Hitachi CJ 90VST User manual

PRODUCT NAME
Hitachi Jig Saw
Model 90 mm (3-1/2”) CJ 90VST
●Cutting or cutting out shapes in various types of wood workpieces
●Cutting various types of metals such as mild steel, aluminum and copper
●Cutting various types of synthetic resin materials such as bakelite and vinyl chloride
●Cutting various decorative sheets and thin, soft construction materials
●Cutting stainless steel sheets
LIST No. E525
Jun. 2010
The new power jig saw Model CJ 90VST is made less expensive than existing jig saw Model CJ 110MV
by limiting its functions.
(1) Fastest cutting speed among jig saws using a high-power motor
(2) Blade holder of the quick-fit chuck type with stronger blade-holding force
(3) 4-stage orbital action
With the features above, the new jig saw will be released in order to increase its market share and sales.
MARKETING OBJECTIVE
APPLICATIONS
SELLING POINTS
International Sales Division
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT.
C
[ NEW FEATURES ]
Fastest cutting speed among jig saws using
a high-power motor
Tool-less blade changing system
[ SAME FEATURES AS THE CONVENTIONAL MODELS ]
4-stage orbital action
Soft grip handle
Blower mechanism for blowing away cutting dust

REMARK:
●For more information about HANDLING INSTRUCTIONS, visit our website at:
http://www.hitachi-koki.com/manual_view_export/
●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:
Competitors
Symbols Utilized
Company Name Model Name
B BOSCH GST75BE
C RYOBI EJS-600QEO
D RYOBI JS550LK

CONTENTS
Page
SELLING POINTS --------------------------------------------------------------------------------------------------------------1
SPECIFICATIONS --------------------------------------------------------------------------------------------------------------3
1. Specifications -----------------------------------------------------------------------------------------------------3
2. Optional Accessories -------------------------------------------------------------------------------------------4
COMPARISON WITH SIMILAR PRODUCTS----------------------------------------------------------------------------5
1. Comparison of Specifications ---------------------------------------------------------------------------------5
ORBITAL MECHANISM AND BLADE ------------------------------------------------------------------------------------6
1. Blade Movement -------------------------------------------------------------------------------------------------6
2. Orbital Position Selection --------------------------------------------------------------------------------------6
3. Blades --------------------------------------------------------------------------------------------------------------7
PRECAUTIONS ON SALES PROMOTION -----------------------------------------------------------------------------8
1. Safety Instructions ----------------------------------------------------------------------------------------------8
REPAIR GUIDE -----------------------------------------------------------------------------------------------------------------9
1. Precautions on Disassembly and Reassembly ----------------------------------------------------------9
STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------16
Assembly Diagram for CJ 90VST

-1-
Fastest cutting speed among jig saws using a high-power motor
Comparison of power input
Model
Item CJ 90VST (Reference)
CJ 110MV BCD
Power input 705 W
(*630 W) 720 W 650 W 600 W (630 W)
* 120V and 127V model
Comparison of cutting speed (The cutting speed greatly depends on cutting conditions.)
●Material: Wood (24 mm thick), Blade: No.41, Orbital position: III, Thrust power: 1.5 (kg)
Cutting speed (cm/min)
Maker Model 0 50 100 150 200
CJ 90VST 187
HITACHI CJ 110MV 231
B117
C68
D165
●Material: Wood (49 mm thick), Blade: No.41, Orbital position: III, Thrust power: 2.0 (kg)
Cutting speed (cm/min)
Maker Model 0 25 50 75 100
CJ 90VST 67
HITACHI CJ 110MV 85
B65
C16
D55
●Material: Mild steel (2 mm thick), Blade: No.16, Orbital position: 0, Thrust power: 2.0 (kg)
Cutting speed (cm/min)
Maker Model 010 20 30 40 50
CJ 90VST 44
HITACHI CJ 110MV 39
B40
C22
D39
●Material: Stainless steel (3 mm thick), Blade: No.95,Orbital position: 0, Thrust power: 2.0 (kg)
Cutting speed (cm/min)
Maker Model 02 4 6 8 10
CJ 90VST 3.5
HITACHI CJ 110MV 5.2
B10
C3.2
D4.9
SELLING POINTS

-2-
Tool-less blade changing system
The blade is easily replaceable because it can be attached
and detached without using such tools as a spanner and
wrench.
The blade can be attached and detached by simply pulling
the lever. Pulling the lever pushes back the holder pin (via a
built-in spring) that holds the blade in place. This allows the
blade to be easily attached and detached.
The only usable competitive blade is BOSCH's blade having
an attaching portion up to 1.7 mm thick or an equivalent
blade of the same shape.
4-stage orbital action
The Model CJ 90VST is equipped with an orbital mechanism that allows the blade to move up and down,
and back and forward. This mechanism allows the blade to cut deeply into wood and other soft materials,
and also discharges cutting chips well to achieve speedy cutting. For details, see “Blade movement” on
page 6.
Soft grip handle
The handle of the Model CJ 90VST is completely covered with soft-touch elastomer (a rubber-like soft
resin). It is slip resistant and securely fits in into palm of even a sweaty hand.
Blower mechanism for blowing away cutting dust
The Model CJ 90VST is equipped with a dust blower mechanism that blows off cutting dust into the air from
the motor cooling fan.
Refer to the Technical Data and Service Manual of the current Model CJ 110MV for the following:
CJ 110MV / List No. E511

-3-
1. Specifications
Model
Item CJ 90VST
Wood 90 mm (3-1/2")
Capacity Max. cutting size
Mild Steel 8 mm (5/16”)
No-load speed 850 to 3,000 min-1
Type of power source Single-phase AC 50/60 Hz
Voltage and current 110 V 120 V 127 V 220 V 230 V 240 V
6.7 A 5.5 A 5.2 A 3.3 A 3.2 A 3.0 A
Power input 705 W (120 V, 127 V model: 630 W)
Length of stroke 20 mm (3/4")
Min. cutting radius 25 mm (1")
Max. cutting radius 45° (right and left)
Type of motor Single-phase AC commutator motor
Insulation method Double insulation
Type of switch Trigger switch
Enclosure
Housing ------------ Glass fiber reinforced nylon resin (black)
and thermoplastic elastomer (green)
Side cover --------- Aluminum alloy die casting (painted silver)
Base ---------------- Aluminum alloy die casting (Ni-plated)
Net 2.2 kg (4.9 lbs) (without cord)
Weight Gross 3.5 kg (7.7 lbs) (with plastic case)
Overall length, overall height
and overall length
228 mm x 202 mm x 66 mm
(8-63/64” x 7-61/64” x 2-41/64”)
Length of cord 2.5 m (8.2 ft.)
Standard accessories
●Blade for wood (No. 41) ------------------------------------------1
●3 mm hex. bar wrench --------------------------------------------1
●Carrying Case -------------------------------------------------------1
SPECIFICATIONS

-4-
2. Optional Accessories
(1) Blades
Blade shape Application Blade No. Pitch Code No. Per pkg.
Wood No.1
(Super) 6 321878 3
No.11 8 879336 5
Wood, pulp,
synthetic resin No.12 20 879337 5
No.15 8 879338 5
Steel pulp,
nonferrous metal,
synthetic resin No.16 25 879339 5
No.21 6 879340 5
Wood, pulp,
synthetic resin No.22 10 879341 5
Stainless steel No.97 21 963400 5
NOTE: Standard blade No. 41 and optional blade No. 21 have the same shape.
(2) Guide
Code No.
321593
(3) Sub base (A) (steel)
Code No.
321992
(4) Sub base (B) (resin)
Code No.
321993
(5) Dust collector
Code No.
321591

-5-
1. Comparison of Specifications (Superior specifications: )
Maker
Model
Item
HITACHI
CJ 90VST
(Reference)
CJ 110MV B C D
Wood 90 mm
(3-1/2”)
110 mm
(4-5/16”)
90 mm
(3-1/2”)
75 mm
(3”)
75 mm
(3”)
Cutting
capacity Mild
steel
8 mm
(5/16”)
10 mm
(3/8”)
10 mm
(3/8”)
8 mm
(5/16”) Not available
Length of stroke 20 mm
(3/4”)
26 mm
(1”)
2 3 mm
(29/32”)
20 mm
(3/4”)
25 mm
(1”)
Power input
( ): for 120V and 127V model
705 W
(630 W) 720 W 650 W 600 W (630 W)
No-load
speed
min-1
(/min) 850 to 3,000 850 to 3,100 500 to 3,100 0 to 2,600 0 to 3,200
Orbital action Provided Provided Provided Provided Provided
Tool-less
blade attachment Provided Provided Provided Provided Provided
Soft grip handle Provided Provided Provided Provided Provided
Material of base Aluminum Aluminum Steel plate Aluminum
+ Resin plate
Aluminum
+ Steel plate
Length (A) 228 mm
(8-63/64”)
246 mm
(9-41/64”)
232 mm
(9-9/64”)
225 mm
(8-55/64”)
238 mm
(9-3/8”)
Height (B) 202 mm
(7-61/64”)
206 mm
(8-7/64” )
204 mm
(8-1/32”)
219 mm
(8-5/8”)
202 mm
(7-61/64”)
Dimension
Width (C) 66 mm
(2-41/64”)
68 mm
(2-11/16”)
80 mm
(3-5/32”)
70 mm
(2-3/4”)
80 mm
(3-5/32”)
Weight
(excluding cord)
2.2 kg
(4.9 lbs)
2.2kg
(4.9 lbs)
2.3 kg
(5.1 lbs)
2.2 kg
(4.9 lbs)
2.7 kg
(6.0 lbs)
No-load noise level 84.5 dB 86 dB 84 dB 87 dB 87 dB
COMPARISON WITH SIMILAR PRODUCTS
B
A
C

-6-
III II
0
I
2.0 mm (5/64”)
1.2 mm
(3/64”)
0.6 mm (1/32”)
20 mm (3/4”)
1. Blade Movement
In the Model CJ 90VST, the orbital mechanism moves the blade up and down, and back and forward. The
amount of fore-and-aft blade movement can be adjusted by simply switching the change knob to any of the
four settings. The table below shows the modeled orbits of blade movement at each orbital position
(change knob position).
III II I 0
Orbital positionBlade edge movement
Perpendicular
movement only
2. Orbital Position Selection
Selecting the most appropriate orbital position for each cutting job is essential to achieve the best possible
cutting efficiency. However, as the best orbital position depends on workpiece hardness and thickness, the
desired finish of the cut surface, and other factors, setting a single, simple standard for selecting the best
orbital position is not practical. Table 1 below can be used as a general guide for the appropriate selection
of orbital position based on various factors.
Table 1 General guide for appropriate selection of orbital position
Orbital position
Factor
III II I 0
Material hardness Soft material Hard material
Material thickness Thick Thin
Cutting speed Faster cutting Slower cutting
Straight cutting or
curved cutting Straight cutting Curved cutting
Surface finish Rough finish acceptable
(splintering, chipping acceptable) Fine finish
Material stability Unstable Very stable
* Set the orbital position to "0" independently of the cutting speed when cutting a small arc or curved line by
using a guide (sold separately).
ORBITAL MECHANISM AND BLADE

-7-
3. Blades
Proper blade selection is very important for achieving maximum performance of the Model CJ 90VST. The
table below can be used as a handy reference for selecting the optimum blade based on the type and
thickness of material to be cut.
No.1
(Long)
No. 1
(Super Long)
No. 11 No. 12,
42 No. 15 No. 16, 46 No. 21 No. 22 No. 41 No. 97 123X
Material
to be cut
Blade
Material quality Thickness of material (mm)
General lumber
Below
90
Below
90
10 to 55
Below
20
10 to 55 5 to 40 10 to 65
Lumber
Plywood
5 to 30
Below
10
5 to 30 3 to 20
Mild steel plate 3 to 6
Below
3
2 to 5 1.5 to 8
Iron
plate
Stainless steel plate
1.5 to 2.5
Aluminum copper,
brass
3 to 12
Below
3
Below
5
Nonferrous
metal
Aluminum sash
Height
up to
25
Height
up to
25
Height
up to
30
Phenol resin,
melamin resin, etc.
5 to 20
Below
6
5 to 15
Below
6
5 to 15
Vinyl chloride,
acryl resin, etc.
5 to 30
Below
10
5 to 20
Below
5
5 to 30 3 to 20 5 to 15 Plastics
Foamed
polyethylene,
foamed styrol
10 to 55 3 to 25 5 to 25 3 to 25 10 to 55 3 to 40 5 to 25
Card board,
corrugated paper
10 to 55 3 to 25 10 to 55 3 to 40
Hardboard 3 to 25
Below
6
3 to 25 Pulp
Fiberboard
Below
6
NOTE: The minimum cutting radius of the No. 1 (Long), No. 1 (Super long), No. 21, No. 22, and No.
41 blades is 100 mm.

-8-
1. Safety Instructions
In the interest of promoting the safest and most efficient use of the Model CJ 90VST Jig Saw by all of our
customers, it is very important when concluding a sale that salesperson carefully ensure that the buyer
seriously recognizes the importance of the Handling Instructions, and fully understands the precautions
listed on the Caution Plate attached to each tool.
A. Handling Instructions
Although every effort is made in each step of design, manufacture, and inspection to provide protection
against safety hazards, the dangers inherent in the use of any electric tool cannot be completely eliminated.
Accordingly, general precautions and suggestions on the use of electric power tools, and specific
precautions and suggestions on the use of the jig saw are listed in the Handling Instructions to enhance the
safe, efficient use of the tool by the customer. Salespersons must be thoroughly familiar with the Handling
Instructions in order to offer appropriate guidance to the customer during sales promotion activities.
B. Name Plate
Each tool is provided with a Name Plate which lists the following basic safety precautions on the use of the
tool.
[For Australia and New Zealand]
[For the USA and Canada]
[For China]
[For Mexico and Panama]
[For Taiwan]
[For Europe and Russia]
PRECAUTIONS ON SALES PROMOTION

-9-
Housing (A). (B) Set [36]
Base [67]
Plate Nut [64]
Base Locker
[
68
]
Hex. Socket HD. Bolt M5 X 16 [69]
●Disassembly of Base
Side Cover (B) [37]Side Cover (A) [58]
Tapping Screw (W/Flange) D4
X 12 (Black) [57]
Steel Ball D3.97 [62]
Spring (C) [61]
Change Knob [60]
Machine Screw
M4 X 30 (Black) [40]
Retaining Ring (E-Type) For D5 Shaft [44]
●Disassembly of Side Cover (A)
Before attempting disassembly or reassembly, always remember to turn off the power switch and
disconnect the plug from the power source outlet. And be sure to remove the blade to prevent damage to
its cutting edge or personal injury due to the blade.
1. Precautions on Disassembly and Reassembly
[Bold] numbers in the descriptions below correspond to numbers in the Parts List and exploded assembly
diagrams for the Model CJ 90VST.
1. Disassembly of Base
Loosen Hex. Socket HD. Bolt M5 X
16 [69] and remove it together with
Base Locker [68] from Plate Nut
[64] mounted on Housing (A).(B)
Set [36].
2. Disassembly of Side Cover (A)
Loosen two Tapping Screws (W/Flange) D4 X 12 (Black) [57] and Machine Screw M4 X 30 (Black) [40],
and then remove Side Cover (B) [37]. To remove Side Cover (A) [58], open Housing (A).(B) Set [36],
detach Retaining Ring (E-Type) For D5 Shaft [44], and then remove Change Knob [60], Spring (C) [61],
and Steel Ball D3.97 [62]. Side Cover (A) [58] then comes off.
Be careful not to lose Spring (C) [61] and Steel Ball D3.97 [62].
Disassembl
y
REPAIR GUIDE

-10-
Tapping Screw (W/Flange) D4 X 16 [49]
Cord [56]
Brush Holder [32]
Carbon Brush [33]
Spring [13]
Tapping Screw (W/Flange) D4 X
20 (Black) [38]
Roller Holder [46]
Needle Roller [47]
Plate Nut [64]
3. Disassembly of Housing (A).(B) Set
(1) Loosen eight Tapping Screws (W/Flange) D4 X 20 (Black) [38] and open Housing (A). (B) Set [36].
(2) Loosen two Tapping Screws (W/Flange) D4 X 16 [49], disconnect Cord [56], and then remove Spring
[13], Plate Nut [64], Roller Holder [46], Needle Roller [47], Brush Holder [32], and Carbon Brush [33]
from Housing (A).(B) Set [36]. The other half of Housing (A).(B) Set [36] can then be removed from the
main body.
●Disassembly of Housing (A).(B) Set

-11-
Seal Lock Hex. Socket HD. Bolt M3 X 10 [1]
Spring (D) [7]
Lever (A) [6]
Special Bolt M4 [5]
Holder Pin (B) [8]
Spring (B) [9]
Blade Holder (B) [10]
Holder Plate [11]
Seal Lock Hex. Socket HD. Bolt M3 X 6 [12]
Blade Holder (A) [3]
Blade Holder Ass’y [2]
Pin D3 [4]
Plunger Holder (A) [14]
Plunger [15]
Plunger Holder (B) [16]
Packing [17]
●Disassembly of Plunger Holder (A) and Blade Holder Assembly
Retaining Ring For D7
Shaft [18]
Connecting Piece (A) [19]
Needle Bearing [20]
Gear [21]
Balance Weight [23]
Orbital Cam [24]
Washer (A) [25]
Gear Holder Ass’y [28]
●Disassembly of Gear Holder Assembly and Armature
4. Disassembly of Plunger Holder (A) and Blade Holder Assembly
(1) Remove Plunger [15], Plunger Holder (A) [14], Plunger Holder (B) [16], and Packing [17] together.
(2) Loosen two Seal Lock Hex. Socket HD. Bolts M3 X 10 [1], remove Blade Holder Ass'y [2], and then pull
out Packing [17] and Plunger Holder (B) [16].
5. Disassembly of Gear Holder Assembly and Armature
(1) Pull out Connecting Piece (A) [19] and Needle Bearing [20] from Gear [21].
(2) Remove Retaining Ring For D7 Shaft [18] at the tip of the spindle.
(3) Remove Gear [21], Balance Weight [23], Orbital Cam [24], and Washer (A) [25] in this order.
(4) Pull out press-fitted Armature [31] from Gear Holder Ass'y [28].

-12-
Steel Ball D3.97 [62] Spring (C) [61]
Change Knob [60]
Retaining Ring (E-Type) Fo
r
D5 Shaft [44]
●Reassembly of Change Knob
Reverse the disassembly procedures above to reassemble the jig saw. However, pay particular attention
when reassembling the jig saw.
1. Reassembly of Change Knob
(1) Reassemble Spring (C) [61] and Steel Ball D3.97 [62] in Change Knob [60] as shown in the following
diagram:
2. Checking Insulator length
Do not strip too much insulation from the end of each lead wire for connection.
Be careful not to let the lead wire be clamped by the joint of Housing (A).(B) Set [36].
3. Other precautions
(1) Make sure Earth Terminal [54] is completely inside Housing (A).(B) Set [36] before closing the set.
Otherwise, the set will be deformed.
(2) Be sure to reassemble Spring [13] and Plate Nut [64], which are often overlooked and not mounted.
Reassembl
y

-13-
(1) Apply Nippeco SEP-3A grease to the following:
●Entire Gear [21], particularly its teeth
●Both sides of Washer (A) [25]
●Both sides of Orbital Cam [24]
●Both sides of Balance Weight [23]
●Periphery of Connecting Piece (A) [19]
●Tooth plane of Armature [31]
●Contacting parts of Spindle [26] and Steel Ball D3.97 [62]
●Entire Plunger [15]
●Sliding part of Roller Holder [46] and Needle Roller [47]
(2) Apply Molub-Alloy No.777-1 grease to the following:
●Inner diameter part of the gear assembly (metal part, grease stopper groove, and needle bearing part: 1.0 g)
●Inner periphery of Connecting Piece (A) [19] (0.5 g)
●Tapping Screw (W/Flange) D4 [38][49][57] ---------------------------- 1.96 ± 0.49 N•m (20 ± 5 kgf•cm)
●Machine Screw (W/Washer) M4 X 8 (Black) [65] ---------------------1.96 ± 0.49 N•m (20 ± 5 kgf•cm)
●Machine Screw M4 X 30 (Black) [40] ------------------------------------ 1.96 ± 0.49 N•m (20 ± 5 kgf•cm)
●Seal Lock Hex. Socket HD. Bolt M3 [1][12] ----------------------------2.45 ± 0.49 N•m (25 ± 5 kgf•cm)
●Hex. Socket HD. Bolt M5 X 16 [69]--------------------------------------- 3.43 to 6.37 N•m (35 to 65 kgf•cm)
●Special Bolt M4 [5]------------------------------------------------------------ 4.4 ± 1.0 N•m (45 ± 10 kgf•cm)
●Machine Screw (W/Washer) M3.5 X 6 [42]----------------------------- 0.6 ± 0.15 N•m (6 ± 1.5 kgf•cm)
Check the following after reassembly:
(1) Confirm normal switching operation of Switch (E) (1p Screw Type) W/Lock [41].
(2) Confirm that the stroke speed changes depending on the turning amount of Controller [43].
(3) Confirm that the blade can be attached securely.
Upon completing disassembly and repair, measure the insulation resistance and conduct an insulation test
(dielectric strength test).
Insulation resistance: 7 MΩor more with 500 V DC megohm tester.
Dielectric strength: AC 4,000 V for 1 minute, with no abnormalities ---- 110 V, 220 V, 230 V, 240 V
AC 2,500 V for 1 minute, with no abnormalities ---- 120 V
After no-load operation for 30 minutes, the no-load current value should be as specified below at a
frequency of 50/60 Hz.
Voltage (V) 110 120 220 230 240
Current (A) Max. 4.0 3.0 1.8 1.8 1.8
Screw Tightening Torque
Checking after Reassembly
Application of Lubricant
Insulation Test
No-load Current

-14-
Varistor [50] Controller [43] Connector 50091 [53]
Switch (E) (1p Screw Type) W/Lock [41]
●Circuit diagram
Carefully ensure that wiring is accomplished as illustrated below, because incorrect wiring will result in
inadequate or reverse rotation.
Wiring Diagram

-15-
Cord [56]
Varistor [50] Connector 50091 [53]
Switch (E) (1p Screw Type) W/Lock [41]
Controller [43]
●Wiring diagram
Connection to the switch (Viewed from A)
with the varistor ass’y
Cord [56] (white, blue)
+Terminal [45] (red)
Varistor [50] (white)
+Terminal (A) M3.5 [52] (red)
Controller [43] (red)
Cord [56] (black, brown)
+Terminal [45] (red)
Varistor [50] (red)
+ Stator [35] (gray)
+ Terminal [51] (blue)
Controller [43] (white, blue)

-16-
MODEL Variable
Fixed 10 20 30 40 50 60 min.
Work Flow
CJ 90VST
General Assembly
Base
Base Locker
Side Cover (A)
Side Cover (B)
Change Knob
Blade Holder (A)
Blade Holder (B)
Lever (A)
Holder Plate
Armature Ass'y
Ball Bearing
608VVC2PS2L
Ball Bearing
608VVC2PS2L
Stator
Switch (E)
Controller
Cord
Cord Armor
Gear Holder Ass'y
Roller Holder
Housing
(A). (B) Set
Connecting
Piece (A)
Needle Bearing
Gear
Balance Weight
Orbital Cam
Washer (A)
Plunger Holder (A)
Plunger
Plunger Holder (B)
Packing
Blade Holder Ass'y
STANDARD REPIR TIME (UNIT) SCHEDULES

Model CJ 90VST
JIG SAW
LIST NO. E525
(E1)
2010㨯6㨯14
1
4
13
16
17
14
15
18
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
39
40
38
37
36
43
47 50
42
49
45
51
54
52
53
44
41
55
56
59
57
58
61
62
60
67
66
65
64
69
68
501
502
503
63
46
3
10
9
8
5
6
7
12
11
2
22
19
48