TECHNICAL INFORMATION

Transcription

1 TECHNICAL INFORMATION Model No. Description BPJ180 Cordless Plate Joiner W OFFICIAL USE for ASC & Sales Shop PRODUCT P 1/11 CONCEPT AND MAIN APPLICATIONS Model BPJ180 has been developed based on PJ7000 as a Cordless plate joiner powered by 18V-3.0A Li-ion battery BL1830, featuring the same easy-to-grip slim motor housing as used for model BGA452 Cordless angle grinder. This product is not compatible with 18V-1.3Ah Li-ion battery BL1815. This product is available in the following variations. Model Charger Battery BL1830 Battery Plastic cover carrying case Offered to BPJ180Z No No No No All countries BPJ180RF 1 DC18RC Yes except listed below BPJ180RFE No No No No North and Central --- DC18RA 2 1 Yes American countries All models also include the accessories listed below in "Standard equipment". Specification Specification Model BPJ180 Battery Cell Voltage: V Capacity: Ah Li-ion Energy capacity: W 54 Charging time (approx.): min. 22 with DC18RC/ RA Max out put: W 350 Diameter: mm (") 100 (4) Cutter blade Thickness: mm (") 4 (5/32) Hole diameter: (") 22 (7/8) Number of teeth 6 No load speed: min-1=rpm 6,500 Electronic current limiter for overload protection Yes Weight according to EPTA-Procedure 01/2003*2: kg (lbs) 3.0 (6.7) *2 with battery H Dimensions: mm (") Length (L) Width (W) Height (H) L 351 (13-3/4) 139 (5-1/2) 149 (5-7/8) Cutting capacity Stopper position Biscuit size: # Cutting depth: mm (") (0.3) (0.4) S --- D (0.48) 13.0 (0.51) 14.7 (0.58) MAX (0.8) Standard equipment Cutter blade Angle guide... 1 Lock nut wrench... 1 Set plate... 1 Dust bag... 1 Note: The standard equipment shown above may vary by country. Optional accessories Biscuits (size: #0, #10, #20) Cutter blade Battery BL1830 Fast charger DC18RA (for USA, Canada, Guam, Panama, Mexico, Colombia) Fast charger DC18RC (for all countries except listed above) Charger DC18SD Charger DC24SC Automotive charger DC18SE

2 [2] LUBRICATION Apply Makita grease N. No.1 to the following portions indicated by the black triangle to protect parts and product from unusual abrasion. P 2/11 CAUTION: the machine in accordance with Instruction manual or Safety instructions. [1] NECESSARY REPAIRING TOOLS Code No. Description Use for 1R004 Retaining Ring Pliers ST-2 Removing/mounting Ring spring 11 1R005 Retaining Ring Pliers RT-2N Removing/mounting Retaining ring R-32 1R022 Bearing Plate for Arbor Press Removing Spiral bevel gear 11 1R031 Bearing Setting Pipe Removing Spiral bevel gear 36 1R218 Adjust Sleeve Removing Spiral bevel gear 11 1R268 Spring Pin Extractor 3 Disassembling Shaft lock mechanism 1R269 Bearing Extractor Removing Ball bearings 629LLB and 696ZZ 1R279 Round Bar for Arbor ø5-50 Removing Spiral bevel gear 11 1R283 Round Bar for Arbor ø9-50 Removing Ball bearings 629LLB 1R355 Pinion Gear Positioning Jig Mounting Spiral bevel gear mm thick flat washer [Flat washer 6 (No ), etc.] Mounting Armature on Item No. Description Portion to lubricate Grease Amount 39 Gear housing complete Gear room approx. 7 g Steel ball 3.5 all surface for smooth click stop of Fence and Stopper Makita Grease N a little 63 O ring 22.4 outer surface No.1 a little 10 O ring 26 outer surface a little 53 Rod 10 (2 pcs) outer surface for smooth sliding Lubricating Oil VG100 (or the equivalent) a little Fig Gear housing complete, viewed from [A] Fence complete Stopper 63

3 P 3/11 [3] -1. Motor Section (1) Disassemble Motor section from the machine. (Fig. 2) Fig Remove Holder cap cover by levering it up with a slotted screwdriver, then remove Brush holder cap and Carbon brush. 2. Flip open Blade cover, and then by unscrewing M4x20 Pan head screws (4pcs), Base section can be separated from the machine. M4x20 Pan head screw (4 pcs.) Base section Carbon brush Brush holder cap Holder cap cover Blade cover 4. Separate Gear section from Motor section by unscrewing M4x22 Tapping screw (4 pcs). 5. Separate Housing (R) from Housing (L) by unscrewing M4x22 Tapping screw (4 pcs). M4x18 Tapping screw (5 pcs.) Housing (R) Motor section Gear section M4x22 Tapping screw (4 pcs.) Housing (L) 6. Disassemble Motor section by removing from the inlaid portion of Housing (L). Yoke unit Armature inlaid portion 7. Pull out Armature together with from Yoke unit. Armature Baffle plate Housing (L) Yoke unit

4 P 4/11 [3] -1. Motor Section (2) Remove Armature from. (Fig. 3) Fig Insert a pair of 1R022 between Spiral bevel gear 11 and as shown below to hold the Motor section, then put them on 1R218 placed on an arbor press. 2. Put 1R279 on the Armature shaft press-fitted in Spiral bevel gear 11, then press down 1R279 to separate Armature from. 1R022 1R022 Spiral bevel gear 11 1R279 1R218 Spiral bevel gear 11 Armature (3) Remove Spiral bevel gear 11. (Fig. 4) Fig Remove Retaining ring with 1R291 from the shaft of Spiral bevel gear 11. Retaining ring 1R Remove Spiral bevel gear 11 by pressing it with arbor press. Gear housing cover 1R283 1R Remove Ball bearing 629LLB from Spiral bevel gear with 1R269. 1R269 Ball bearing 629LLB shaft of Spiral bevel gear 11 Ball bearing 629LLB Spiral bevel gear 11 Spiral bevel gear 11 ASSEMBLING (1) Install Spiral bevel gear 11 on in the reverse order of disassembly. (Fig. 4) (2) Place a 1mm thick flat washer on the shaft portion of 1R355, then insert 1R355 into the hole of Spiral bevel gear 19, and then press down Armature with arbor press until the armature shaft contacts 1R355. (Fig. 5) Fig. 5 *1 Important: In order to prevent incomplete insertion, use a 1mm thick flat washer as a jig, for example, Flat washer 6 (No ). *2 Armature Gear housing cover Spiral bevel gear 11 1mm thick flat washer*1 1R355 *2 Important: Armature is apt to tilt when pressing down with arbor press. If you press down tilted Armature, armature shaft can be deformed in the worst case. In order to press straight down, press Armature carefully every quarter turn until the armature shaft contacts 1R355.

5 P 5/11 [3] -1. Motor Section ASSEMBLING (3) Gear section to Motor section. (Fig. 6) Fig Be sure to put Rubber ring 13 in Bearing box of Endbell complete before assembling Housing (L) and Housing (R) together. 2. Place the notch of on the opposite side of Switch lever, then press down the top end of Spiral bevel gear 11 to fit the ball bearing on the commutator end of Armature securely in the bearing box of End bell complete. 3. Place Pin cap of Shaft lock mechanism on the same side as Switch lever, assemble Gear section to Motor section. Rubber ring 13 Endbell Pin cap Spiral bevel gear 11 notch Switch lever Switch lever side Gear section Motor section Housing (4) Assemble Base section and Gear section together. (Fig. 2) Fix Grip to Gear housing at 90 degrees to the Base. (Fig. 7) Fig. 7 Grip Gear housing 90 degrees Base [3] -2. Base Section (1) Separate Base section from the machine. (Fig. 2) (2) Remove Rod 10. (Fig. 8) Fig. 8 Remove M5x6 Hex socket set screw (2pcs), then pull out Rod 10. Bearing box section can now be removed in the direction indicated by the arrow. M5x6 Hex socket set screw Rod 10 Bearing box section

6 P 6/11 [3] -2. Base Section (3) Remove Bearing box. (Fig. 9) Fig Push Bearing box toward Fence complete to avoid the friction between Bearing box and Base caused by Tension spring 8, then lift up Bearing box. Fence complete Bearing box Tension spring 8 Base 2. Pull Bearing box towards rear side while keeping it parallel to Base. 3. Disengage Bearing box from Tension spring 8. Bearing box Tension spring 8 Base (4) Separate Fence complete from Base. (Fig. 10) Fig Remove Stop ring E-8, then remove M6x20 Flat head square neck bolt, M6 Hex nut and Flat washer 6 by using Lever 40 as a wrench. Flat head sq. neck bolt M6x20 Fence complete 2. Slowly tilt Fence complete while covering the circled portion with your finger until Steel ball 3.5 comes out to your finger. Then remove Steel ball 3.5 along with Compression spring 2.4. Fence complete Flat washer 6 Compression spring 2.4 Steel ball 3.5 Base Hex nut M6 Base Lever 40 Stop ring E-8 3. By removing Stop ring E-3 and Pin 4 (2pcs), Fence complete can be separated from Base. Stop ring E-3 (2 pcs.) Pin 4 Pin 4

7 P 7/11 [3] -2. Base Section ASSEMBLING (1) Assemble Base section in the reverse order of disassembly. (Figs. 9, 8, 7, 6) (2) Assemble Rod 10 to Base. (Fig. 11) Fig Place the grooved end of each Rod 10 on M5x10 Thumb screw side, then insert each Rod 10 into Rod holder of Base. 2. Insert each Rod 10 until its end surface is flush with that of rod holding portion of Base. Then fix Rod 10 with M5x6 H.S. set screw. M5x6 H.S. set screw Rod 10 (2 pcs) groove end surface of rod holding portion of Base M5x10 Thumb screw O ring 4 Leaf spring M5x10 Thumb screw Note: Do not forget to insert O ring 4 when assembling M5x10 Thumb screw and Leaf spring to Base. ADJUSTMENT Fix each Lever 40 (2 pcs) in the position indicated in Fig. 12; one of the levers is used for locking Fence complete and the other for Angle guide assembly. Fig. 12 Before fixing each Lever 40 with Stop ring E-8, adjust the position of the lever so that it is positioned within the angle range shown below when Fence complete/ Angle guide assembly is locked. 45 degrees Fence complete Angle guide assembly 30 degrees

8 P 8/11 [3] -3. Spiral Bevel Gear 36, Ball Bearing 6201DDW (1) Separate Base section from the machine. (Fig. 2) (2) Remove Rod 10 and Bearing box from Base. (Figs. 8, 9) (3) Disassemble Bearing box. (Figs. 13, 14) Fig Remove Ball bearing 696ZZ with 1R Ring spring 11 can be removed by expanding the ends of the spring with 1R004, then by levering up the opposite side of the spring with slotted screwdriver as shown below. Ball bearing 696ZZ Ring spring 11 Bearing box Ring spring 11 Fig After Ring spring 11 is removed, put Bearing box section onto 1R031, then remove Spindle by pressing with an arbor press. Note: Do not re-use the removed Ball bearing 6201DDW because it is damaged when Spindle is removed from Spiral bevel gear Remove Retaining ring R-32 with 1R005. Retaining ring R-32 arbor press Spindle Spiral bevel gear 37 Spiral bevel gear Ball bearing can be removed from Bearing box by tapping the Bearing box against the work bench. Spindle 1R031 Ball bearing 6201DDW ASSEMBLING Assemble in the reverse order of disassembly (Figs. 14, 13).

9 P 9/11 [3] -4. Shaft Lock Mechanism (1) Open Blade cover and unscrew four M4x20 Pan head screws. (Fig. 2) And then, separate Base section from Gear housing. (Fig. 2) (2) Place Gear housing section on 1R350, then disassemble Shaft lock mechanism. (Figs. 15, 16) Fig. 15 Fig. 16 Shoulder pin 4 can be removed from Gear housing by applying 1R268 to Shoulder pin 4 through the small hole on Pin cap, then by knocking 1R268 with Hammer. 1R268 Pin cap Carefully remove 1R268 and Pin cap so as not to lose Compression spring 8. Pin cap Compression spring 8 1R350 Shoulder pin 4 O ring 4 Note: Shoulder pin 4 deforms Pin cap when it is removed. So do not reuse Pin cap because it cannot be properly fixed again to Shoulder pin 4. Clean plastic dust on Shoulder pin 4 before re-assembling. ASSEMBLING Remove plastic dust from Shoulder pin 4 before re-assembling. Assemble Shoulder pin 4, Compression spring 8 and Pin cap (new one) to Gear housing by pressing the new Pin cap (Figs. 16, 15).

10 P 10/11 Circuit diagram Fig. D-1 Color index of lead wires' sheath Black Red Switch Controller Endbell complete LED circuit Terminal Connector Wiring diagram [1] Endbell Complete Assembly Fig. D-2 Set Endbell complete with its Lead wire holder portion facing Switch lever side. [Correct Setting] [Wrong Setting] Switch lever Lead wire holder of Endbell complete Switch lever Lead wire holder of Endbell complete

11 P 11/11 Wiring diagram [2] Connecting Controller's Lead Wires to Switch and Terminal Fig. D-3 [2]-1. Connecting Controller's Lead Wires to Switch Connect Connecting terminals to Switch as shown below. Fig. D-4 [2]-2. Connecting Controller's lead wires to Terminal Connect Flag connectors to Terminal as shown below. Endbell Housing R side Connecting portion of Lead wire Switch Connecting portion of Lead wire Pole marks Flag connectors Housing L side Connecting terminals Lead wire (red) of Controller Lead wire (black) of Controller Terminal [3] Wiring in Housing Fig. D-5 Assemble Yoke unit to Housing (L) with its notch engaged with the rib of Housing (L). notch of Yoke unit Controller's lead wires (black, red) to Terminal must be routed under Controller. Controller s Lead wires (black and red) to Terminal rib of Housing (L) Terminal Switch lever Housing (L) Endbell complete Yoke unit Switch LED Circuit Line filter Lead wire holder Lead wire of LED circuit to Connector Controller Flag connector Put Line filter in this position if it is used. Lead wires (black, red) of LED circuit to Connector must be fixed in this Lead wire holder.