Hitachi CR 24DV User manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
CORDLESS SABER SAW
CR 24DV
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. F850 May 2001
C
MODEL
CR 24DV

REMARK:
Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s)
is(are) used in the place of company name(s) and model name(s) of our
competitor(s). The symbol(s) utilized here is(are) as follows:
Symbols Utilized Competitors
Company Name Model Name
P DEWALT DW008
1645 (USA)
GSA24VE(EUROPE)
B BOSCH

1. PRODUCT NAME........................................................................................................................... 1
2. MARKETING OBJECTIVE ............................................................................................................. 1
3. APPLICATIONS.............................................................................................................................. 1
4. SELLING POINTS .......................................................................................................................... 1
4-1. Selling Point Descriptions ............................................................................................................... 2
5. SPECIFICATIONS .......................................................................................................................... 4
5-1. Specifications.................................................................................................................................. 4
5-2. Optional Accessories ...................................................................................................................... 5
6. COMPARISONS WITH SIMILAR PRODUCTS .............................................................................. 7
6-1. Specification Comparisons ............................................................................................................. 7
6-2. Working Performance per Single Charge (reference only)............................................................. 7
7. PRECAUTIONS IN SALES PROMOTION ..................................................................................... 9
7-1. Safety Instructions .......................................................................................................................... 9
7-2. Inherent Drawbacks of Cordless Saber Saw Requiring Particular Attention
during Sales Promotion..................................................................................................................11
7-3. Front Cover................................................................................................................................... 12
8. REPAIRE GUIDE .......................................................................................................................... 12
8-1. Precautions in Disassembly and Reassembly.............................................................................. 12
9. STANDARD REPAIR TIME (UNIT) SCHEDULES ....................................................................... 19
Assembly Diagram for CR 24DV
CONTENTS
Page

--- 1 ---
1. PRODUCT NAME
Hitachi 24 V Cordless Saber Saw, Model CR 24DV
2. MARKETING OBJECTIVE
The Model CR 24DV is the Hitachi's first cordless saber saw developed as one of our 24 V product lineup.
The Model CR 24DV realizes the class-top cutting performance thanks to the technical innovations such as the
DC motor whose carbon brush is replaceable from the outside and the slide-type battery. In addition, the Model
CR 24DV features the Hitachi-original mechanism that enables one-hand mounting and dismounting of saw
blades (same as the Model CR 13VA) and the soft grip handle for ease of operation.
3. APPLICATIONS
Cutting metal, wood, plastics, etc.
4. SELLING POINTS
Saw blade can be mounted
and removed without the
use of tools
Saw blade can be mounted
in either direction, upward
or downward
Widely rubber-covered case
for comfortable handling Lock-off button
Effective cooling to enable
continuous cutting
Soft-touch rubber
grip handle
Convenient switch with large
trigger shape for easy operation
Replaceable carbon brush
to elongate motor life

--- 2 ---
4-1. Selling Point Descriptions
(1) Saw blade can be mounted and removed without the use of tools
The Model CR 24DV eliminates such inconvenience by adopting the Hitachi-original detachable mechanism
that enables one-hand mounting and removal of saw blades without the use of a wrench or other tools.
< Features of the Hitachi-original detachable mechanism >
The saw blade can be mounted and removed just by turning the holder sleeve.
The sleeve holder can be automatically secured in a released state by turning it all the way. In the
released state, the built-in spring force pulls the holder pin back to the correct position automatically.
Thus, saw blades can be smoothly replaced with one hand.
1
2
(2) Saw blade can be mounted in either direction, upward or downward
The Model CR 24DV is convenient for cutting materials on the floor or near window frames, and also for
plunge cutting on plywood panels because the saw blade can be installed upside down.
< Plunge cutting on plywood panels >
Refer to the Handling Instructions for detailed information about saw blade
replacement.
Competitor's products require two-hand operation.
Fig. 1

--- 3 ---
(3) Replaceable carbon brush to elongate motor life
The carbon brush can be replaced from the outside of the motor to elongate the motor life and to enhance the
maintainability. The carbon brush can be easily removed from the motor with a flat-blade screwdriver as
shown in Fig. 2, and can also be easily and securely mounted to the motor by hooking the claw of the carbon
brush on the connecting portion on the outside of the brush tube.
Fig. 2
Fig. 3
(4) Lock-off button
The lock-off button is adopted to avoid the switch from unintentionally being turned on during storage or
carrying.
(5) Convenient switch trigger shape for easy operation
The switch trigger is large enough to operate with two fingers for ease of operation. Even if the tool is upside
down as shown in Fig. 1, the trigger switch can be easily operated.

--- 4 ---
5. SPECIFICATIONS
Max. cutting size Steel pipe outer diameter 100 mm (4")
Wood thickness 100 mm (4")
Mild steel plate (thickness) 10 mm (3/8")
Capacity
5-1. Specifications
Number of stroke 0 ---2,500/min.
Stroke 28 mm (1-1/8")
Enclosure
Type of motor DC magnet motor Max. output: 500 W
Housing...................................Glassfiber reinforced polycarbonate resin
Handle.....................................Polycarbonate resin
Grip cover................................Polycarbonate resin + Elastomer
Front cover ..............................NBR (Acrylonitrile-butadiene rubber)
Gear cover and upper cover ...Aluminum alloy die casting
Storage battery........................Glassfiber reinforced polyamide resin
Charger ...................................ABS resin
Type of switch Variable trigger switch (with brake)
Handle shape D-type handle
Weight Main body 4.3 kg (9.6 lbs.) (with battery)
Battery EB 2420 1.3 kg (2.87 lbs.)
EB 2430HA 1.4 kg (3.09 lbs.)
Charger UC 24YFB 0.6 kg (1.3 lbs.)
Battery
(Model EB 2420) Sealed cylinder nickel cadmium storage battery
Nominal voltage: DC 24V
Nominal life: Charging/discharging approximately 1,000 cycles
(in case of Model UC 24YFB)
Nominal capacity: 2.0 Ah
Battery
(Model EB 2430HA) Sealed cylinder nickel-metal hydride storage battery
Nominal voltage: DC 24V
Nominal life: Charging/discharging approximately 500 cycles
(in case of Model UC 24YFB)
Nominal capacity: 3.0 Ah
Charger
(Model UC 24YFB) Power source: Single-phase AC 50/60 Hz
Voltage: Depending on the order specification
Power input: 90 W
Charging system: Constant current charge with full wave phase control
Overcharge protection system: (1) Battery voltage detection ( 2V system)
for EB 2420 battery
Ni-MH battery temperature detection
(dT/dt system) for EB 2430HA battery
(2) Battery surface temperature detection
(thermister)
(3) 120 minutes timer
Output voltage: DC 24V
Output current: 2.5 A
Charging time: Approx. 50 minutes (for EB 2420 at 20˚C (68˚F))
Approx. 70 minutes (for EB 2430HA at 20˚C (68˚F))
Operable ambient temperature range: 0˚C ---40˚C (32˚F ---104˚F)
The maximum allowable temperature of the Model EB 2420 battery is 60˚C
(140˚F) and the Model EB 2430HA battery is 45˚C (113˚F).

--- 5 ---
5-2. Optional Accessories
The motor may lock depending on types of blades and materials used. For example, the motor may lock when
cutting a steel pipe 45 mm in outer diameter with the No. 132 BI-METAL blade. Customers must be instructed to
use appropriate blades corresponding to the materials to be cut.
(1) HCS blades
The blade numbers of HCS blades in Table 1 are engraved in the vicinity of the mounting position of each blade.
Select appropriate blades by referring to Tables 1 and 3 below.
Table 1: HCS blades
Red pilot lamp
remains lit or flashes
Green pilot lamp is lit.
Prior to charging
During charging
Charging completed
Charging not possible
High battery
temperature
Blinks
Blinks
Lit
Flickers
Lit
0.5 sec ON, 0.5 sec OFF
Stays ON constantly
0.1 sec ON, 0.1 sec OFF
0.5 sec ON, 0.5 sec OFF
Stays ON constantly
Storage battery or
charger is faulty.
Charging not possible
because storage battery
temperature is too high.
Pilot lamp indications (UC 24YFB)
Blade No. Uses Thickness (mm)
2.5 --- 6 (3/32" --- 1/4")
No. 1
No. 3
No. 96
No. 95
No. 9
No. 8
No. 5
No. 4
No. 2 2.5 --- 6 (3/32" --- 1/4")
50 --- 70 (2" ---2-3/4")
2.5 --- 6 (3/32" --- 1/4")
Below 2.5 (3/32")
Below 2.5 (3/32")
Below 3.5 (1/8")
Below 30 (1-3/16")
Below 100 (4")
2.5 --- 15
(3/32" ---5/8")
For cutting and roughing lumber
For cutting steel pipes less than 100 mm (4") in outer diameter
For cutting steel pipes less than 30 mm (1-3/16") in outer diameter
For cutting steel pipes less than 30 mm (1-3/16") in outer diameter
For cutting and roughing lumber
For cutting vinyl chloride pipes less than 100 mm (4")
in outer diameter
For cutting and roughing lumber
For cutting steel pipes less than 100 mm (4") in outer diameter
For cutting steel and stainless pipes less than 100 mm (4")
in outer diameter
For cutting steel and stainless pipes less than 30 mm (1-3/16")
in outer diameter

--- 6 ---
(2) BI-METAL blades
The blade numbers of BI-METAL blades in Table 2 are engraved in the vicinity of the mounting position of each
blade. Select appropriate blades by referring to Table 2 and 3 below.
Table 2: BI-METAL blades
(3) Selection of blades for other materials
Table 3
Blade No. Uses Thickness (mm)
2.5 --- 6 (3/32" --- 1/4")
2.5 --- 6 (3/32" --- 1/4")
For cutting steel and stainless pipes less than 60 mm (2-3/8") in outer diameter
No. 101
For cutting steel and stainless pipes less than 60 mm (2-3/8") in outer diameter
No. 103
For cutting steel and stainless pipes less than 100 mm (4") in outer diameter
No. 102
For cutting steel and stainless pipes less than 100 mm (4") in outer diameter
No. 104
For cutting steel and stainless pipes less than 100 mm (4") outer diameter
No. 108
For cutting steel and stainless pipes less than 60 mm (2-3/8") in outer diameter
No. 107
For cutting steel and stainless pipes less than 100 mm (4") in outer diameter
No. 106
For cutting steel and stainless pipes less than 60 mm (2-3/8") in outer diameter
No. 105
For cutting and roughing lumber
No. 121
All purpose
No. 131
All purpose (except for cutting steel and stainless pipes more than 30 mm
(1-3/16") in outer diameter)
No. 132
2.5 --- 6 (3/32" --- 1/4")
2.5 --- 6 (3/32" --- 1/4")
Below 3.5 (1/8")
2.5 --- 6 (3/32" --- 1/4")
Below 3.5 (1/8")
100 (4")
2.5 --- 6 (3/32" --- 1/4")
Below 3.5 (1/8")
Material to be cut Material quality
2.5 --- 10 (3/32" --- 3/8") No. 1, 2, 101, 102, 103, 104,
105, 106, 131, 132
No. 3, 6, 107, 108
Iron plate
Synthetic resin
Nonferrous metal
Mild steel plate
Aluminum
Copper
Brass
Vinyl chloride
Acrylic resin etc.
Phenol resin
Melamine resin etc.
Thickness (mm)
Below 5 (3/16") No. 3, 6, 107, 108
No. 1, 2, 101, 102, 103, 104,
105, 106, 131, 132
5 --- 10 (3/16" --- 3/8")
5 --- 20 (3/16" --- 3/4")
10 --- 30 (3/8" --- 1-3/16")
5 --- 20 (3/16" --- 3/4")
10 --- 30 (3/8" --- 1-3/16")
No. 3, 5, 8, 105, 106, 107, 108
No. 1, 2, 4, 101, 102, 103, 104,
131, 132
No. 3, 5, 8, 105, 106, 107, 108
No. 1, 2, 4, 101, 102, 103, 104,
131, 132
Blade No.

--- 7 ---
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons
6-2. Working Performance per Single Charge (reference only)
Fig. 4

--- 8 ---
The following test data should be used for reference purposes only since the cutting speed and the working
capacity may vary depending on the operating conditions such as the pressing force, type of blades, materials,
etc.
Fig. 5

--- 9 ---
7. PRECAUTIONS IN SALES PROMOTION
7-1. Safety Instructions
In the interest of promoting the safest and most efficient use of the Model CR 24DV by all our customers, it is very
important that at the time of sale the salesperson carefully ensures that the buyer seriously recognizes the
importance of the contents of the Handling Instructions, and fully understands the meaning of the precautions
listed on the Caution Plate and Name Plate attached to each tool.
A. Handling Instructions
Salespersons must be thoroughly familiar with the contents of the Handling Instructions in order to give pertinent
advice to the customer. In particular, they must have a thorough understanding of the precautions in the use of
the cordless (battery charger type) electric power tools which are different from those of ordinary electric power
tools.
(1) Before use, ensure that the unit is fully charged.
New units are not fully charged. Even if the units were fully charged at the factory, long periods without use,
such as during shipping, cause the storage battery to lose its charge. Customers must be instructed to fully
charge the unit prior to use.
(2) When charging storage batteries, use only the exclusive Model UC 24YFB Charger provided with the tool.
Because of designed rapid-charging feature (about one hour), use of other battery chargers is hazardous.
(3) Ensure the power source voltage is the same as that indicated on the Name Plate of the charger. Use of any
other power source (DC outlet, fuel powered generator, etc.) will cause the charger to overheat and burnt out.
(4) Do not use any voltage increasing equipment (transformer, etc.) between the power source and the charger.
If the charger is used with voltage over and above that indicated on the unit, it will not function properly.
(5) Conduct battery charging at an ambient temperature range of 0˚C ---4 ˚C (32˚F --- 104˚F).
Special temperature sensitive devices are employed in the charger to permit rapid charging.
Ensure that customers are instructed to use the charger at the indicated ambient temperature range.
At temperature over 40˚C (104˚F), the storage battery cannot be sufficiently charged. The optimum
temperature range is 20 --- 25˚C (68˚F --- 77˚F).
(6) The battery charger should not be used continuously.
At high ambient temperatures, if over three storage batteries are charged in succession, the temperature of
the coils on the transformer will rise. After charging one battery, please charge the next battery after about a
fifteen-minute interval.
(7) Do not insert foreign objects into the air vents on the charger.
The charger case is equipped with air vents to protect the internal electronic components from overheating.
Caution the customer not to allow foreign materials, such as metallic or inflammable objects, to be dropped or
inserted into the air vents. This could cause electrical shock, fire or other serious hazards.
(8) Do not attempt to disassemble the storage battery or the charger.
Special devices, such as a thermistor, are built into the storage battery and charger to permit rapid charging.
Incorrect parts replacement and/or wiring will cause malfunctions which could result in fire or other hazards.
Instruct the customer to bring these units to an authorized service center in the event repair or replacement is
necessary.

--- 10 ---
(2) The following cautions are listed on the Name Plate attached to the Model EB 2420 and EB 2430HA batteries.
B. Caution Plates
(1) The following basic safety precautions are listed on the Name Plate attached to the main body of each tool.
(3) The following caution is listed on the Name Plate attached to the Model UC 24YFB Charger.
For the U.S.A. and Canada
For the U.S.A.
For Australia and New Zealand
For Europe
(9) Disposal of the Model EB 2420 or EB 2430HA storage battery
Ensure that all customers understand that Model EB 2420 or EB 2430HA Storage Batteries should be returned
to the Hitachi power tool sales outlet or authorized service center when they are no longer capable of being
recharged or repaired. If thrown into a fire, the batteries may explode, or if discarded indiscriminately, leakage
of the cadmium compound contained in the battery may cause environmental pollution.
For the U.S.A. and Canada

--- 11 ---
7-2. Inherent Drawbacks of Cordless Saber Saw Requiring Particular Attention during Sales Promotion
The cordless saber saw offers many advantages; it can be used in places where no power source is available, the
absence of a cord allows easy use, etc. However, any cordless tool has certain inherent drawbacks.
Salespersons must be thoroughly familiar with these drawbacks in order to properly advise the customer in the
most efficient use of the tool.
A. Suggestions and precautions for the efficient use of the tool
(1) Do not insert a foreign object into body vent holes.
The body of this tool has vent holes for improving the cooling efficiency. As a fan is built into the motor, a
foreign object inserted through a vent hole may cause a failure. Please instruct customers to never insert a
foreign object into the vent hole.
(2) Avoid "locking" of the motor
Locking of the motor will cause an overload current that could result in burning of the motor and/or rapid
deterioration of the battery. Salespersons should advice the customer to immediately release the switch and
stop operation if the motor becomes locked.
(3) Variation in amount of work possible per charge
Although the nominal chargeable capacity of the storage batteries used with the Model CR 24DV is 2.0 Ah and
3.0 Ah, the actual capacity may vary within 10% of that value depending on the ambient temperature during
use and charging, and the number of times the batteries have been recharged. It should be noted that other
factors which may have a bearing on the amount of work possible per charge are the working conditions
(ambient temperature, type and moisture content of the workpiece, sharpness of the saw blades, etc.) and
operational skill of the user.
B. Suggestions and precautions for the efficient use of the charger and storage batteries
If the Model EB 2420 Storage Battery is exposed to direct sunlight for an extended period or if the tool has just
been operated for a long time, charging may not be possible if the temperature of the battery is above 60˚C
(140˚F). If the Model EB 2430HA Storage Battery is exposed to direct sunlight for an extended period or if the tool
has just been operated for a long time, charging may not be possible if the temperature of the battery is above
45˚C (113˚F). In such a case, the customer should be advised to place the battery in a shaded area with a good
airflow, and allows sufficient cooling before recharging. This phenomenon is common to all existing batteries and
chargers which employ temperature sensitive overcharge protection devices. The cooling time required before
recharging can be accomplished varies from a few minutes to 30 minutes, depending on the load, duration of use,
and ambient temperature.

--- 12 ---
7-3. Front Cover
[WARNING]
The Model CR 24DV is equipped with the front cover to protect the operator against possible electric
shock, and it is not intended for cutting live lines. The front cover covers both the gear cover and the
upper cover to protect the operator against electric shock in the event that a live line is accidentally cut
and electricity flows from the blade to the metallic enclosure. Customers must be instructed to hold the
handle (made of polycarbonate resin) with one hand and the other hand on the front cover to support the
main body during the cutting operation. Be sure to instruct the customers that the front cover must not
be removed when using the Model CR 24DV.
8. REPAIRE GUIDE
8-1. Precautions in Disassembly and Reassembly
Please follow the precautions below for disassembly and reassembly procedures. The circled numbers in the
following figures and the [Bold] numbers in the descriptions below correspond to the item numbers in the Parts
List. Prior to attempting disassembly or replacement of the saw blade, ensure that the battery is removed.
8-1-1. Disassembly
(1) Removal of the Upper Cover Ass'y [20]
Remove the Saber Saw Blade [501]. Remove the two Hex. Socket Hd. Bolts (W/Flange) M5 x 12 [30] and
pull out the Base [21]. Remove the two Machine Screws (W/SP. Washer) M4 x 12 [22] and the Cover Plate
[23], and pull out the Front Cover [24]. Remove the four Hex. Socket Hd. Bolts (W/SP. Washer) M5 x 16 [19]
from the Upper Cover Ass'y [20]. Pull the Upper Cover Ass'y [20] straight and remove it.
(2) Removal of the Plunger [14] from the Upper Cover Ass'y [20]
Remove the two Seal Lock Hex. Socket Flat Hd. Bolts M5 x 12 [33] from the Connector [38]. If the Seal Lock
Hex. Socket Flat Hd. Bolts M5 x 12 [33] are too tight, heat the Upper Cover Ass'y [20] to 100 ---150˚C then
loosen the Seal Lock Hex. Socket Flat Hd. Bolts M5 x 12 [33]. Pull the Plunger [14] forward (toward the
blade) and remove from the Upper Cover Ass'y [20].
(3) Removal of the Gear Cover Ass'y [32] and the Housing [52]
Remove the Brush Cap [63] and the Carbon Brush [64]. Remove the Tapping Screw (W/SP. Washer) D5 x 30
[31]. Then the Gear Cover Ass'y [32] (together with the ArmatureAss'y [46]), Housing [52] and Fan Guide
[48] can be removed.
(4) Removal of the Gear Cover Ass'y [32] from the Armature Ass'y [46]
Remove the three Machine Screws (W/SP. Washer) M4 x 12 [22]. Then the Gear Cover Ass'y [32] can be
removed from the Armature Ass'y [46].
(5) Disassembly of the Armature Ass'y [46]
Remove the Retaining Ring (E-type) for D10 Shaft [43] from the Armature Ass'y [46] with a flat-blade
screwdriver. Remove the Ball Bearing 6001VVCMPS2L [44] from the pinion side with the bearing puller ass'y
(J-30). Then Bearing Cover (A) [45] can be removed. Remove the Ball Bearing 608VVC2PS2L [47] from the
commutator side with the bearing puller ass'y (J-30).

--- 13 ---
Fig. 6
(6) Removal of the Gear [42] from the Gear Cover Ass'y [32]
Remove the three Seal Lock Flat Hd. Screws M4 x 12 [25] through the hole of the Balance Weight [41].
Then the Gear [42] (together with the Balance Weight [41], Spindle [28] and others) can be removed from the
Gear Cover Ass'y [32].
(7) Removal of the Gear [42] from the Spindle [28]
Hold at the width-across-flat portions of the Spindle [28] with a vise and remove the Nylock Hex. Socket Flat
Hd. Bolt M6 x 16 [34]. Remove the Balance Weight [41], Gear [42], Bearing Cover (B) [26] and Ball Bearing
6901ZZCMPS2L [27].
(8) Disassembly of the blade mounting section
Remove the Retaining Ring (E-type) for D14 Shaft [13] from the Plunger [14] with a flat-blade screwdriver. Be
careful that the Retaining Ring (E-type) for D14 Shaft [13] is always loaded by Spring (A) [9]. Slide the Guide
Washer [7] backward and remove the two Steel Balls D4.76 [5]. Move Holder Sleeve (B) [4] backward and
align the notch of Holder Sleeve (B) [4] so that the Holder Pin [1] can be removed. Remove the Holder Pin [1]
and Spring (B) [2] with a magnet. Do not damage Spring (B) [2] by forced removal or omission of removal.
Remove Holder Sleeve (A) [3], Holder Sleeve (B) [4], Holder Sleeve (C) [6], Guide Washer [7], Dust Washer
[8], Spring (A) [9], Washer (D) [12], Thrust Bearing [11] and Washer (E) [10] from the Plunger [14].

--- 14 ---
(9) Disassembly of the handle section
Remove the two Tapping Screws (F/Flange) D4 x 25 (Black) [61] and pull out the Grip Cover [60] backward.
Remove the four Tapping Screws (W/Flange) D4 x 30 (Black) [59] and Handle (A).(B) Set [57]. Then the
Pushing Button [66] and the power supply ass'y (DC-speed Control Switch [56], Brush Holder (B) [54], Brush
Holder (A) [65] and Terminal Support [69] are mounted) can be removed.
(10) Removal of the power supply ass'y from the Housing [52]
Disconnect the internal wire from the Housing [52] and pull out Brush Holder (B) [54] and Brush Holder (A)
[65] backward.
(11) Disassembly of the Housing [52]
Remove the two Hex. Hd. Tapping Screws D4 x 60 [50] and remove the Magnet [49].
Fig. 7

--- 15 ---
8-1-2. Reassembly
Reassembly can be accomplished by following the disassembly procedures in reverse. However, special
attention should be given to the following items.
(1) Reassembly of the blade mounting section (Figs. 8, 9 and 10)
Apply Doubrex 251 grease (Code No. 971042)
to the inner circumference of Holder Sleeve (B)
[4] and the cam groove of the Plunger [14].
Insert the tip of the Plunger [14] into Holder
Sleeve (C) [6], Holder Sleeve (B) [4] and
Holder Sleeve (A) [3] in order. Next, align the
hole of the Plunger [14] with the notches of
Holder Sleeve (A) [3] and Holder Sleeve (B) [4]
as shown in Fig. 9. Insert the Holder Pin [1]
into the hole and push it in. Slide Holder
Sleeve (B) [4] and Holder Sleeve (C) [6]
forward and turn them about 90˚clockwise
viewing from "A". Insert the two Steel Balls
D4.76 [5] (use the arrow marks shown in Figs.
9 and 10 as the reference). Insert the other
end of the Plunger [14] into the Guide Washer
[7], Dust Washer [8], Spring (A) [9], Washer
(D) [12], Thrust Bearing [11] and Washer (E)
[10] in order. Mount the Retaining Ring (E-
type) for D14 Shaft [13] securely by adjusting
Spring (A) [9]. Be careful of the projections
and depressions on Holder Sleeve (B) [4] and
Holder Sleeve (C) [6] when mounting. After
reassembly, test-mount and remove a saw
blade to check for proper operation.

--- 16 ---
(2) Reinstallation of the spindle and gear section to the Gear Cover Ass'y [32]
Insert the Spindle [28] into the Ball Bearing 6901ZZCMPS2L [27], Bearing Cover (B) [26], Gear [42] and
Balance Weight [41] in order. Secure the spindle and gear section secured with the Nylock Hex. Socket Flat
Hd. Bolt M6 x 16 [34] to the Gear Cover Ass'y [32] with the three Seal Lock Flat Hd. Screws M4 x 12 [25]
aligning the holes of the Balance Weight [41] with the holes of Bearing Cover (B) [26] and the screw holes of
the Gear Cover Ass'y [32]. If the first Seal Lock Flat Hd. Screw M4 x 12 [25] is tightened firmly, the other two
Seal Lock Flat Hd. Screws M4 x 12 [25] cannot be aligned. Lightly tighten the first Seal Lock Flat Hd. Screw
M4 x 12 [25].
(3) Mount the Felt Packing [16], Packing Washer [15] and O-ring [17] without fail before inserting the Plunger [14]
into the Upper Cover Ass'y [20].
(4) Mount the Seal Packing [35] and Packing (B) [36] without fail when mounting the Upper Cover Ass'y [20] to
the Gear Cover Ass'y [32].
(5) Align the notch of the Magnet [49] with the protrusion of the Housing [52] when mounting the Magnet [49] to
the Housing [52].
(6) Do not pinch internal wires between the mating surfaces of the Handle (A).(B) Set [57] when mounting the
Handle (A).(B) Set [57] to the Housing [52].
(7) Adhesives are applied to the following screws and bolts. When reusing these screws and bolts, apply
Cemedine 1500 or Three Bond TB2410 to them.
Nylock Hex. Socket Flat Hd. Bolt M6 x 16 [34].................................Cemedine 1500
Seal Lock Hex. Socket Flat Hd. Bolt M5 x 12 [33]............................Cemedine 1500
Seal Lock Flat Hd. Screw M4 x 12 [25] ............................................Three Bond TB2410
(8) Atotal of 50 g Nippeco SEP-3A grease is applied in the Gear CoverAss'y [32] and the Upper Cover Ass'y [20].
Apply grease sufficiently to the following portions:
Needle Roller [40] in the Gear Cover Ass'y [32]
Connecting Piece (A) [39]
Tooth space and D7 pin of the Gear [42]
Inside of the Connector [38]
Sliding surface between the Connector [38] and the Upper Cover Ass'y [20]
Sliding surface between the Metal [18] and the Plunger [14]
Inside of the Gear Cover Ass'y [32]
Sliding surface of the Spindle [28]

--- 17 ---
(9) Tightening Torques
Tapping Screw (W/Flange) D4 x 30 (Black) [59] ............................. 2.0 0.5 N•m (20 5 kgf•cm)
Tapping Screw (W/Flange) D4 x 25 (Black) [61] ............................. 2.0 0.5 N•m (20 5 kgf•cm)
Hex. Hd. Tapping Screw D4 x 60 [50] ............................................. 2.9 0.5 N•m (30 5 kgf•cm)
Tapping Screw (W/SP. Washer) D5 x 30 [31].................................. 2.9 0.5 N•m (30 5 kgf•cm)
Machine Screw (W/Washers) M3 x 12 [68] ..................................... 0.4 to 0.6N•m (4 to 6 kgf•cm)
Machine Screw (W/SP. Washer) M4 x 12 [22] ................................ 1.8 0.4 N•m (18 4 kgf•cm)
Seal Lock Flat Hd. Screw M4 x 12 [25] ........................................... 1.8 0.4 N•m (18 4 kgf•cm)
Hex. Socket Hd. Bolt (W/SP. Washer) M5 x 16 [19]........................ 8.8 1.0 N•m (90 10 kgf•cm)
Seal Lock Hex. Socket Flat Hd. Bolt M5 x 12 [33] .......................... 5.4 0.5 N•m (55 5 kgf•cm)
Nylock Hex. Socket Flat Hd. Bolt M6 x 16 [34] ............................... 12 1.0 N•m (120 10 kgf•cm)