Makita XRU09Z-DC18RD Installation guide

Brand: Makita

Model: XRU09Z-DC18RD

Type: Installation guide

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

P 11/ 19

Repair

Fig. 3-1-4

Fig. 3-1-5

Fig. 3-1-6

1. Remove six 4x18 Tapping screws and M5x18

Hex socket head bolt, and then remove Grip R.

Note: When you want to remove Power supply cord unit (long) from Pipe complete, both the connector ends of

the power supply cord unit must be disconnected in advance. Therefore, do the following steps.

1. Disconnect the other connector of the power supply cord unit from the connector of Stator ass’y in

Motor housing complete.

2. Loosen Strain relief in Motor housing complete, and then remove the clamped Power supply cord unit.

3. Pull out the power supply cord unit toward Housing set side with care of the connector that is passed through

Pipe complete.

2. Remove Lock off lever together with

Torsion spring 9 by lifting them up.

3. Remove Switch lever together with

Torsion spring 10 by lifting them up.

Loosen M5x18 Hex socket head bolt, and then remove Spacer 24 and Hanger from Pipe complete.

4x18 Tapping screw (6 pcs.)

M5x18 Hex socket head boltGrip R

Torsion spring 9

Housing set side

To Motor housing complete

Lock off lever

Switch lever

Torsion spring 10

Spacer 24 Hanger

M5x18 Hex socket head bolt

P 12/ 19

Fig. 3-2-1

1. Install Hanger from two holes side of Pipe complete.

Assemble by reversing the disassembly procedure.

Also, refer to the point shown in Fig. 3-2-1 as follows and Figs. 3-2-2 in next page.

2. Tighten M5x18 Hex socket head bolt to secure Hanger as drawn below,

then install Spacer 24 to the end of Hanger.

3. Fit the projection of Housing L into the hole on Housing side of Pipe complete, then the projection of Grip L into

the hole on Grip set side of Pipe complete.

4. Assemble two holes side of Pipe complete to Housing L with 4x18 Tapping screw and Clamp 24.

Housing and Grip set side Motor housing side

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

3-2 Assembling

Pipe complete

Hanger

Spacer 24

Caution label

34mm 14mm

Two holes One hole

482±3mm

The center in the hole of Hanger

M5x18 Hex socket head bolt

Hole on Housing side

of Pipe complete

Hole on Grip set side

of Pipe complete

Projection of

Housing L

Two holes side of Pipe complete

Projection of

Grip L

4x18 Tapping screw

Clamp 24

Housing L/ Note: Power supply cord (short) with Corrugated tube disappears because of

simple inside view.

P 13/ 19

Fig. 3-2-2

Torsion spring 9

1. Insert Lock off lever halfway over the boss of Grip L

while pressing Torsion spring 9.

2. Push Lock off lever to the bottom of Grip L after holding

the Torsion spring’s arm with the rib of Grip L.

Boss of Grip L Lock off lever

Rib of Grip L

3. Assemble Lock off lever by fitting its projection to the groove in Grip L as shown in the following four pictures.

Projection of Lock off lever

Groove in Grip L

Viewed from the inside

Lock off lever

Rib of Grip L Groove of Grip L

Switch lever

4. Insert Switch lever over the pin of Grip L until it stops while

pressing the arm of Torsion spring 10 to the rib of Grip L.

5. Push Switch lever in direction of the yellow arrow

until the projection is fit into the groove in Grip L.

Viewed from Sub controller/ the upper side of Lock off lever

Push and align the projection of

Lock off lever.

Torsion spring 10

Pin of Grip L Groove of Grip L

Projection of Switch lever

P 14/ 19

Fig. 4-1

4 CIRCUIT DIAGRAM

White

ON / OFF,

High / Low

speed

Reversing

switch

R / L

change

Red

Orange

Blue

Brown

Yellow

Switch unit for Trigger

Sub controller complete

High speed

LED

Indicator

Low speed

Stator

Controller B

Power supply cord unit (long)

Polyolefin tube

Insulated connector

5.5 -SD

Tape

Connector

Symbol Electrical Parts

Straight receptacle

with polyolefin

tube

Controller

Terminal A

Terminal B

Battery fuel

gauge

Power supply

cord unit (short)

with corrugate

tube

Purple

Gray

Color index of lead wires' sheath

Black

Flag receptacle

28 AWG*

22 AWG*

28 AWG*

16 AWG*

Insulated

connector

5.5-SD

Tape to distinguish Motor side

16 AWG*

28 AWG*

16 AWG*

22 AWG*

16 AWG*

22 AWG*

16 AWG*

Flag terminal

with lock (#250, t=0.8)

Straight terminal

with lock (#187, t=0.8)

* AWG: American Wire Gauge

28 AWG*

P 15/ 19

Fig. 5-1

Put Connectors to the space between the bottom of Motor housing

and Power supply cord unit (long).

Connectors

Power supply cord unit (long)

Wiring in Motor housing

Strain relief

Connectors

The bottom of

Motor housing

Strain relief

Section A-A

Power supply cord

unit (long)

Mount Strain relief while facing its looped side

to the bottom of Motor housing.

Insulated connector 5.5-SD

Power supply cord unit (long) has to be fixed with the end

protruding from Strain relief in the direction of Controller B.

End of Power supply cord unit (long)

Strain relief

Controller B

Put Insulated connectors 5.5-SD and sags

of lead wires to the drawn place between

Controller B and Power supply cord unit.

Looped side of Strain relief Looped side of Strain relief

End of Power supply cord unit (long)

Strain relief

Controller B

5 CIRCUIT DIAGRAM

P 16/ 19

Fig. 5-2

Wiring in Grip set

Switch unit

Lead wires of

Power supply cord unit

(short) to Sub controller

Set the connector on blue lead

wires and black lead wires

to the connector for

Switch unit as drawn.

Set the connector of Sub controller and the connector on the one of

Power supply cord unit (short) as drawn.

Sub controller

Rib C

Rib B

Rib A

Heat shrink tube

Sub controller

Corrugated tube

with Power supply

cord unit (short)

Strain relief

Note: Be careful not to pinch Corrugated tube of

Power supply cord unit (short) with Strain relief .

Do not put the sag of any Lead wires

on Connectors.

Do not put the sag of Lead wires on the connectors.

First, set lead wires of

Switch unit to Grip set.

The Lead wires for Sub controller have to be put

so that the end of Heat shrink tube protrudes

from the border line of Rib A.

Put Lead wires with tape between

Rib C and Rib B.

Fix Power supply cord unit (long) by pulling out at least 3 mm from the end of Rib D as shown.

Flag receptacles of Terminal A and

Terminal B have to be connected

so that their wire connecting portions

are located over the marks of + - poles.

Housing L side

Terminal A

Terminal B

Wire connecting portions

3 mm

Corrugated tube

Strain relief

Power supply cord unit (short)

Controller

Rib A

Rib B

Rib C

Rib D

Rib E

Flag

receptacles

P 17/ 19

Fig. 5-3

Put Power supply cord (long) between Rib D and Rib E.

Put lead wires with Insulated

connectors 5.5-SD in front

of Noise suppressor.

(between Noise suppressor

and Housing R)

Put lead wires of Terminals

between Rib A and Rib B,

and Rib B and Rib C.

Put Lead wires for 10 pin Connector

between Rib B and Rib C.

Place 2 pin / 5 pin connectors here.

Wiring in Housing set

Insulated

connectors

5.5-SD

10 pin Connector

Be careful not to pinch Corrugated tube

on Power supply cord unit (short)with

Strain relief .

P 18/ 19

6 TROUBLE SHOOTING

Symptom Cause Corrective action

6-1 Check List for Trouble Shooting

Check items from the top. (For description of the item, refer to Circuit diagram in Fig. 4-1).

After corrective action, return to the start of Trouble shooting and check again.

Does Tester indicate 0.9V ~ 1.3V?

When tester cannot be prepared, go to “Yes”.

Yes

Scratch on Core

of Rotor or any

mechanical trouble

is recognized.

Motor runs when

pulling Switch lever

of Switch unit.

Yes

The machine shows same symptom

in spite of the above corrective actions

No trouble

on the machine

Replace Controller.Controller is broken.

Replace Sub controller.

Replace Controller.

Replace Controller B.

Sub controller is broken.

Controller is broken.

Controller B is broken.

Replace Controller.

Incomplete connection of

Terminal with battery

Check the connection

with Battery

Replace Terminal.

Replace Controller.

Replace Motor unit.

* Incomplete connection

of Connectors

* Disconnection of Power

supply cord unit

connected to Switch unit

Controller is broken.

Check the connected

condition of Connectors

Replace Power supply

cord unit.

Replace Power supply

cord unit

Check the connected

condition of Connectors

or Closed end splices.

Motor unit is broken.

Each three lamps on Indication label indicate

power remaining of each Batteries.

Controller is broken.

Indication label

Power lamp on Sub controller turns on

by a long press.

* Disconnection of Power

supply cord unit

connected to Stator

* Incomplete connection

of Connectors or Closed

end splices

Replace Controller.Controller is broken.

P 19/ 19

Repair

6-2 Note in Repairing

(1) Make sure to use full charged battery with Star mark (Fig. 6-2-1).

(2) When Housing is disassembled, check the conditions of electrical parts

(Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc.

(3) Do the running test 10 times in every work mode.

Star mark

Fig. 6-2-1

Fig. T-2

6-3 Test for recognizing the short-circuit of FET (Field Effect Transistor) on controller

Trouble on Controller can be checked with Tester as follows.

(1) Set Digital tester (1R402-A) in the Diode mode.

(3) Contact Black probe with (+) Terminal.

Contact Red probe with (-) Terminal.

Wait until the figure on Tester gets stable.

Note: Be careful not to reverse them. The

reversed contacts could spoil the test.

(4) Controller is in order if Tester indicates

0.9V ~ 1.3V. If Tester indicates 0 V~0.4 V approx.,

Controller is broken. Replace it with a new one.

(+) Terminal (-) Terminal

Black probe

Red probe

(2) Remove Battery from the machine.

Lock Switch trigger to ON position

by fixing with Band.

Switch trigger

Band

Makita XRU09Z-DC18RD Installation guide

Makita XRU09Z-DC18RD Installation guide

Makita XRU09Z-DC18RD Installation guide

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