Makita DUR361U Manual

CONCEPT AND MAIN APPLICATIONS
Specification
Model No. DUR361U, DUR362L
Description Cordless Grass Trimmer
Battery
Specification Model
Handle style
Energy capacity: Wh
Voltage: V
Capacity: Ah
Weight according to
EPTA-Procedure 01/2003*2: kg (lbs)
Cell Li-ion
Charging time (approx.): min. 15x2, 24x2, 22x2, 36x2, 45x2 with DC18RC
36 (18x2)
DUR361U DUR362L
Bike handle Loop handle
Current limiterOverload protection
Yes
YesSoft start
Yes
5.4 (11.9)
5.9 (13.1)*4
5.1 (11.3)*3,
5.6 (12.3)*4
Yes
No load speed*1: min.-1 = rpm
Electric brake
Reversing switch
Variable speed control
Standard cutting tool
3,500 - 7,300 3,500 - 6,600
230mm (9") 4-tooth star blade or
230mm (9") TCT Saw blade 300mm (11-3/4") Nylon cutting head
PRODUCT
P 1/ 16
Models DUR361U and DUR362L are cordless grass trimmers
powered by two 18V Li-ion batteries in series.
Their main features are:
• Battery capacity warning lamp
• XPT (eXtreme Protection Technology)
• Variable speed control by dial
DUR361U is equipped with Off-set Bike handle.
DUR362L is equipped with Loop handle.
Note: 1.3Ah Li-ion battery of BL1815 cannot be used for this model.
1.5, 2.0, 3.0, 4.0, 5.0
27x2, 36x2, 54x2, 72x2, 90x2
*1 No load speed of the cutting tool *2 With Nylon cutting head or 4-tooth star blade
*3 With two BL1815N or two BL1820 batteries *4 With two BL1830, BL1840 or BL1850 batteries
Dimensions: mm (")
Width (W)
*without Cutting tool
Height (H)
Model
Length (L2*)
600 (23-5/8)
1,816 (71-1/2)
DUR361U
458 (18)
286 (11-1/4)
1,840 (72-1/2)
Length (L1) 1,888 (74-1/2) 1,856 (73)
DUR362L
246 (9-11/16)
Standard equipment
Optional accessories
Battery*5Charger*5
Shoulder strap
Hex wrench 4
Safety goggles
Accessory bag
Box driver 13-16
Hex wrench 5
Nylon cutting head
4-tooth star blade (for DUR361U)
Blade cover (Metal blade/TCT Saw blade)
*5 Battery and charger are not supplied with “Z” model.
Note: The standard equipment may vary by country or model variation.
Metal blades (3-tooth blade, 4-tooth blade, 8-tooth blade) Battery BL1815N
TCT Saw blade Battery BL1820
Battery BL1830Plastic blade (cutting width: 260mm)
Battery BL1840
Battery BL1850
Nylon cutting head
Fast charger DC18RC
Nylon cord
Charger DC18SD
Protector set (for Nylon cutting head)
Charger DC24SC
TECHNICAL INFORMATION
DUR361U
L1
L2
W
H
DUR362L
L1
L2
WH
OFFICIAL USE
for ASC & Sales Shop
*3,
Quad Port Charger DC18SF
Automotive charger DC18SE

P 2/ 16
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Repair for off-set bike handle model DUR361U
Note: Regarding loop handle model DUR362L, refer to the data as follows;
DUR362L.pdf
Code No. Description Use for
1R006 Retaining ring R pliers RT-2E removing/ assembling Retaining ring R-24
1R027 Bearing setting pipe 18-10.2 assembling Cutter shaft complete to Gear case
1R031
1R033 Bearing setting plate 10.2
1R130
1R232
1R268
1R269
1R282
1R285
1R291
1R350
Nose 10-30
Pipe 30 holding Helical gear 33 when removing Spindle hub
Spring pin extractor M3 removing Compression spring 4 from Lock off button
Bearing extractor
Round bar for Arbor 8-50
Round bar for Arbor 11-50
Retaining ring S and R pliers
Ring 60
removing Ball bearing 6000DDU
removing Spiral bevel gear 14 from Ball bearing 609ZZ
removing Spindle hub from Helical gear 33
removing Retaining ring R-26 from Gear case
assembling Motor housing
Bearing setting pipe 28-20.2 holding Ball bearing 690ZZ when removing Spiral bevel gear 14
holding Ball bearing 6000ZZ when removing Spindle hub
removing Ball bearing 6901ZZ if it is left in in Gear box
[2] LUBRICATION
26
70
Gear of Armature
Helical gear 33
29
Apply Makita grease N. No.2 to the following portions designated with the black triangle to protect parts and product
from unusual abrasion.
Fig. 1
Item No. Description AmountPortion to lubricate
26
66
70
26 Shaft Spline portion
Gear case assembly Gear room where Gears of Cutter shaft set engages each other
Gear room where Helical gear 33 engages with Armature’s gear
29
Gear box approx. 3 g
approx. 5 g
a little
a littleO ring 22 Whole portion
66

P 3/ 16
Fig. 2
Fig. 3
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Shaft pipe complete
DISASSEMBLING
Hex wrench 4
(1) Remove Clamp washer complete, Blade and Receive washer. (Fig. 2)
(2) Remove Gear case assembly. (Fig. 3)
1. While inserting Hex wrench 4 into the hole of Gear case
assembly to stop Cutter shaft revolving, turn M8 Hex nut
clockwise to remove Blade.
2. Remove Clamp washer complete,
Blade and Receive washer.
Gear case
assembly
M8 Hex nut
Receive
washer
Blade
Clamp washer complete
Protector clamp
Protector
1. Loosen two M5x20 Hex socket head bolts, then unscrew M5x16
Hex socket head bolt, and then remove Protector and Protector clamp.
Note: Because M5x20 Hex socket head bolts with Polypropylene
washers 4 is drop-proofness, it is not necessary to entirely
remove from Protector clamp.
2. Loosen M5x25 Hex socket
head bolt, then pull off Gear
case assembly.
M5x25 Hex socket
head bolt
M5x16 Hex
socket head bolt
M5x20 Hex socket head bolt
with Polypropylene washer 4
Gear case assembly

P 4/ 16
Fig. 4
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Shaft pipe complete (cont.)
DISASSEMBLING
(3) Remove Handle section, and pull off Shaft pipe complete. (Fig. 4)
1. Remove Handle holder by unscrewing
two M5x30 Hex socket head bolts.
2. Unscrew M5x35 Pan head screw,
then pull off Handle complete
from Main grip set.
3. Unscrew five 4x18 Tapping
screws to disassemble Main
grip set.
4. Remove Main grip set (R) from
Main grip set (L).
5. Remove Cord clamp by unscrewing 4x18 Tapping
screw, separate electrical parts (Receptacles, Main
switch, Closed end splice) from Main grip set (L).
Handle holder
M5x30 Hex socket
head bolt (2 pcs.)
M5x35 Pan head screw
4x18 Tapping screw
(5 pcs.)
Main grip set
Handle complete
Main grip set (R)
Main grip set (L)
Cushion
Power supply cord unit
6. Pull out Power supply cord unit through Cushion. 7. Pull off Shaft pipe complete by removing M5x20
Hex socket head bolt and M5x16 Pan head screw.
Note: If it is difficult to remove by hand, pull off
the pipe by gripping it with water pump pliers.
Main grip set (L)
Cord clamp
4x18
Tapping screw
Receptacles
Main Switch
M5x20 Hex socket
head boltM5x16 Pan head screw
Shaft pipe complete
Shaft
Rag to prevent the shaft
from damaging
Water pump pliers

P 5/ 16
Fig. 5
Repair
DISASSEMBLING
ASSEMBLING
(4) Remove Cushion from Shaft pipe complete. (Fig. 5)
(1) Assemble Pipe rubber, Cushion with Hanger to Shaft pipe complete. (Fig. 6)
1. Pull off Pipe rubber, and then loosen
M5x18 Hex socket head bolt.
2. Receive the end of Shaft pipe on wood and tap Cushion
with plastic hammer to remove Cushion and Hanger
from Shaft pipe.
3. After assembling the above parts, adjust their positions as drawn below.
Then, fix Hanger with M5x18 Hex socket head bolt.
M5x18 Hex
socket head bolt
Wood as a
cushion
Hanger
[Motor side]
[Gear case ass’y side] [Gear case ass’y side]
[Motor side]
Pipe rubber
Hanger
Plastic hammer
Cushion
Hanger
Hanger
1. Set Hanger to Cushion.
Cushion
Pipe rubber
103mm
304 ~306mm
447 ~ 457mm
Fig. 6
Cushion
2. Shaft pipe ends have holes.
Install Cushion with Hanger and Pipe rubber to Shaft pipe complete from
Motor section side so that the long pitch between one end and one hole
faces to Cushion.
[Gear case ass’y side][Motor side]
52.5 mm
(Long pitch)
15 mm
(Short pitch)
holes
Hanger
Cushion
Pipe rubber
Shaft pipe complete
[Gear case ass’y side][Motor side]
Handle holder
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Shaft pipe complete (cont.)
M5x18 Hex socket head bolt

P 6/16
Fig. 7
Repair
ASSEMBLING
(4) Assemble Shaft pipe complete to Motor section. (Fig. 7)
1. Pass power supply cord unit through the hole of Cushion on Shaft pipe complete.
M5x20 Hex socket head bolt
M5x16 Pan head screw
Joint of Housing set
2. Assemble Shaft pipe complete to Motor section with M5x16 Pan head screw and M5x20 Hex socket
head bolt while aligning the following parts to the joint of Housing set.
* Slit of screw acceptance of Hanger
* Center groove of Handle holder 2
Slit of Screw acceptance
of Hanger Center groove of Handle holder 2
Shaft pipe complete
power supply cord unit
hole of Cushion
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Shaft pipe complete (cont.)

1R282
1R031
Ball bearing
609ZZ
Spiral bevel
gear 14
Ball bearing
6000DDU
P 7/ 16
Fig. 8
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear case assembly
DISASSEMBLING
(1) Remove Gear case assembly from Shaft pipe complete. (See Figs. 2 and 3)
(2) Remove Spiral bevel gear 14 section and Cutter shaft complete from Gear case assembly. (Fig. 8)
3. Strike Gear case assembly against workbench.
Spiral bevel gear 14 section (Ball bearing 609ZZ,
Ball bearing 609ZZ, Retaining ring EX S-9) are
removed from Gear case assembly.
Note: If Spiral bevel gear 14 section can not be removed
in the way shown below, heat Gear case assembly
with a heat gun or like. And then, strike Gear case
assembly against workbench.
4. Remove Retaining ring (EX) S-9 from
the shaft of Spiral bevel gear 14.
And separate Spiral bevel gear 14 from
Ball bearing 609ZZ using 1R031, 1R282
and arbor press.
1. Remove M6x8 +Hex bolt, then remove Guard
by unscrewing two M5x12 Pan head screws.
Note: Without removing M6x8 +Hex bolt, Spiral bevel gear 14
cannot be separated from Gear case assembly.
M6x8 +Hex bolt
Guard
M5x12 Pan head screw
Retaining ring R-24
Retaining ring
(EX) S-9
Guard
2. Remove Retaining ring R-24 using 1R006.
Spiral bevel
gear 14 section
5. Remove Retaining ring
R-26 with 1R291.
6. Heat Gear case assembly with a heat gun or like.
Then, remove Cutter shaft complete and Ball
bearing 6000DDU by tapping the edge of
the gear case with a plastic hammer.
Retaining ring R-26
Cutter shaft
complete
Cutter shaft
complete
Plastic
hammer
7. Remove Ball bearing
6000DDU from Cutter
shaft with 1R269.

(1) Assemble Ball bearing 6000DDU to Cutter shaft complete. (Refer to the bottom right drawing in Fig. 8.)
(2) Assemble Cutter shaft complete to Gear case. (Fig. 9)
P 8/ 16
Fig. 9
Repair
ASSEMBLING
1. Receive Gear case assembly with the U-shape table of Arbor press,
then press down Ball bearing 6201DDU with 1R027 to set Cutter
shaft complete in place.
1R027
Gear case
assembly
Cutters shaft
complete
2. Secure Cutter shaft complete
with Retaining ring R-26.
U-shape table of
Arbor press
Ball bearing
6201DDU Retaining ring R-26
(3) Assemble further step by reversing the disassembly procedure. (Refer to Fig. 8)
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear case assembly (cont.)

(1) Remove the Blade and Pipe shaft complete. (Figs. 2 and 4)
(2) Disassemble Helical gear 33 and Spindle hub. (Fig. 10)
P 9/ 16
Fig. 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] - 3. Helical gear 33, Spindle hub
DISASSEMBLING
1. Disassemble Gear box cover by unscrewing
two M5x20 Pan head screws.
2. Disassemble Pipe bracket by unscrewing
four M5x20 Pan head screws.
Spindle
hub
Ball bearing
6001ZZ
Ball bearing
6901ZZ
Ball bearing
6901ZZ
Helical
gear 33
Helical gear 33
3. Remove Spindle hub, Helical gear 33, Ball bearing 6001ZZ and Ball bearing 6901Z.
Note: If Ball bearing 6901ZZ is left in Gear box, set 1R130 temporarily into the hole of the bearing and tap
the edge of Gear box with a plastic hammer while tilting and pulling 1R130 slightly by fingers.
Ball
bearing
6901ZZ
1R130
Tilt and pull 1R130 slightly
by fingers.
(3) Remove Helical gear 33 from Spindle hub. (Fig. 11)
1R285
1. Receiving Helical gear 33 on 1R232,
press down the end of Spindle hub
with 1R285 to remove Ball bearing
6901ZZ, Flat washer 12 and Helical
gear 33 from Spindle hub.
2. Receiving Ball bearing 6001ZZ on 1R036, press the end of Spindle hub
with 1R285 to remove Ball bearing 6001ZZ and another Flat washer 12
from Spindle hub.
3. Remove O ring 6 from the shaft
connecting hole of Spindle hub.
1R232
Spindle hub Flat washer 12
Helical
gear 33
Ball bearing 6901ZZ
Ball bearing 6001ZZ
Flat washer 12
1R285
Spindle hub
Spindle hub
Spindle hub
O ring 6
Fig. 11
Gear box cover
Gear box cover
Pipe bracket
1R036
Tap Gear box with
a plastic hammer.
M5x20 Pan
head screw
(2 pcs.)
M5x20 Pan
head screw
(4 pcs.)

Assemble Helical gear 33 to Spindle hub by reversing the disassembly procedure. (Refer to Figs. 11 and 10)
Note: • Refer to Fig. 12 for the positions of the components of Helical gear 33 section.
• Do not fail to set O-ring 6 and two Flat washers 12 in place.
P 10/ 16
Fig. 12
Repair
ASSEMBLING
DISASSEMBLING
1. Unscrew three + M4x12 screws and
remove Battery guard.
2. Unscrew four 5x25 Tapping screws from Gear box.
Then unscrew five 4x18 Tapping screws to remove
Housing (R).
3. Disconnect the connector of Stator from
that of Controller. then, separate Motor
housing together with Gear box from
Housing (L).
4. Unscrew four 4x18 Tapping screws, and then
remove Motor housing from Gear box.
Fig. 13
Spindle hub
O ring 6
Ball bearing 6001ZZ
Helical gear 33
Flat washer 12
Flat washer 12
Ball bearing 6901ZZ
[3] - 4. Rotor, Stator
(1) Remove the Blade and Pipe shaft complete. (Figs. 2 and 4)
(2) Disassemble Gear box cover, Pipe bracket and Spindle hub section. (Fig. 10)
(3) Disassemble Motor section from Housing (L). (Fig. 13)
Battery guard
Gear box
4x18 Tapping
screw (5pcs.)
Housing (R)
Housing (L)
Gear box
Motor housing
5x25 Tapping
screw (4pcs.)
4x18 Tapping
screw (4pcs.)
Connector of
Stator
Connector of
Controller
[3] DISASSEMBLY/ASSEMBLY
[3] - 3. Helical gear 33, Spindle hub (cont.)
+ M4x12 screw (3 pcs.)

(4) Disassemble Rotor and Stator from the Motor section. (Fig. 14)
P 11/ 16
Fig. 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] - 4. Rotor, Stator (cont.)
1. Unscrew three 4x18 Tapping screws, then remove
Motor housing (R). And then, separate Stator and
Rotor from Motor housing (L).
DISASSEMBLING
Motor
housing (R)
Motor
housing (L)
Stator
Rotor
2. Push the shaft end of Rotor against workbench
and slide Stator toward workbench.
Then pull out Rotor from Stator.
Caution for Handling of Rotor
Stator
Rotor
When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 15
because Rotor is a strong magnet, failure to follow this instruction could result in:
• Finger injury caused by pinching between Rotors pulling each other
• Magnetic loss of Rotors or damage on the magnet portion of Rotor. See Fig. 16.
Fig. 16Fig. 15
* Magnetic loss of Rotors
* Damage on the magnet
portion of Rotor
enough
distance

P 12/ 16
Repair
ASSEMBLING
Two halves of Motor housing set are difficult to meet
their mating surfaces.
Therefore, put them on 1R350 to align the four holes
surfaces with Gear box contact portions.
And tighten three 4x18 Tapping screws for assembling
Motor housing (R) to Motor housing (L).
(1) Pass Rotor into Stator as drawn in Fig. 17.
(2) Assemble Rotor and Stator to Motor housing (L).
(3) Assemble Motor housing (R) to Motor housing (L). (Fig. 18)
1. Holding Stator complete on workbench, slowly insert Rotor
in Stator complete until small ball bearing end reaches workbench.
2. When the drive end of Rotor
reaches workbench, lift up
Stator complete slowly.
small ball
bearing
Fig. 17
Fig. 18
[3] DISASSEMBLY/ASSEMBLY
[3] - 4. Rotor, Stator (cont.)
Four holes surfaces of
Motor housing set for
setting Gear box in place 1R350
4x18 Tapping
screw (3pcs.)

P 13/ 16
Fig. D-1
Circuit diagram
White
Orange
Blue Brown
Controller
Terminal A
Terminal B
Power supply
cord unit
Battery capacity
warning lamp
Adapter circuit
complete
Printed wiring
board of Stator
Fuse
Fuse is not used
for some countries.
Sub Controller
Reverse
switch
Trigger
switch
Yellow
Color index of lead wires' sheath
Black
Red
Gray Green
Connector
Speed control dial
Connector
Connector
Connector
Power switch

Power supply cord unit
Controller
P 14/ 16
Fig. D-2
Wiring diagram
Put Fuse here,
if it is used.
Sub Controller
Wiring in Housing (L) before setting Terminals and Adapter circuit complete
Power supply cord unit
Controller
Rib D Cord clamp Tube
Rib B
Rib A
Rib C
Fuse 9-Pin connector
9-Pin connector
10-Pin connector
3-Pin connector to connect
with Power supply cord unit
3-Pin connector to connect
with Power supply cord unit
3-Pin connector to connect
with Adapter circuit complete
Put Controller’s lead wires
connected to 9-Pin connector
between Rib B and Rib C.
Put the following Controller’s lead wires between Controller and Rib A.
* Lead wires to Stator
* Lead wires to Power supply cord unit
Connect 9-Pin connector of
Controller to that of Stator, then
put them on 3-Pin connector
of Power supply cord unit.
Aligning the end of Power supply cord to Rib D,
fix the cord with Cord clamp.
Note: Be careful not to clamp Tube with Cord clamp.

P 15/ 16
Wiring diagram
Wiring in Housing (L) with Terminals and Adapter circuit complete
Wiring to Terminals
Power supply cord unit
Controller
Rib J
Rib H
Terminal A
Set Flag connectors to Terminals A and B as shown below.
Flag connector
Flag connector
Rib G
Rib F
Rib E Rib A
Terminal A
Pass Adapter circuit complete’s
lead wires between Housing (L)
and Adapter circuit complete.
Put Adapter circuit complete’s
lead wires connected to Terminal A
between Ribs E and F.
Put Adapter circuit complete’s
lead wires connected to Terminal B
between Ribs G and H.
Terminal B
Rib I
Adapter circuit complete
Fig. D-3
Fig. D-4
Terminal B
Put Adapter circuit complete’s lead wires connected
to 3-Pin connector between Ribs I and J.
3-Pin connector of
Adapter circuit complete
Lead wires of Adapter circuit complete have to be
put between Rib A and Adapter circuit complete.
Note: Be careful not to put them onto Rib A.

P 16/ 16
Wiring diagram
Wiring of Power supply cord unit in Main grip set
Wiring to reverse switch
Fig. D-5
Cord clamp
Tube
Rib
Trigger switch
Receptacle
(with Receptacle sleeve)
Receptacle
Connect Receptacles to Reverse switch
as shown below.
Reverse switch
Reverse switch
Pin
Power supply cord unit
Be careful not to clamp
Tube with Cord clamp.
Lead wires of Reverse
switch have to be put
under Trigger switch.
Lead wires of Power supply cord unit
with Closed end splices have to be put
between Pin and Rib.
Note: The other wires can also be put
between Pin and Rib.