HIKOKI CS 3630DA User manual

PRODUCT NAME
36 V Cordless Chain Saw
Model CS 3630DA C
REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly------------------------------------------------------------- 1
• Disassembly ----------------------------------------------------------------------------------------------------- 1
• Reassembly------------------------------------------------------------------------------------------------------ 3
• Lubrication points and type of lubricant ------------------------------------------------------------------- 8
• Tightening torque ----------------------------------------------------------------------------------------------- 8
• Checking after reassembly ----------------------------------------------------------------------------------- 8
• Circuit diagram -------------------------------------------------------------------------------------------------- 9
2. Precautions on disassembly and reassembly of the charger ----------------------------------------- 9
STANDARD REPAIR TIME (UNIT) SCHEDULES---------------------------------------------------------------------10
CONTENTS Page
Overseas Sales Management Dept.
Power Tools Service Manual
CONFIDENTIAL
Sep. 2018

-1-
WARNING: Be sure to remove the battery from the main body before starting repair or
maintenance work. If the switch is activated inadvertently with the battery still
mounted on the main body, the motor may turn unexpectedly and could cause serious
injury.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts list and exploded
assembly diagram for the Model CS 3630DA.
NOTE: Remove all residual chain oil from the oil tank before disassembling the chain saw. If the
tank cap is tightened too hard and it is difficult to loosen, insert a flat-blade screwdriver
into the groove and rotate it to facilitate removal. There are also cases in which the chain oil
may soil the work area. Put a waste cloth under the chain saw before disassembling.
1. Removing the carbon brush
(1) Remove the two Brush Caps [85] with a flat-blade screwdriver and remove the Carbon Brush (1 pair)
[84].
(2) Do not apply excessive pressure to the Brush Holders [83] and [89] when removing the Carbon Brush
(1 pair) [84]. Otherwise, the Brush Holders [83] and [89] may be damaged.
2. Removing the saw chain and chain bar
(1) Loosen the Hex. Socket Hd. Bolt M5 x 20 [17] with the Hex. Bar Wrench 4 mm [504]. Then loosen the
Knob [13] and remove the Chain Side Cover [18]. If necessary, rotate the Tension Dial [14]
counterclockwise slightly to reduce tension on the saw chain to facilitate this.
(2) Remove the Saw Chain [27] and the Chain Bar [28] together.
3. Removing the clutch housing
(1) Hold the sprocket of the Clutch Housing [12] in place with pliers. Loosen and remove the Lock Nut
(Left Hand) M8 [9] by rotating it clockwise. Remove the Super Lock Washer M8 [10] and the Side
Plate [11]. Then remove the Clutch Housing [12].
4. Disassembling the housing. handle cover set
(1) Push the Brake Handle [91] forward to OFF position. Then the inner diameter of the Brake Band [5] is
smaller than before and it is easy to disassemble or reassemble.
(2) Remove the eight Tapping Screws D4 x 20 [30], Tapping Screw D3 x 16 [35], and Nozzle [53]. Then
the Housing. Handle Cover Set [37] can be removed with all internal parts in it.
(3) Do not lose the Trigger [72], Spring [63], and Lock Button [64] when disassembling the Housing.
Handle Cover Set [37].
Disassembly
REPAIR GUIDE

-2-
5. Removing the inner cover
(1) Peel off the tape securing the Urethane Tube 95L [76] to the Oil Tank [77] and remove the Urethane
Tube 95L [76] from the Oil Tank [77].
(2) Remove the Tapping Screw D4 x 20 [30] securing the Oil Pump [54] in place. Then remove the Oil
Pump [54].
(3) Remove the four Tapping Screws D4 x 20 [30] securing the Inner Cover [55] in place to remove the
Inner Cover [55].
NOTE: The Inner Cover [55] can be removed with the Armature and Pinion Set [56] attached.
6. Removing the magnet
(1) Remove the two Hex Hd. Tapping Screws D4 x 45 [70] securing the Magnet [51] in place. Tap the end
surface of the housing with a wooden hammer to remove it.
7. Removing the front handle
(1) Remove the four Tapping Screws D4 x 20 [65] securing the Front Handle [90] in place to remove the
Front Handle [90] from the Housing. Handle Cover Set [37].
8. Removing the oil tank
(1) Remove the Tank Cap [88] from the Oil Tank [77] and then remove the Oil Tank [77].
9. Removing the brake handle
(1) Remove the Tapping Screw D5 x 45 [92] securing the Brake Handle [91] in place to remove the Brake
Handle [91] and the Brake Lever [62].
10. Disassembling the power supply unit
(1) Cut the Connector [60] connection with nippers to remove the Brush Holders [83] and [89].
(2) Remove the solder from the internal wire connection with a soldering iron to disconnect the internal
wire from the Controller Terminal Set [68].
(3) Loosen and remove the screws to disconnect the internal wires from the two Switches [57].
11. Removing the brake link cover
(1) Remove the three Tapping Screws D4 x 20 [41], then remove the Brake Link Cover [1] from the
Housing. Handle Cover Set [37] together with the Brake Link [7], Brake Spring [8], and Brake Band
[5].
(2) Remove the Brake Spring [8] from the brake spring post and separate the unit into parts such as the
Brake Band [5] and Brake Link [7].
NOTE: At this time, do not lose the Needle Roller D3 [6].
12. Removing the chain side cover
(1) Insert a flat-blade screwdriver between the Tension Dial [14] (green) and the Chain Side Cover [18]
and rotate it slightly to remove the Tension Dial [14] and the Knob [13] together.

-3-
Fig. 1 • Mounting the brush holders
Fig. 2 • Sticking sponges (A)
Conduct reassembly by reversing the disassembly procedure, but note the following.
1. Mounting the brush holders
(1) Pass the internal wires of the Brush Holders [83] and [89] through the holes on the rear edge of the
housing as shown in Fig. 1 paying attention to the polarity of the internal wires.
(2) Stick two Sponges (A) [82] to the specified locations as shown in Fig. 2.
Reassembly
Pass through the holes.
To the Brush Holder [89] (Black)
To the Brush Holder [83] (Red)
Sponge (A) [82]

-4-
Fig. 3 • Mounting the magnet
Fig. 4
Fig. 5
2. Mounting the magnet
(1) Pass the internal wires of the Brush Holders [83] and [89] between the Magnet [51] and the Housing.
Handle Cover Set [37]. Ensure that they are not pinched (Fig. 3).
(2) Attach the Magnet [51] so that its concave portion correctly meshes with the protrusion on the Housing.
Handle Cover Set [37] (Fig. 4).
(3) When tightening the Hex Hd. Tapping Screw D4 x 45 [70], mount Washer (B) [71] so that the ribs of
the Housing. Handle Cover Set [37] are not deformed.
(4) Be sure to mount the thermistor at the tip of the internal wire when tightening the Hex. Hd. Tapping
Screw D4 x 45 [70] (Fig. 5).
Protrusion on the
Housing. Handle Cover Set [37]
Concave portion o
f
the Magnet [51]
Ribs
To the Brush Holder [89] (Black)
To the Brush Holder [83] (Red)
Thermistor
[71]
Thermistor
[71]
[70]
[51]
[70]

-5-
Fig. 6 • Mounting the oil pump
Fig. 7 • Mounting the nozzle
[69]
[77]
[55]
[54]
[52]
[76]
3. Mounting the front handle
(1) Secure the Front Handle [90] to the Housing. Handle Cover Set [37] with four Tapping Screws D4 x 20
[65].
4. Mounting the oil pump
(1) Check that the needle pin D2.5 (included in the Inner Cover [55]) is mounted correctly.
(2) Check that the pump gear of the Oil Pump [54] can be rotated lightly at reassembly.
(3) Secure the Urethane Tube 95L [76] to the Oil Tank [77] with adhesive cellophane tape. (Before
adhering cellophane tape, wipe oil off the surface of the Oil Tank [77].)
(4) Insert the hole side of the Nozzle [53] into the Housing. Handle Cover Set [37] aligning the Nozzle [53]
parallel to the ridge line (stepped portion) of the Housing. Handle Cover Set [37].
* Pay attention to the orientation of
the Nozzle [53].
• Insert the hole side of the Nozzle
[53] into the Housing. Handle
Cover Set [37].
• Align the Nozzle [53] parallel to
the ridge line of the Housing.
Handle Cover Set [37].
[69]
Secure in place with
adhesive cellophane tape.
[53]
[52]
[37]
Ridge line
(stepped portion)

-6-
Fig. 8 • Connecting diagram
Battery terminal
[57]
(White)
(Red)
Noise suppressor
[57]
LED light
[68]
[75]
(Brown)
(Red)
(Black)
Tact switch
Thermistor
Ferrite core
(Black)
(Black)
Fig. 9 • Wiring diagram
Internal wire (brown)
Internal wire
(brown)
[57]
Noise
suppressor
Internal wire
(
red
)
Internal wire (white)
[68]
[60]
[60]
[57]
[67]
[62]
5. Wire connection of the power supply unit
(1) Be sure to perform wire connection in accordance with the connecting diagram. Pay attention to colors
of the internal wires and the terminals to be soldered.
(2) When connecting the internal wires to the two Switches [57],insert the cores of the internal wires into
the terminal holes as far as they will go and then secure them with screws. Check that the internal
wires cannot be pulled out by force of 200 g after connection.
(3) Be careful of the polarity of the Diode [75] when mounting.
[60]
[60]
[60]
NOTE: Be careful not to pinch the internal wires.

-7-
Fig. 10 • Mounting the spindle and gear
Fig. 11 • Mounting the parts inside the brake link cover
6. Mounting the spindle and gear
(1) Mount the Gear [47] to the Spindle [44] in accordance with the dimensions shown in Fig. 10.
(2) Mount the above assembly of the Gear [47] and the Spindle [44] to the Inner Cover [55] being careful
not to damage the tooth flank of the pump gear in the Oil Pump [54].
(3) Insert the Oil Pipe [69] and the Urethane Tube 130L [52] into the pump at two locations.
(4) Apply grease (Shell Alvania RL3) to the tooth flank of the Gear [47].
7. Mounting the parts inside the brake link cover
(1) Mount the parts inside the Brake Link Cover [1] as shown in Fig. 11.
8. Mounting the housing. handle cover set
(1) Mount the Lock Button [64], Spring [63], Battery Rubber (B) [38] and Hook [39] to their correct
locations. Insert the Nozzle [53] coming from the Oil Pump [54] into the spout of the Housing. Handle
Cover Set [37] and mount the handle cover of the Housing. Handle Cover Set [37]. Check that the
internal wires do not sag or are not pinched.
(2) Check that the Brake Lever [62] of the Brake Handle [91] is not detached from the Switch Lever [67].
(3) Check that the Brake Lever [62] meshes with the Brake Link Holder [4].
(4) Apply grease (Shell Alvania RL3) to the Link Sleeve [40] and mount it to the Brake Link Holder [4].
[47]
[45]
[49] [44]
[48]
3.5±0.1
(2.8±0.1)
18±0.1 (3)
Brake spring post
[8]
[5]
[1]
[6]
[4]
[7]
[2]

-8-
Shell Alvania Grease RL3
• Pinion of the Armature and Pinion Set [56]: 2 g
• Tooth flank of the Gear [47]: 5 g
• Sliding portions of the Brake Link [7], Brake Link Holder [4] and Brake Support Plate [2]: 0.5 g
• Outer circumference of the Brake Link Holder [4] and the sliding portion at the inner circumference of the
Brake Link Holder [4] insertion hole on the Housing. Handle Cover Set [37]: 0.5 g
Item No. Part name Tightening torque
N•m kgf•cm
[9] Lock Nut (Left Hand) M8 8.0±1.0 80±10
[15] Machine Screw (W/Washer) M4 x 8 (Black) 2.0±0.5 20±5
[17] Hex. Socket Hd. Bolt (W/Flange) M5 x 20 3.4±0.7 35±7
[20] Tapping Screw D3 x 6 0.5 to 0.7 5 to 7
[21] Tapping Screw D3 x 12 0.5 to 0.7 5 to 7
[30] Tapping Screws (W/Flange) D4 x 20 2.1 to 3.0 20 to 30
[35] Tapping Screw (W/Flange) D3 x 16 (Black) 1.3±0.3 13±3
[41] Tapping Screws (W/Flange) D4 x 20 (Black) 2.1 to 3.0 20 to 30
[42] Machine Screws (W/Washers) M4 x 10 (Black) 1.8±0.4 18±4
[43] Machine Screw (W/Washers) M5 x 10 (Black) 3.4±0.7 35±7
[65] Tapping Screws (W/Flange) D4 x 20 (Black) 2.1 to 3.0 20 to 30
[70] Hex. Hd. Tapping Screws D4 x 45 2.9±0.5 30±5
[85] Brush Caps 1.2±0.2 12±2
[92] Tapping Screw (W/Flange) D5 x 45 2.9±0.5 30±5
• Check that the chain oil discharges properly (operating time: 1 to 3 minutes).
• Check that the LED lights and the remaining battery indicator lamp light properly.
• Check that the Brake Handle [91] can be operated properly and the brake can be applied.
Checking after reassembly
Lubrication points and type of lubricant
Tightening torque

-9-
Fig. 12 • Circuit diagram
2. Precautions on disassembly and reassembly of the charger
Refer to the Service Manual for precautions on disassembly and reassembly of the charger Model
UC 36YRSL.
Circuit diagram
Switch
Switch
Controller terminal set LED holder ass’y
Battery terminal
Ferrite core
Ferrite core

-10-
Model
Repair
time 10 20 30 40 50 60 min.
CS 3630DA
General assembly
Inner Cover
Clutch
Housing
Spindle
Ball Bearing
6001VV
Gear
Worm
Ball Bearing
606VV
Oil Pump
Armature and
Pinion Set
Switch x 2
Oil Tank
Tank Cap
Brake Handle
Brake Lever
Housing.
Handle
Cover Set
Magnet
Work Flow
Brake Link
Cover
Brake Support
Plate
Brake Lever
Spring
Brake Link
Holder
Brake Band
Brake Link
Brake Spring
Chain Bar
Saw Chain
Knob
Tension Dial
Tension Gear
Chain Side
Cover
Chain Puller
Guide Plate
STANDARD REPAIR TIME (UNIT) SCHEDULES

Model CS 3630DA
CORDLESS CHAIN SAW
LIST NO. K866
(E1)
2017·12·13
A
A
30
82
17
504
60
35
505
33
79
30
30
32
69
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
20
21
23
25
26
27
28
31
37
38
36
29
30
30
41
44
45
46
47
48
49
53
54
55
56
50
51
57
57
72
65
60
58
61
62
63
64
65
66 67
70
71
76
77
90 91 92
88
85 84 89
86
30
39
65
501
52
68
502
503
84 85
83
19
78
22
24
40
87
75
59
74
73
80
81
34
42
43
93
82

PARTS CS 3630DA
DESCRIPTION REMARKS
1 335134 BRAKE LINK COVER 1
2 6696782 BRAKE SUPPORT PLATE 1
3 6696783 BRAKE LEVER SPRING 1
4 335135 BRAKE LINK HOLDER 1
5 6699013 BRAKE BAND 1
6 6685391 NEEDLE ROLLER D3 1
7 6685388 BRAKE LINK 1
8 6685389 BRAKE SPRING 1
9 335192 LOCK NUT (LEFT HAND) M8 1
10 957042 SUPER LOCK WASHER M8 1
11 335139 SIDE PLATE 1
12 6685403 CLUTCH HOUSING 1
13 335151 KNOB 1
14 335150 TENSION DIAL 1
15 315500 MACHINE SCREW (W/WASHER) M4 X 8 (BLACK) 1
16 335152 TENSION GEAR 1
17 336349 HEX. SOCKET HD. BOLT (W/FLANGE) M5 X 20 1
18 336347 CHAIN SIDE COVER 1
19 335156 BEVEL GEAR (A) 1
20 696352 TAPPING SCREW D3 X 6 1
21 370905 TAPPING SCREW D3 X 12 1
22 335688 DUST SHEET 1
23 939543 RETAINING RING FOR D14 SHAFT (10 PCS.) 1
24 996407 O-RING (1AP-12) 1
25 335153 CHAIN PULLER 1
26 335154 GUIDE PLATE 1
27 6697852 SAW CHAIN (3/8 X 12') 91PX-45XJ 1
28 6696990 CHAIN BAR 12 INCH 3/8 SPROCKET PRC 1
29 335142 SPIKE 1
30 339250 TAPPING SCREW (W/FLANGE) D4 X 20 18
31 BRAND LABEL 1
32 335155 CHAIN CATCHER 1
33 336350 SPECIAL NUT M5 1
34 MV LABEL (B) 1
35 313687 TAPPING SCREW (W/FLANGE) D3 X 16 (BLACK) 1
36 371750 BATTERY BSL 36A18 (EUROPE,AUS,NZL) 1 INCLUD.505
37 373112 HOUSING.HANDLE COVER SET 1
38 370328 BUTTERY RUBBER (B) 1
39 6698696 HOOK 1
40 335690 LINK SLEEVE 1
41 301653 TAPPING SCREW (W/FLANGE) D4 X 20 (BLACK) 3
42 304043 MACHINE SCREW (W/WASHERS) M4 X 10 (BLACK) 2
43 336342 MACHINE SCREW (W/WASHERS) M5 X 10 (BLACK) 1
44 335137 SPINDLE 1
45 6001VV BALL BEARING 6001VV 1
46 939542 RETAINING RING FOR D12 SHAFT (10 PCS.) 1
47 335138 GEAR 1
48 6696886 WORM 1
49 606ZZM BALL BEARING 606VV 1
50 335140 FAN GUIDE 1
- 2 - 12 - 17
*ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.CODE NO.

PARTS CS 3630DA
DESCRIPTION REMARKS
51 323156 MAGNET 1
52 335148 URETHANE TUBE 130L 1
53 335147 NOZZLE 1
54 6696887 OIL PUMP 1
55 335136 INNER COVER 1
56 360948 ARMATURE AND PINION SET 1
57 335124 SWITCH 2
58 335687 INTERNAL WIRE (RED) L240 1
59 335694 INTERNAL WIRE (RED) L490 1
60 959141 CONNECTOR 50092 (10 PCS.) 3
61 372228 BATTERY TERMINAL 1
62 335132 BRAKE LEVER 1
63 314429 SPRING 1
64 331682 LOCK BUTTON 1
65 301653 TAPPING SCREW (W/FLANGE) D4 X 20 (BLACK) 5
66 319956 WASHER (B) 1
67 335133 SWITCH LEVER 1
68 373111 CONTROLLER TERMINAL SET 1 INCLUD.60,61
69 335146 OIL PIPE 1
70 981824 HEX. HD. TAPPING SCREW D4 X 45 2
71 319956 WASHER (B) 2
72 335125 TRIGGER 1
73 335695 INTERNAL WIRE (BROWN) L165 1
74 335696 INTERNAL WIRE (BLACK) L120 1
75 335689 DIODE 1
76 335145 URETHANE TUBE 95L 1
77 335143 OIL TANK 1
78 MV LABEL (A) 1
79 NAME PLATE 1
80 335692 CAUTION LABEL (EX) 1
81 PANEL SHEET 1
82 335867 SPONGE (A) 2
*
83 335698 BRUSH HOLDER 1
*
83 335126 BRUSH HOLDER 1 FOR NZL
84 999068 CARBON BRUSH (1 PAIR) 2
85 319847 BRUSH CAP 2
86 335141 TAIL COVER 1
87 335691 TANK CAP PACKING 1
88 335144 TANK CAP 1
*
89 335699 BRUSH HOLDER 1
*
89 335127 BRUSH HOLDER 1 FOR NZL
90 335130 FRONT HANDLE 1
91 335131 BRAKE HANDLE 1
92 316321 TAPPING SCREW (W/FLANGE) D5 X 45 1
*
93 334379 FERRITE CORE 2 EXCEPT FOR NZL
12 - 17 - 3 -
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.

CS 3630DA
DESCRIPTION REMARKS
501 6699116 CHAIN COVER 1
502 OIL FEEDER (50CC) 2 SUPPLIED WITH ITEM NO.601
503 CHARGER (MODEL UC 18YSL3) 1
504 944458 HEX. BAR WRENCH 4MM 1
505 329897 BATTERY COVER 1
DESCRIPTION REMARKS
601 371710 LUBRICANT OILER (120CC) 1
- 4 - Printed in Japan 12 - 17
(171213N)
*ALTERNATIVE PARTS
STANDARD ACCESSORIES
OPTIONAL ACCESSORIES
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.