Assembling Cord; How To Find Broken Varistor; Removing Broken Varistor; Assembling New Varistor - Makita DC24SA Technical Information

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epair
<8> Assembling cord
Hold the cord with labyrinth figured lead holder as illustrated in Fig. 8.
<9> In case of damaged varistor or fuse, they can be repaired according to the following procedure without
replacing the circuit board.

(1) How to find broken varistor

a. In case that the surface of varistor (ref. to the following illustration) has broken or has become black, and
fuse has been cut, the varistor has been damaged.
b. Varistor can be damaged easily, if the charger is plugged in a double voltage of the rating one.
c. It is considered that the varistor has been broken for other reasons, if the fuse is broken while the surface
of varistor is not damaged. In this case charging circuit complete has to be replaced.
Circiut board complete

(2)Removing broken varistor

A. Cut the lead wire of varistor at the height
of about 10mm from the surface of urethane resin.
Cut approx. by 10mm
B. Take off lead wire's sheath by 2-3mm
with nipper to expose the core.
Fig. 8
Varistor
Fuse for 120V
Fuse for 220 - 240V
Fig. 9
Fig. 10
2-3mm
Insert about 5mm depth.
Fig. 11
Cord has to be passed through
cord guard.
(3)Assembling new Varistor (See Fig. 12)
a. Cut new varistor's lead wires to 10 mm, and insert
them about 5mm depth between the sheath
and the core.
b. Solder both lead wires, being so careful that they
may not contact with each other.
Approx. 10mm
Fig. 12
P 6 / 8
Solder here.