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IQ Power Tools iQ360XR Repair Manual

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IQ360XR DISASSEMBLY ................................................................................................................................................................................ 3
Filter Removal ......................................................................................................................................................................................... 3
Blade Removal ........................................................................................................................................................................................ 5
Blade Guard Removal .......................................................................................................................................................................... 8
Blade Shaft Assembly Removal ....................................................................................................................................................... 9
Control Module Disassembly ......................................................................................................................................................... 11
Saw Motor Removal........................................................................................................................................................................... 15
Saw Motor Stator Disassembly ..................................................................................................................................................... 17
Saw Motor Armature Removal ..................................................................................................................................................... 20
Support Arm Disassembly and Removal .................................................................................................................................. 21
Pivot Shaft Disassembly and Removal ...................................................................................................................................... 26
Vacuum Motor Disassembly and Removal .............................................................................................................................. 29
Vacuum Brushes Removal .............................................................................................................................................................. 30
IQ360XR ASSEMBLY .................................................................................................................................................................................... 32
Vacuum Brushes Installation ........................................................................................................................................................ 32
Vacuum Motor Installation ............................................................................................................................................................. 34
Pivot Arm Assembly and Installation ........................................................................................................................................ 37
Saw Mount and Gear Housing Assembly .................................................................................................................................. 40
Saw Armature Installation.............................................................................................................................................................. 47
Saw Stator Assembly and Installation ....................................................................................................................................... 48
Control Module Assembly and Installation ............................................................................................................................. 51
Arbor Installation ............................................................................................................................................................................... 53
Blade Guard Installation .................................................................................................................................................................. 55
Blade Installation ................................................................................................................................................................................ 56
Wiring Diagram 360XR ............................................................................................................................................................................... 58
IQ360X TO IQ360XR CONVERSION GUIDE ........................................................................................................................................ 59
iQ360X Removal .................................................................................................................................................................................. 59
iQ360XR Installation ......................................................................................................................................................................... 64
IQ360 TO IQ360XR CONVERSION GUIDE ........................................................................................................................................... 67
iQ360 Removal .................................................................................................................................................................................... 67
iQ360XR Allen Wrench Holder Installation (OPTIONAL) ................................................................................................ 71
iQ360XR Installation ......................................................................................................................................................................... 73
888 - 274 - 7744
www.iqpowertools.com
iQ Power Tools
Repair Manual
iQ360XR

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iQ360XR
Repair Manual

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Summary of Contents for IQ Power Tools iQ360XR

  • Page 1: Table Of Contents

    IQ360X TO IQ360XR CONVERSION GUIDE ............................59 iQ360X Removal ....................................59 iQ360XR Installation ..................................64 IQ360 TO IQ360XR CONVERSION GUIDE ............................67 iQ360 Removal ....................................67 iQ360XR Allen Wrench Holder Installation (OPTIONAL) ....................71 iQ360XR Installation ..................................73 888 - 274 - 7744 iQ360XR www.iqpowertools.com...
  • Page 2 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 3: Iq360Xr Disassembly

    Q360XR DISASSEMBLY Filter Removal 1. Remove filter cover retaining screws 2. Remove filter knob 3. Remove filter cover 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 4 4. Remove filter 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 5: Blade Removal

    Blade Removal 1. Raise saw arm to ease removal of saw blade 2. Depress blade lock 3. Loosen blade lock nut 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 6 4. Remove blade lock nut and washer 5. Remove outer blade flange 6. Remove blade 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 7 7. Remove inner blade flange 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 8: Blade Guard Removal

    Blade Guard Removal 1. loosen blade guard cover retaining screws 2. remove blade guard cover retaining screws 3. remove blade cover 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 9: Blade Shaft Assembly Removal

    Blade Shaft Assembly Removal 1. remove blade arbor retaining screws 2. Remove the arbor gearbox, be aware of the blade locking device 3. Remove blade locking device 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 10 4. Clean and inspect the arbor gear box housing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 11: Control Module Disassembly

    Control Module Disassembly 1. Remove the control module cover retaining screws 2. Lift top cover 3. Disconnect all wire connections from the circuit board 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 12 4. Remove the circuit board retaining screw 5. Lift and remove the circuit board 6. Disconnect the Main Power connection from the On/Off switch 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 13 7. Separate and remove the control module top cover 8. Remove the control module retaining screws 9. Remove the Main Power Ground wire 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 14 10. Route the saw and vacuum motor wire conductors through the control module base 11. Route the Main Power wire conductors through the control module base 12. Remove the control module base 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 15: Saw Motor Removal

    Saw Motor Removal 1. Remove the saw motor brush covers 2. Remove the saw motor brushes 3. Remove the saw motor case retaining screws from the saw arm 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 16 4. Pull the saw motor cover with the stator directly out. Beware of the armature. The armature may remain attached to the saw support arm 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 17: Saw Motor Stator Disassembly

    Saw Motor Stator Disassembly 1. Remove the saw motor end cover retaining screws 2. Remove the saw motor end cover 3. Disconnect the stator brush connectors from the brush connectors 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 18 4. Route the stator conductors through the saw motor stator case 5. Remove the stator retaining screws 6. Remove the stator from the saw motor case 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 19 7. Check the saw motor case to ensure the armature bearing bushing has been removed 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 20: Saw Motor Armature Removal

    Saw Motor Armature Removal 1. Firmly pull the armature from the support 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 21: Support Arm Disassembly And Removal

    Support Arm Disassembly and Removal 1. Remove the support arm stop from the arm pedestal 2. Unlock the support arm 3. Raise the support arm fully 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 22 4. Loosen and remove the cord clamps 5. Pull the main power and vacuum cords through the support arm holes 6. Lower the support arm 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 23 8. With a pair of strain relief pliers, remove the vacuum cord strain relief with the vacuum cord 9. with a pair of strain relief pliers, remove the main power cord strain relief with the main power cord 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 24 11. remove the support arm locking device retaining screws and remove the locking device 12. gently tap the support arm pivot shaft out. Tap towards the direction of the locking device 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 25 13. Remove the pivot shaft 14. Remove the pivot shaft spring and bushing 15. Separate the support arm from the pivot shaft 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 26: Pivot Shaft Disassembly And Removal

    1. Remove the back panel retaining screws 2. Pull the back panel away from the saw main body to expose the band clamp securing the vacuum output hose 3. Loosen the band clamp 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 27 6. Remove the nut securing the pivot arm to the saw body from the blade chamber 7. Remove the both nuts securing the pivot arm to the saw body in the vacuum chamber 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 28 8. Lift and remove the pivot arm 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 29: Vacuum Motor Disassembly And Removal

    3. Remove and collect all the securing hardware 4. Verify you have 3 sets with: 1 each bolt 1 each rubber bushing 2 each flat washer 1 each plastic spacer 1 each nylock nut 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 30: Vacuum Brushes Removal

    2. Lift the plastic cover from the vacuum 1. With a flat head screw driver, push the brush connector away from the brush housing, towards the center of the vacuum motor 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 31 2. Remove the brush housing retaining screws 3. Lift and remove the brush housing retainers 4. Remove the vacuum motor brush 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 32: Iq360Xr Assembly

    Q360XR A SSEMBLY Vacuum Brushes Installation 1. Install new vacuum brushes 2. Slide brush connector on to the brush socket 3. Place brush retainer over the brush 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 33 4. Tighten brush retainer screws 1. Check brush connection by pushing into the socket with a flat head screw driver 2. Place plastic cover over the vacuum motor 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 34: Vacuum Motor Installation

    Vacuum Motor Installation 1. Slide the vacuum retaining bolts through the saw body 1. Slide the rubber bushing over the bolt 2. Next, slide a flat washer over the bolt 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 35 3. Next, slide the plastic spacer over the bolt 4. Slide the second flat washer over the bolt Ensure to repeat steps 1 – 5 for all 3 vacuum bolts. 5. Install the vacuum in the vacuum housing area 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 36 6. Secure the vacuum with the nylock nut 7. Install the vacuum flex hose and tighten the band clamp 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 37: Pivot Arm Assembly And Installation

    2. With a pair of strain relief pliers, pull the strain relief through the opening provided and ensure it engages 3. Route the vacuum power cord thru the vacuum table 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 38 5. Secure the pivot stand on to the saw table with flat washer and nylock nut on the vacuum chamber side 6. Loosely tighten the nylock nut to allow for final adjustment later 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 39 7. Secure the pivot stand on to the saw table with flat washer and nylock nut on the vacuum filter side 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 40: Saw Mount And Gear Housing Assembly

    2. Start the saw mount shaft by sliding into the saw mount 3. Allow the gear housing to couple with the saw mount but allow space to insert the torsion spring and bushing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 41 7. Tap the gear housing shaft until it is thru 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 42 9. Apply RED Loctite on the gear housing shaft retainer plate locking screws 10. Install the gear housing shaft retainer plate lock screws on to the saw stand 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 43 13. Route the saw motor power cord thru the rear of the gear housing 14. With a pair of strain relief pliers, insert the strain relief with the vacuum power cord into the rear of the gear housing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 44 16. With a pair of strain relief pliers, install the strain relief on the saw power cord and secure on to the rear of the gear housing 17. Unlock the gear housing lock pin 18. Raise gear housing fully 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 45 20. Route the saw power cord thru the top of the gear housing 21. Secure both the saw and vacuum power cord with a plastic clamp on the underside of the gear housing 22. Lower the gear housing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 46 23. Lock the gear housing by engaging the lock pin knob 24. Install the gear housing stop 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 47: Saw Armature Installation

    Saw Armature Installation 1. Lubricate the armature gear housing O-ring and install 2. Firmly insert the armature into the gear housing 3. Install the armature rear bearing bushing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 48: Saw Stator Assembly And Installation

    The winding conductors should line up with the hole provide on the plastic case 2. Secure the stator with the retaining screws 3. Route the stator wires through the opening provided 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 49 5. Install the motor case end cap 1. Secure the motor end cap with retaining screws 2. Slide the stator and plastic motor case over the armature 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 50 3. Secure the motor case and stator with retaining screws 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 51: Control Module Assembly And Installation

    2. Secure the control module base on to the support arm with retaining screws 3. Secure the main power cord ground wire on to the support arm with retaining screw 1. Install the printed circuit board 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 52 3. Make all the proper connections on the printed circuit board and On/Off switch using the correct wiring diagram as a guide 4. Secure the control module cover on to the control module base with retaining screws 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 53: Arbor Installation

    3. Maneuver the arbor gear so the arbor stop and arbor gear slides into the support arm housing 4. Check the arbor stop by rotating the arbor output shaft and depressing the arbor stop push button 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 54 5. Secure the arbor gear onto the support arm housing with retaining screws 6. Tighten the arbor gear retaining screws 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 55: Blade Guard Installation

    Blade Guard Installation 1. Align and slide the blade guard over the arbor 2. Secure the blade guard onto the support arm with retaining screws 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 56: Blade Installation

    Blade Installation 1. Slide the inner flange onto the arbor shaft 2. Check the blade for rotation direction 3. Install the blade, ensure the blade rotation arrow is correct 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 57 4. Install the outer blade flange Insert the outer retaining washer and lock nut Tighten lock nut 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 58: Wiring Diagram 360Xr

    Wiring Diagram 360XR 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 59: Iq360X To Iq360Xr Conversion Guide

    Q360X Q360XR C TO I ONVERSION UIDE iQ360X Removal 1. Remove the blade 2. Remove the backplate retaining screws 3. Loosen the vacuum exhaust hose clamp 4. Remove the backplate 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 60 5. Disconnect the wires from the relay 6. Unplug both power and vacuum quick disconnects 7. Disconnect the ground (Green) wire from the vacuum 8. Disconnect the ground (Green) from the case 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 61 9. Disconnect the ground (Green) wire from the backplate 10. Remove the power cord strain relief from the backplate 11. Route all conductors thru the back plate 12. Remove the relay 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 62 1. Remove the strain relief from located at the base of the stand 2. Remove the divot lock 3. Remove the gear housing stop and raise the gear housing to the fully open position 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 63 4. Tap the gear housing shaft half way out 5. Remove the tension spring and bushing 6. Pull the gear housing shaft all the way 7. Remove the iQ360X gear housing 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 64: Iq360Xr Installation

    Installation 1. Slide the iQ360XR Gear housing onto the stand and insert the gear housing pivot shaft 2. Install the tension spring and bushing and tap the gear housing pivot shaft thru 3. Rotate the gear housing to the down and...
  • Page 65 8. Attach the vacuum exhaust on to the backplate and tighten the hose clamp 9. Install the backplate on to the tub. 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 66 10. Install the blade 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 67: Iq360 To Iq360Xr Conversion Guide

    Q360 Q360XR TO I ONVERSION UIDE iQ360 Removal 1. Remove the blade 2. Remove the backplate retaining screws 3. Loosen the vacuum exhaust hose clamp 4. Remove the backplate 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 68 1. Disconnect the ground (Green) wire from the vacuum 8. Disconnect the ground (Green) from the case 9. Disconnect the wires from the relay 10. Unplug both power and vacuum quick disconnects 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 69 OPTIONAL: Drill out the rivets to remove the relay and current sensor 13. Remove saw mount center nut 14. Remove saw mount side nut 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 70 15. Turn the saw on its side 16. Remove the final saw mount bolt 17. Remove the saw mount and 360 saw motor 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 71: Iq360Xr Allen Wrench Holder Installation (Optional)

    Allen Wrench Holder Installation (OPTIONAL) 1. Place 360XR saw mount in table mount 2. Drill a ½ inch hole on the blade side rear of the saw mount NOTE: Just penetrate the table top to create a starter hole 3.
  • Page 72 5. The finished hole should look like this 6. Place the rubber grommet into the ½ inch hole on the saw mount 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

  • Page 73: Iq360Xr Installation

    Installation 1. Install the saw mount the table and secure the 3 bolts with nylock nuts 2. Slide the iQ360XR Gear housing onto the stand and insert the gear housing pivot shaft 3. Install the tension spring and bushing and tap the gear housing pivot shaft thru 4.
  • Page 74 7. Route the Vacuum power cord into the vacuum chamber 8. Connect the vacuum power cord to the vacuum 9. Insert the rubber plug into the opening previously used for the power cord on the backplate 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...
  • Page 75 10. Attach the vacuum exhaust on to the backplate and tighten the hose clamp 11. Install the backplate on to the tub. 12. Install the blade 888 - 274 - 7744 iQ360XR www.iqpowertools.com Repair Manual...

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