Makita DJR187 Manual

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April 2016
TECHNICAL INFORMATION
OFFICIAL USE
for ASC & Sales Shop
Model No.
Description Cordless Recipro Saw
DJR187
CONCEPT AND MAIN APPLICATIONS
Model DJR187 is a Cordless reciprosaw powered by 18V Li-ion battery
and has beendeveloped for highercutting efficiency and more compact and
lightweight by adopting Vertical crank mechanism and BrushLess DC motor.
Its main features are:
•Ergonomically designed handle
•Toolless shoe adjustment by lever system
•Toolless blade change
•Electric 2 speed for wood/ metal cutting
•Retractable rafter hook
•LEDjob light with preglow and afterglow functions
Note: BL1815 is not compatible.
Specification
Model
Specification DJR187
Battery
Voltage: V 18
Capacity: Ah 1.5, 2.0, 3.0, 4.0, 5.0, 6.0
Energy capacity: Wh 27, 36, 54, 72, 90, 108
Cell Li-ion
Charging time (approx): min 15, 24, 22, 36, 45, 55 with DC18RC
Max output (W) 670
Strokes per minutes: min-1= spm (strokes per minute) High: 0 - 3,000, Low: 0 - 2,300
Length of stroke: mm (") 32 (1-1/4)
Electric 2 speed Yes
Capacity: mm (") Wood*2255 (10)
Pipe: Ø 130 (5-1/8)
Blade clamp type Toolless
Switch lock function Lock-off
Electric brake Yes
Variable speed control by trigger Yes
LED job light Yes
Weight according to
EPTA-Procedure 01/ver.2.1: kg (lbs) 3.4 (7.6)*3or 3.7 (8.2)*1
*2 When 300mm (11-3/4") blade is used.
*3 With battery BL1815N, BL1820(B)
Dimensions: mm ( " )
Length (L) 439 (17-1/4)
Width (W) 83 (3-1/4)
Height (H) 231 (9-1/8)*1
*1 With battery BL1830(B), BL1840(B),
BL1850(B), BL1860B
Recipro saw blade 152mm (6") for wood and metal
Recipro saw blade 200mm (7-7/8") for metal
Battery*4
Charger*4
Battery cover*5
Plastic carrying case*4
*4 Battery and Charger and Plastic carrying case are not supplied with “Z” model.
*5 Supplied with the same quantity of extra Battery.
Note: The standard equipment may vary by country or model variation.
Recipro saw blades
Fast charger DC18RC
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Two port multi fast charger DC18RD
Four port multi charger DC18SF
Battery BL1815N
BL1820(B),
BL1830(B), BL1840(B),
BL1850(B), BL1860B
Standard equipment
Optional accessories
L
HW

1INDEX
1INDEX.......................................................................................................................................................................................... 2
2CAUTION .................................................................................................................................................................................... 3
3NECESSARY REPAIRING TOOLS ........................................................................................................................................... 3
4LUBRICANT AND ADHESIVE APPLICATION ...................................................................................................................... 4
5REPAIR ........................................................................................................................................................................................ 6
5-1 Insulation cover.................................................................................................................................................................... 6
5-1-1 Disassembling ............................................................................................................................................................. 6
5-1-1-1 For DJR187, DJR360.............................................................................................................................................. 6
5-1-1-2 For DJR186............................................................................................................................................................. 6
5-1-2 Assembling.................................................................................................................................................................. 7
5-2 Slider assembly .................................................................................................................................................................... 7
5-2-1 Disassembling ............................................................................................................................................................. 7
5-2-2 Assembling.................................................................................................................................................................. 9
5-3 Rotor ass'y (Armature ass'y)............................................................................................................................................... 12
5-3-1 Disassembling ........................................................................................................................................................... 12
5-3-1-1 For DJR187, DJR360............................................................................................................................................ 12
5-3-1-2 For DJR186........................................................................................................................................................... 14
5-3-2 Assembling................................................................................................................................................................ 15
5-3-2-1 For DJR187, DJR360............................................................................................................................................ 15
5-3-2-2 For DJR186........................................................................................................................................................... 16
5-4 Gear complete .................................................................................................................................................................... 17
5-4-1 Disassembling ........................................................................................................................................................... 17
5-4-1-1 For DJR187, DJR360............................................................................................................................................ 17
5-4-1-2 For DJR186........................................................................................................................................................... 18
5-4-2 Assembling................................................................................................................................................................ 19
5-5 Slider section...................................................................................................................................................................... 19
5-5-1 Disassembling ........................................................................................................................................................... 19
5-5-2 Assembling................................................................................................................................................................ 19
6Circuit diagram ........................................................................................................................................................................... 20
7Wiring diagram ........................................................................................................................................................................... 21
8Troubleshooting .......................................................................................................................................................................... 23
8-1 Note in Repairing ............................................................................................................................................................... 23
8-2 Test for recognizing the short-circuit of FET (Field Effect Transistor) on controller ......................................................... 23
8-3 Flowchart of Troubleshooting............................................................................................................................................ 24
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2CAUTION
Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Follow the instructions described below in advance before repairing:
· Wear gloves.
· Remove the recipro saw blade from the unit.
· In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what are the parts.
It is also recommended to have boxes ready to keep disassembled parts by group.
· Handle the disassembled parts carefully. Clean and wash them properly.
· If some bolts and screws are too tight, use an impact driver.
· Tighten the bolts and the screws to the specified torque.
3NECESSARY REPAIRING TOOLS
Code No.
Description
Use for
1R269
Bearing extractor
removing Ball bearings
1R291
Retaining ring S and R pliers
removing Retaining ring S-12
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4LUBRICANT AND ADHESIVE APPLICATION
Apply the following lubricants and adhesives.
Item No.
Description
Portion to lubricate
Lubricant
Amount
16
Slider
Outer circumference
Makita grease
FANo.2
a little
17
Roller
Inner surface
-
Gear shaft
Outer circumference
27 Flat washer 4
Side surface that contacts Needle bearing
1012 of Gear complete
28
Gear complete
Gear portion
14g
29
Flat washer 54
Both side surfaces (front and back)
a little
32 Rod guide L
(a) Side surfaces that contact Roller
(b) Bottom surface that contacts Roller
1g
39
Gear housing L
Around Slider
5g
Fig. 4-1
Gear complete
Flat washer 54
(a) Rod guide L
Gear shaft
Roller
(b) Rod guide L
Gear housing L
Gear housing L
Slider
Flat washer 4
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Item No.
Description
Portion to lubricate
Lubricant
Amount
4
Shoulder pin 5
Head point
Makita grease
FANo.2
a little
5
Compression spring 6
Outer circumference
8
Pin 3
Outer circumference
15
Slider guide complete
Inner circumference (both sides)
18
Pin 6
Outer circumference
19
Roller
Inner circumference
22 Rod guide R
(a) Side surfaces that contact Roller
(b) Bottom surface
1g
23
Gear housing R
Around Slider
5g
69
Felt 16x16
Whole surface
Lubricant VG100
a little
14
Rubber ring
Between Rubber ring and Seal ring ThreeBond 1215
30
Seal ring
Gear housing R
(b) Rod guide R
(a) Rod guide R
Roller
Pin 6
Slider guide complete
Pin 3
Shoulder pin 5
Compression
spring 6
Felt 16x16
Seal ring
Rubber ring
Fig. 4-2
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5REPAIR
5-1 Insulation cover
5-1-1 Disassembling
5-1-1-1 For DJR187, DJR360
5-1-1-2 For DJR186
[2] Pull out Insulation cover. (Fig. 5-1-1-1-3, Fig. 5-1-1-1-4, Fig. 5-1-1-1-5)
Fig. 5-1-1-1-1
[1] Pull Lock lever.
Fig. 5-1-1-1-2
[2] Pull out Shoe.
[3] Remove Lock lever, and remove Lock pin.
Lock lever
Shoe
Lock pin
Lock lever
Fig. 5-1-1-1-3
[4] Pull and slide Insulation cover
forward.
Fig. 5-1-1-1-5
[6] Pull out Insulation cover.
Insulation cover
Fig. 5-1-1-1-4
[5] Pour soapy water between Gear
housing assembly and Insulation
cover.
Insulation cover
Fig. 5-1-1-2-1
[1] Loosen M6x14 Hex socket head bolt, and remove Shoe.
Shoe
M6x14 Hex
socket head bolt
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5-1-2 Assembling
5-2 Slider assembly
5-2-1 Disassembling
[1] Pull out Shoe. (Refer to 5-1 Insulation cover.)
Fig. 5-1-2-1
Apply soapy water onto the inner circumference of Insulation cover, and mount Insulation cover to Gear housing assembly by
thrusting it.
Note: Apply Loctite 272 on M6x14 Hex socket head bolt when you use it again. (Fig. 5-1-1-2-1)
Insulation cover
Gear housing
assembly
Fig. 5-2-1-1
[2] Remove Protector.
Fig. 5-2-1-2
[3] Insert a slotted screwdriver from the end of Retaining
ring 18, then pry it off.
Protector
Slotted
screwdriver
Retaining
ring 18
Fig. 5-2-1-3
[4] Remove Driving sleeve guide, Guide sleeve, Pin 3, Shoulder pin 5, Compression spring 6 and Driving sleeve.
Note: Be sure not to lose Shoulder pin 5 and Compression spring 6.
Driving
sleeve guide
Shoulder pin 5
Compression
spring 6
Driving sleeve
Guide sleeve
Pin 3
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Fig. 5-2-1-4
[5] Twist Sleeve while pulling it up toward the blade install
side to set it in release position.
Fig. 5-2-1-5
[6] While holding the top of Slider by finger, push out Pin 3
with a thin bar.
Note: Without holding Slider, Push plate will pop out from
the slit of Slider.
Sleeve
Pull
Sleeve in Lock
position
Sleeve in release
position
Pin 3
Slider
Pull out
Fig. 5-2-1-6
[7] Remove Sleeve, Push plate, Compression spring 2 and Torsion spring 17. (Compression spring 2 is in the groove on Slider.)
Groove on
Slider
Torsion spring 17
Compression spring 2
Push plate
Sleeve
Fig. 5-2-1-7
[8] The components of Slider assembly are as follows:
Compression spring 2
Torsion
spring 17
Pin 3
Sleeve
Shoulder pin 5
Compression
spring 6
Driving sleeve
Retaining ring (EXT) 18
Protector
Pin 3
Guide sleeve
Driving
sleeve guide
Push plate
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5-2-2 Assembling
Fig. 5-2-2-1
[1] Assemble Torsion spring 17 to
Sleeve by inserting its short tail into
the hole of Sleeve.
Fig. 5-2-2-2
[2] Set Sleeve by passing the long tail of Torsion spring 17 through the slit of
Slider.
Fig. 5-2-2-4
[4] Mount Guide sleeve temporarily, then Put Compression
spring 2 and Push plate into the slit of Slider.
Hole where
Pin 3 is
installed
Note: Face the short tail of Torsion spring 17
to the hole where Pin 3 is installed.
Sleeve
Short tail of
Torsion spring 17
Long tail of
Torsion spring 17
Fig. 5-2-2-3
[3] Turn Sleeve clockwise and insert Pin 3 into the hole
temporarily as shown below.
Sleeve
Pin 3
Compression spring 2
Guide sleeve
Push plate
Fig. 5-2-2-5
[5] While pushing Push plate straight into Slider with Recipro sawblade, insert pin 3 through the hole of Push plate as shown
below. Then remove Guide sleeve.
Note: Guide sleeve is used as a jig. Do not assemble it to Slider in this step.
Recipro saw
blade
Guide sleeve
Pin 3
Hole of Push
plate
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Fig. 5-2-2-6
[6] Remove Guide sleeve.
Fig. 5-2-2-7
[7] Set Driving sleeve to Sleeve while fitting its two projections to
the two concaves of Sleeve.
Guide sleeve
Fig. 5-2-2-8
[8] While push Driving sleeve into Gear housing, turn the sleeve clockwise to lock Pin 3 in place. Then, remove Driving sleeve.
Viewed from the bottom
Driving sleeve
Projections
Concaves of
Sleeve
Pin 3
Sleeve
Driving sleeve
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