Ring 14 must be faced to Rotor.

1R027

1R028

2. Insert the shaft of Rotor into

the bearing in Motor housing.

3. Support Motor housing with 1R027.

Press down 1R028 while applying

1R028 on the bearing to assemble

Rotor into Motor housing.

Rotor

Shaft of Rotor

No paint portion

painted

in green

[cross section]

no paint

Motor housing

Ball bearing 607ZZ Motor housing

Note: Be sure to

avoid the pin

from 1R023.

2 ROTOR, STATOR ASS’Y

2-2 Assembling

Ring 14

P 9/ 19

Fig. 2-2-4

1. Place Stator ass’y on the shaft of Rotor.

Note:

* Be careful not to pinch your fingers between Stator and Rotor by strong magnet power.

* Mount Stator ass’y while aligning its hole to the locating pin on Motor housing.

(5) Mount Stator ass’y to Motor housing. (Fig. 2-2-4)

2.Set Motor housing on 1R033.

Apply 1R026 on Stator ass’y and press down 1R026.

Locating pin on

Motor housing

Hole of Stator ass’y

1R026

Stator ass’y

Shaft of Rotor

Motor housing

1R033

Motor housing

P 10/ 19

3 Loop handle set, Pipe complete, Grip set, Switch lever, Lock off lever

3-1 Disassembling

Fig. 3-1-1 Fig. 3-1-2

Fig. 3-1-3

See Figs. 3-1-1, 3-1-2, 3-1-3 as follows and Figs. 3-1-4, 3-1-2, 3-1-3 in the next page.

Note: No need to remove Nylon cutting head / Plastic blade from Motor housing.

4. Disconnect the connectors of Power supply cord unit (long)

from the connectors of Controller complete in Housing L.

Battery

guard

2. Remove Battery guard

by unscrewing

three M4x12 + Screws.

1. Disassemble Roop handle set.

3. Remove Housing R by unscrewing seven 4x18 Tapping screws.

Housing R

Controller complete

5. To remove Power supply cord unit (long) completely

from the lead wires of Controller complete, cut three

Insulated connectors 5.5-SD at the portion designated

with red lines.

Note: Cut each clamped portion to leave the lead wires

because of the easy reassembling process.

M4x12 + Screw

(3 pcs.)

M5x25 Hex socket

head screw (2 pcs.)

Clamp cover B

Clamp 33

Roop handle set

Roop handle

Pipe complete

(It is not included in Loop handle set.)

4x18 Tapping screw (7 pcs.)

Clamped portions of

Insulated connectors 5.5-SD (3 pcs.)

6. Disconnect the connector of Power supply cord unit

(short) from the connector of Contoller complete.

7. Remove Strain relief by unscrewing 4x18 Tapping

screw. Power supply cord (short) is removed together

with Corrugated tube.

Connector of Power supply cord (short)

4x18

Tapping

screw

Strain relief

Power supply cord unit

(long)

Power supply cord

unit (short) with

Corrugated tube

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