Makita HM1801 Manual

Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output(W)
110
120
220
230
240
16.0
15.0
9.6
9.2
8.8
50/60
AC/DC
50/60
50/60
50/60
1,700
1,700*1
2,000
2,000
2,000
950
950
1,240
1,240
1,240
2,300
2,300
2,500
2,500
2,500
Models No.
Description
PRODUCT
Current (A)
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
P 1 / 18
HM1801
Electric Breaker
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 824 (32-1/2)
146 (5-3/4)
633 (25)
L
W
Model HM1801 has been developed as 28.6mm hex shank electric breaker
conforming to the permissible noise level limit of 2006 stage of European
Noise Directive for Outdoor Equipment.
Despite such low noise level, features highest-in-class chipping efficiency.
This model is the economy version of HM1810, not featuring AVT.
H
Hex wrench 5 ................ 1 pc
Bull point
Cold chisel
Scaling chisel
Clay spade
Rammer
Blows per min.: bpm=min-1
Model HM1801
Protection from electric shock
Net weight: Kg (lbs)
Power supply cord: m (ft)
Noise*2:
dB(A)
*2: Noise indicates sound power level.
*3: This is the permissible noise level limit of 2006 stage of the "European Noise Directive for Outdoor
Equipment" (2000/14/EC). And in and after 2006, it will be prohibited in Europe to sell the products
with the sound power level exceeding this noise level limit.
The values of the permissible noise level limit listed above are calculated by us in accordance with the
directive. (The calculation is based on the weight of product.)
*4: Vibration level on the catalog for European countries
*1: Continuous Rating Input: Taiwan=1,570W, UK (low voltage)=1,700W, Saudi Arabia (low voltage)=1,650W
Specification
Shank: mm (")
Anti-vibration
technology
Vibration*4: m/s2
1,100
5.0 (16.4) [brazil only: 2.0m (6.6ft)]
Hex 28.6 (1-1/8)
Double insulation
Permissible noise level limit*3
Guaranteed noise level on the
catalog for European countries
Impact energy: J (catalog value) 63
Vibration absorbing handle No
Counterweight mechanism
30 (66.2)
110
No
106
16

P 2 / 18
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Disconnect the machine from the power source for safety before repair/maintenance!
1R005 Retaining Ring R Pliers RT-2N
1R023 Pipe Ring (for arbor press)
Removing Retaining ring R-80 from Crank box
Removing Helical gear 47
1R045 Gear extractor, large
1R346 Center Attachment for 1R045 Disassembling Tool retainer section
1R347 Jig for Tool Retainer Disassembling
1R231 1/4" Hex Shank Bit for M8
1R263 Bearing Extractor
Loosening/ tightening Hex socket head bolt M8x75
1R348 Spring Pin Extractor Removing Spring pin 8-40 from Tool retainer shaft
Removing Ball bearings
1R269 Bearing Extractor
1R291 Retaining Ring S and R Pliers Removing Retaining ring S-20 from Crank shaft
784408-3 Socket Bit 13-55 Loosening/ tightening Hex nut M8 that secures Fan 100
Code No. Description Use for
[2] ADHESIVE APPLICATION AND LUBRICATION
[2] -1. Adhesive Application
Apply an appropriate amount of adhesive to the following parts in order to lock them against vibration loosening or
leakage. Be sure to wipe off grease or oil from the parts before adhesive application.
Tool holder
10 Brush holder cap (2pcs) Threaded portion
12 Hex socket head bolt M6x22 (4pcs)
22 Gear housing complete
Threaded portion
16 Hex bolt M5x85 (2pcs) Threaded portion
Figure 8 inlaid portion that contacts Gear housing cover
83 Hex socket head bolt M12x55 (4pcs) Threaded portion
Item No. Description Portion to apply adhesive
Threaded portion
94 Hex socket head bolt M12x45 (4pcs)
Fig. 1
22
: ThreeBond 1215
: ThreeBond 1321B or 1324,
or Loctite 242
Barrel
83
94
Gear housing cover
12
16
10
Bearing box
Motor housing B
Field
Motor housing A
Crank housing

P 3 / 18
Repair
[2] LUBRICATION
Apply Makita grease to the following portions designated with the black triangle and gray triangle to protect
parts and product from unusual abrasion.
Tool holder
Impact bolt
Striker
Impact bolt holder
85
Crank complete
Pin 15
22 Gear housing complete approx. 80g of Makita grease N No.1 in the gear chambers
24 Spur gear 22
35 Helical gear 50
appropriate amount of Makita grease N No.1 to the teeth portion
31 Crank housing approx. 110g of Makita grease R No.00 in the crank room
appropriate amount of Makita grease N No.1 to the teeth portion
43 Spur gear 47 appropriate amount of Makita grease N No.1 to the teeth portion
appropriate amount of Makita grease R No.00 to the whole portion
Piston
53 O ring 55
appropriate amount of Makita grease R No.00 to the whole portion
56, 58 O ring 52
appropriate amount of Makita grease R No.00 to the whole portion
100 O ring 60
approx. 10g of Makita grease R No.00 to the inside
57 Cylinder liner 62
appropriate amount of Makita grease R No.00 to the inside surface of the two holes
52 Connecting rod
Cylinder B appropriate amount of Makita grease R No.00 to the inside surface
98 X ring 40 appropriate amount of Makita grease R No.00 to the whole portion
Fig. 2
Item No. Description Portion to lubricate
22
: Makita grease N No.1
: Makita grease R No.00 31
24
35 43
56
53
57
58
98
85
100
52

P 4 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Disassembling/Assembling Motor Section
Fig. 3 Fig. 4
1) Remove Motor housing cover set. Fan 100 secured with Hex nut M8 will be now visible.
2) Remove the assembly of Rear cover and Handle (switch side), then Brush holder caps and Carbon brushes.
3) Remove hex nut M8 by turning counterclockwise with Socket bit 13-55 (No.784408-3) and Impact driver.
Now Fan 100 can be separated from Armature shaft. (Fig. 3)
4) After unscrewing four M6x22 Hex socket had bolts, remove Bearing box from Crank housing using
Gear extractor, large (No.1R045). (Fig. 4)
Important:
When unscrewing Brush holder caps, be careful not to break the screwdriver insertion slot because the adhesive-applied
Brush holder caps are secured tight.
Socket Bit 13-55
(No.784408-3)
Fan 100
Bearing box
Bearing box
Hex socket head bolt
M6x22 (4pcs)
Gear extractor, large
(No.1R045)
Crank housing
Fig. 5
5) Pull off Motor housing B from Crank housing. Then remove Motor housing A from Crank housing by tapping the
edge of Crank housing with plastic hammer. (Fig. 5) Sometimes, when tapping Crank housing, Armature may be
removed from Crank housing before Motor housing A.
6) After unscrewing two M5x85 Hex bolts, remove Field by tapping the edge of Motor housing A with plastic hammer.
(Fig. 6)
Crank housing
Motor housing A
Motor housing B
Hex bolt M5x85Field
Motor housing A
Fig. 6
Armature
REMOVING FIELD

P 5 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Disassembling/Assembling Motor Section (cont.)
INSTALLING FIELD
Fig. 7
Motor housing A
Field
Motor housing B side
Field lead wires
Field lead wires
Fig. 9
[Correct] [Wrong]
Motor housing B side
Lead wire side
Lead wire side
Do the reverse of the disassembling steps.
Important:
Field is not reversible when assembled into Motor housing A. Be sure to assemble so that the Lead wire side of the Field
is placed on the Motor housing B side as illustrated to left in Fig. 7.
It will be impossible to route the lead wires to Motor housing B if assembled as illustrated to right in Fig. 7.
REMOVING ARMATURE
If Armature is not removed in removal of Field as described in 5)
of "Removing Field", remove by following the steps described below:
1) Remove the parts of Fan 100 side (Fan 100, Bearing box and
Motor housing B). (See Figs. 3, 4, 5)
Note: It is not necessary to remove Motor housing A and Field.
Remove four M8x75 Hex socket head bolts with 1R231.
2) Remove Gear housing cover by raising with Slotted screwdriver and
Bearing extractor (No.1R263) as in Fig. 8.
Note: The two tools are necessary because Gear housing cover is
securely fastened to Gear housing using adhesive.
3) After removing the assembly of Helical gear 50 and Spur gear 22,
insert the arms of 1R045 through the opening of Gear housing.
Then grip the bearing chamber of Gear housing with the jaws of 1R045.
Now, by turning the handle of 1R045 clockwise, Armature can be
removed form Gear housing. (Fig. 9)
Assembly of
Helical gear 50
and Spur gear 22
Fig. 8
Gear housing cover
Gear housing
Armature shaft
Bearing chamber
of Gear housing
No.1R045
Armature

P 6 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
Fig. 10
1) After separating Gear housing from Crank housing, remove Ball bearing 6302LLB with Gear extractor, large
(No.1R045). At this time, be careful not to lose Pin 5. Then using Retaining ring S and R pliers (No.1R291)
remove Retaining ring S-20. (Fig. 10)
2) Put Gear housing on Pipe Ring (No.1R023), and press down Crank shaft using arbor press. (Fig. 11)
3) Now Crank shaft complete, Spur gear 47 and Sleeve 25 can be removed from Gear housing. (Fig. 12)
Note: Be careful not to lose two woodruff keys.
4) Two 6202 Ball bearings can be removed from the assembly
of Helical gear 50 and Spur gear 22 using Bearing extractors
(No.1R263) as illustrated in Fig. 13.
5) As illustrated in Fig. 15, the assembly of Helical gear 50 and
Spur gear 22 can be disassembled using Pipe ring (No.1R023),
Round Bar for Arbor 14-100 (No.1R243), arbor press and
two appropriate steel plates.
Note: Be careful not to lose two Woodruff keys.
[3] -2. Disassembling/Assembling Gear Section
Ball bearing
6302LLB
Retaining
ring S-20
Gear housing
Fig. 11 Fig. 12
Crank shaft
complete
Crank shaft complete
Arbor press
Pipe Ring
(No.1R023)
Spur gear 47
Sleeve 25
Woodruff key 4
Fig. 13
Helical gear 50 Spur gear 22
Bearing Extractor
(No.1R263)
Ball bearing 6202
(on Helical gear 50 side)
Ball bearing 6202
(on Spur gear 22 side)
Fig. 14
Pipe Ring (No.1R023)
Round bar
for arbor 14-100
(No.1R243 )
Arbor press
Woodruff key 4
Spur gear 22
Metal plates
for supporting Gear
Helical gear 50
DISASSEMBLING

P 7 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Disassembling/Assembling Gear Section (cont.)
ASSEMBLING
1) After setting O ring 40, O ring 90 and Pin 4 in place on Gear housing complete, press-fit Crank shaft complete and
Armature onto Gear housing using arbor press as illustrated in Fig. 15.
2) Put Sleeve 25 through Crank shaft complete. Set woodruff keys onto the concaves of Crank shaft complete.
Mount Spur gear 47 to Crank shaft complete. After fixing Spur gear 47 with Retaining ring S-20, assemble Ball
bearing 6302LLB to Crank shaft complete. (Fig. 16)
3) Assemble Helical gear 50 to Spur gear 22. Mount the assembly to Gear housing complete.
4) Put Gear housing complete onto Crank housing complete as illustrated in Fig. 18.
5) Apply an appropriate amount of ThreeBond 1215 to the figure 8 inlaid portion that contacts Gear housing cover.
Then secure Gear housing cover to Gear housing complete with four M8x75 Hex socket head bolts. (Fig. 19)
Hex socket head bolt M8x75
Gear housing cover
Fig. 18Fig. 17
Assembly of Helical gear 50
and Spur gear 22
Crank housing comp.
O ring 40
Clean this bearing chamber
of Gear housing complete
before mounting O ring 40
and Armature to protect
O ring 40.
Apply Makita grease N No.1 to the gear portion
of Armature before press-fitting Armature onto
Gear housing.
Fig. 15
O ring 90
Crank shaft complete
Fig. 16
Crank shaft complete
Spur gear 47
Sleeve 25
Gear housing complete
Woodruff key 4
(2 pcs)
Ball bearing 6302LLB
Retaining ring S-20
Pin 5
Pin 4
Fit Pin 4 on Gear housing
complete in the hole of
Crank housing complete.
Before putting Gear housing
cover, apply ThreeBond 1215
to the figure 8 inlaid portion
designated with white arrow.

P 8 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Disassembling/Assembling Barrel Section
DISASSEMBLING
ASSEMBLING
1) Remove Barrel from Crank housing complete by unscrewing four M12x55 Hex socket head bolts.
Then remove Cylinder liner 62. (Fig. 19)
Note: Use an appropriate steel pipe to extend the grip of hex wrench for easy removal of the bolts securely fastened
with adhesive.
2) Take out Striker from Cylinder liner 62, then remove O ring 52 from Striker. (Fig. 19)
3) Take out Piston and Connecting rod from Crank housing complete, and remove O ring 52 and O ring 55 from the
removed Piston. (Fig. 19)
Do the reverse of the disassembling steps.
Note:
Striker and Spacer are not reversible when assembled to Cylinder liner 62. Be sure to install as illustrated in Fig. 20.
Fig. 19
Fig. 20
Piston
Barrel Flat washer 63
Spacer
Crank housing comp.
Cylinder liner 62
Striker O ring 52
Steel pipe
[Tool retainer side]
[Crank housing side]
Cylinder liner 62
Spacer
Striker
Pin 5
Crank housing completeGasketBarrel
Fig. 21
CORRECT
WRONG
[Cross section]
Do not forget to put Flat washer 63 between Cylinder
liner 62 and Crank housing complete.
When assembling Barrel to Crank housing complete,
first fit Pin 5 in the hole on Barrel, and put the pin
through the hole of Gasket.
Then fit Barrel to Crank housing complete so that
Pin 5 is inserted into the hole on Crank housing
complete. (Fig. 21)
Piston and Connecting Rod
O ring 52 O ring 55

P 9 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
DISASSEMBLING
[3] -4. Disassembling/Assembling Tool Retainer Section
1) Tool retainer can be removed as illustrated in Fig. 22.
2) For removing Tool retainer poles, first set Gear extractor, large (No.1R045) as illustrated in Fig. 23.
*Attach Center attachment (No.1R346) to No.1R045.
*Adjust the pitch of the arms of No.1R045 to minimum for securely holding Retainer ring.
*Set Tool retainer pole removing tool (No.1R347) between No.1R346 and Tool retainer pole.
3) Then pull Retainer ring in the direction of Tool retainer pole by turning the handle of 1R045 clockwise, and remove
Pin 4 from the rod hole of Tool retainer pole by hand. (Fig. 23)
Be sure to securely hold the arms of No.1R045 not to spread out, or the arms will fall off from retainer ring and
Compression spring and Retainer ring will fly away.
4) Slowly loosen the handle of No.1R045 by turning counterclockwise until Retainer ring is released from Compression
spring 12. Now Tool retainer pole can be removed from Tool holder 29. (Fig. 24)
Retainer ring
Tool retainer pole
Compression
spring 12
Fig. 24
No.1R347
Pin 4
Retainer ring Tool retainer pole
Compression spring 12
No.1R346
No.1R045
Adjust the pitch between
the arms to minimum.
Fig. 23
Tool holder 29
Tool retainerTool holder 29
Swivel Tool retainer to the
position illustrated above.
Spring pin 8-40
Remove spring pin 8-40
with Spring pin extractor
(No.1R348).
Tap out Tool retainer shaft
using slotted screwdriver.
Now Tool retainer can be
removed from Tool holder.
Tool retainer shaft
Slotted
screwdriver
Fig. 22

P 10 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
ASSEMBLING
[3] -4. Disassembling/Assembling Tool Retainer Section (cont.)
Fig. 25
Fig. 26
Fig. 27 Fig. 28
Tool retainer shaft
Bit insertion hole
Concave portion
Tool retainer shaft
Tool holder 29
Barrel
Tool holder 29 Tool retainer pole
Compression spring 12
Do the reverse of the disassembling steps.
Note:
When assembling Tool retainer to Tool holder 29, follow the instructions described below. (Fig. 25 - 28)
B) Insert Tool retainer shaft from the end chamfered more than the other. (Fig. 27)
C) Tool retainer shaft is not reversible when inserted into Tool retainer. As illustrated in Fig. 28, be sure to insert so that
the concave portion on Tool retainer shaft is positioned on the bit insertion hole of Tool holder 29.
Slotted screwdriver
Insert tool retainer shaft by tapping with plastic hammer
till the Pin 4 insertion hole of Tool retainer shaft is aligned
with that of Tool retainer.
A) See Fig. 26. As illustrated to left, when assembled to Tool holder 29, Tool retainer pole is pulled in the direction of
Barrel by the force of Compression spring 12, and the hole of Tool retainer pole is not aligned with the hole of Tool
holder 29.
Therefore, as illustrated to right, while aligning the two holes by sliding Tool retainer pole with slotted screwdriver,
assemble Tool retainer and Tool retainer shaft to Tool holder 29.
Slotted screwdriver
A
B
C
Tool retainer
Pin 4 insertion hole
Tool holder 29
End chamfered more
Tool retainer shaft
Tool retainer

P 11 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
DISASSEMBLING
[3] -5. Disassembling/Assembling Tool Holder Section
Fig. 29 Fig. 30 Fig. 31
Steel pipe
Hex wrench
1) Remove Tool retainer section from Tool holder 29. (Figs. 22, 23, 24)
2) Separate Tool holder 29 from Barrel by unscrewing four M12x45 Hex socket head bolts as illustrated in Fig. 29.
Note: Use an appropriate steel pipe to extend the grip of hex wrench for easy removal of the bolts securely fastened
with adhesive.
3) Remove Impact bolt by tapping the edge of Tool holder 29. (Fig. 30)
4) Take out X ring 40 from Tool holder 29 using small screwdriver or the like. (Fig. 31)
Now Tool holder 29 can be replaced. If Cylinder B is contaminated with dust, X ring 40 can be damged.
In this case, also replace X ring 40, and clean up the inside of Barrel section.
5) Take out Cylinder B from Barrel by tapping its edge with plastic hammer. (Fig. 32)
6) Take out Impact bolt holder from Cylinder B by tapping its edge with plastic hammer. Then remove O ring 53
from Cylinder B. (Fig. 33)
7) Remove O ring 60 and Rubber ring 54 from Impact bolt holder. (Fig. 34)
Hex socket head bolt
M12x45 (4pcs)
X Ring 40
Cylinder B
Barrel
Barrel
Tool bolder 29
Tool bolder 29
Impact bolt holder
Cylinder B
O ring 53
Cylinder B Impact bolt holder
Barrel
Fig. 32 Fig. 33
O ring 60
Impact bolt holder
Rubber ring 54
Fig.34
ASSEMBLING
Do the reverse of the disassemblidng steps.
Note: Do not forget to apply adhesive to M12x45 Hex socket head bolts.
Impact bolt
Tool bolder 29

P 12 / 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[4] Maintenance
[3] -6. Assembling Handle
See Fig. 35.
When mounting Handle and Side handle, be sure to:
a) Place Handle (on which Switch and Switch lever
are installed) on the side where oil gauge cap is
installed.
b) Place Side handle on the opposite side.
When replacing carbon brush, it is recommended to do the following maintenance at the same time for longer service life
of the machine:
1) Replace the following parts (Fig. 36);
56. O ring 52 mounted to Piston
58. O ring 52 mounted to Striker
84. O ring 53 mounted to Cylinder B
98. X ring 40 mounted to Tool holder 29
100. O ring 60 mounted to Impact bolt holder
Fig. 35
Oil gauge cap
Switch lever
Handle
Side handle
2) Additionally apply approx. 60g of Makita grease R No.00 to the inside of Crank housing complete.
Piston Striker Cylinder B Impact bolt holder Tool holder 29
Fig. 36
56 58 100 9884

Circuit diagram
P 13/ 18
Color index of lead wires' sheath
Black
White
Red
Orange
Purple
Motor housing B
Field
Side B
Side A
Countries That Require Noise Suppression Circuitry
USA, Canada, Panama, Mexico, Cyprus, Korea
Lead unit
Terminal block
Insulated
connector
Insulated
connector
Pilot lampConnector
Insulated
connector
Switch
Field
Brush holder
on side B
Brush holder
on side A
Power supply cord
Lead unitTerminal block
Noise suppressor Line filter
Insulated
connector Insulated
connector
Pilot lampConnector
Insulated
connector
Switch
Field
Brush holder
on side B
Brush holder
on side A
Power supply cord

Circuit diagram
P 14/ 18
Color index of lead wires' sheath
Black
White
Red
Orange
Purple
Motor housing B
Field
Side B
Side A
Other Countries
Insulated
connector
Insulated
connector
Insulated
connector
Switch
Field
Brush holder
on side B
Brush holder
on side A
Power supply cord
Lead unit Pilot lampConnector
Insulated
connector

Wiring diagram
P 15/ 18
[1] Wiring in Crank Housing Cap
Motor housing B
Field lead wire (black)
Purple lead wires
(Field lead wire, Lead wire
from Brush holder)
Note: Illustrated below in Fig. 38 is Crank housing cap viewed from Cap cover side.
We are explaining the wiring in three sections. (Fig. 37)
Insulated connector
Line filter
(See the illustration below.)
Insulated connector
Noise suppressor
Pilot lamp
Sponge sheet
If Line filter is used,
put Sponge sheet under it.
Lead wire holder A
Lead wire holder B
If noise suppressor is used, put here
in place after wrapping with Sponge.
Fix Pilot lamp with this holder.
If Noise suppressor is used,
be careful not to move Noise
suppressor out of place when
connecting its lead wires with
the insulated connector in
Cap cover.
Cap cover side
Lead wire holder C
Fix the following lead wires with
Lead wire holders A, B and C;
ATwo orange lead wires
(Field lead wire, Lead wire from Brush holder)
BTwo purple lead wires
(Field lead wire, Lead wire from Brush holder)
Two Field lead wires (black)
CTwo Field lead wires (black)
Rear case [2] Handle sub base
Motor housing B
[3] Cap cover Top cover
[1] Crank housing cap
Orange lead wires
(Field lead wire, Lead wire
from Brush holder)
Wind Field lead wires (black) around
Line filter as illustrated to right,
then cover the Line filter with Sponge. Line filter
Sponge
Field lead wire (black)
Line filter
When fixing Lead wires with
Lead wire holders A and B,
be sure that all the wires are tight
between the Lead wire holders and
the opening of Motor housing B.
Motor side
Handle side
Fig. 37
Fig. 38
Route the following six lead wires
through this opening of Motor housing B:
*Four Field lead wires
(orange, black, black, purple)
*Two lead wires from Brush holder
(orange, purple)
Lead wires

Wiring diagram
P 16/ 18
[2] Wiring in Handle Sub Base
When Using Terminal Block
Connector of
Lead unit
rib B
rib C
rib A
pin Important: Be careful not to route over the rib A.
Noise
suppressor
(if used)
Switch
Route each wire between the inside wall of Handle
sub base and the rib B/ rib C.
Pin Pin
Terminal
block
Terminal
block
If Noise suppressor is used, wrap it with sponge,
and put in the space between the rib A and the rib B
so that the surface A of Noise suppressor is parallel
to the bottom of Handle sub base as illustrated to right.
Bottom of
Handle Sub Base
Terminal block surface A
Noise suppressor
Sponge
1) Before installing Switch, connect the lead wires with Terminal blocks as illustrated in Fig. 41.
Fig. 41
boss
boss
to Switch
[Handle sub base viewed
from Handle side]
Motor side Handle side
Before routing, be sure to put through the pipe of
Handle sub base from Motor side as illustrated below.
Route round the pin, then route between the boss and
the inside wall of Handle sub base.
Route round the pin and the rib B, then route between
the boss and the inside wall of Handle sub base.
Lead wires of Lead unit
Relay wires (white)
Lead wires of Power supply cord
Route each wire between the boss and the inside wall
of Handle sub base.
How to Put Noise Suppressor in Place
2) After installing Switch, connect the lead wires with Switch as illustrated in Fig. 42.
Fig. 42
rib B
rib D
Before routing, be sure to
put through the pipe of
Handle sub base from
Motor side as illustrated
to right.
Relay wires (white)
Relay wires (red)
Route each wire between the pin and the inside wall
of Handle sub base.
Lead wires of Noise suppressor
Be careful not to route over the ribs B and D.
3) After finishing the wiring in Sub handle base, route the
following lead wires through the opening of Top cover
and Rear cover as illustrated in Fig. 43:
Lead wires of Lead unit
Relay wires (red)
Fig. 43
Top cover
Rear cover
Handle sub cover
opening of the pipe

Wiring diagram
P 17/ 18
[2] Wiring in Handle Sub Base
When Not Using Terminal Block
Connector of
Lead unit
rib B rib C
Route each wire between the inside wall of Handle
sub base and the rib B/ rib C.
Insulated
connector
If Noise suppressor is used, wrap it with sponge,
and put in the space between the rib A and the rib B
so that the surface A of Noise suppressor is parallel
to the bottom of Handle sub base as illustrated to right.
Bottom of
Handle Sub Base
surface A
Noise suppressor
Sponge
1) Before installing Switch, connect the lead wires with Insulated connectors as illustrated in Fig. 44.
Fig. 44
boss
boss
[Handle sub base viewed
from Handle side]
Motor side Handle side
Before routing, be sure to put through the pipe of
Handle sub base from Motor side as illustrated below.
Lead wires of Lead unit
Relay wires (white)
Lead wires of Power supply cord
Route each wire between the boss and the inside wall
of Handle sub base.
How to Put Noise Suppressor in Place
2) After installing Switch, connect the lead wires with Switch as illustrated in Fig. 45.
Fig. 45
Before routing, be sure to
put through the pipe of
Handle sub base from
Motor side as illustrated
to right.
Relay wires (white)
Relay wires (red)
Route each wire between the pin and the inside wall
of Handle sub base.
Lead wires of Noise suppressor
Be careful not to route over the ribs B and D.
3) After finishing the wiring in Sub handle base, route the
following lead wires through the opening of Top cover
and Rear cover as illustrated in Fig. 46:
Lead wires of Lead unit
Relay wires (red)
Fig. 46
Top cover
Rear cover
Handle sub cover
Insulated connector
to Switch
Insulated
connector Route each wire between the inside wall of Handle
sub base and the rib B/ rib C.
opening of the pipe
Switch
Noise
suppressor
(if used)
Pin Pin
rib B
rib D

Wiring diagram
P 18/ 18
[2] Wiring in Cap Cover
Sponge sheet
1) First, if Noise suppressor is used, in order to protect lead wires, stick Sponge sheet to the surface A of Cap
cover so that the longer side of Sponge sheet contacts the surface B of Cap cover and the shorter side
contacts the surface C. (Fig. 47)
2) Then connect the lead wires as illustrated in Fig. 48.
Surface A
Surface B
Surface C
Cap cover
Connector
Noise suppressor
Crank housing cap
Handle sub base
Top cover
Sponge sheet
longer side
shorter side
Be sure to connect the lead wires
after routing through the opening of Cap cover.
After connecting the lead wires, put Connector,
Insulated connectors and the slack of lead wires
into the opening of Cap cover as illustrated
to right.
Cap cover
Field lead wires (black)
Lead wires of Pilot lamp
Lead wires of Noise suppressor (white)
(if Noise suppressor is used)
Relay wires to Switch (red)
Lead wires of Lead unit
If Noise suppressor is used, be careful not to move
Noise suppressor out of place when connecting
these lead wires with the insulated connector.
Opening of Cap cover
Fig. 47
Fig. 48
Rear case
Important