IQ Power Tools iQTS244 Repair Manual

IQ Power Tools iQTS244 Repair Manual

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Table Louver and Vacuum Suction Clearance Check and Adjustment
888-274-7744
www.iqpowertools.com
iQ Power Tools
Repair Manual
iQTS244

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iQTS244
Repair Manual

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Summary of Contents for IQ Power Tools iQTS244

  • Page 1: Table Of Contents

    Power Tools Repair Manual iQTS244 Table of Contents IQTS244 DISASSEMBLY Blade Removal Blade Guard Removal and Disassembly Blade Guard Dust Seal Removal Laser Assembly Removal Blade Shaft Assembly Removal Control Module Removal and Disassembly (Early Version) Control Module Removal and Disassembly (Newer Version)
  • Page 3: Iqts244 Disassembly

    QTS244 DISASSEMBLY Blade Removal Loosen the locking Knob Pull the Lock Pin Knob Raise the Gear Housing 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 4 Lift the Dust Guard Lift the Dust Guard Quick Set so the Dust Guard may be removed With the Dust Guard Quick Set in the UP position, lower the Dust Guard and Remove 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 5 Loosen the Outer Blade Guard locking knob Lift the Outer Guard up to expose the tile blade Depress the Spindle Lock Button and engage the Spindle Lock 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 6 10. loosen hex nut using the wrench provided. 11. Remove the blade hex nut and outer blade flange and the blade. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 7: Blade Guard Removal And Disassembly

    Blade Guard Removal and Disassembly 1. Loosen and remove the Outer Blade Guard retaining screw 2. Remove the outer blade guard cover 3. Remove the Control Module Cover retaining screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 8 4. Lift the Control Module Cover to expose the Printed Circuit Board 5. Disconnect the Laser connection 6. Remove the Inner Dust Guard retaining screws and remove the Inner Dust Guard 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 9: Blade Guard Dust Seal Removal

    NOTE: The Dust Seal Plates are specific to the Inner and Outer Blade Guards and are NOT interchangeable 1. Remove the Dust Seal Plate retaining screws 2. Lift and remove the Dust Seal Plate 3. Lift and remove the Dust Seal 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 10 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 11: Laser Assembly Removal

    Laser Assembly Removal 1. Remove the Laser Assembly retaining screw 2. The Laser Assembly can be pulled out of the wire channel 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 12 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 13: Blade Shaft Assembly Removal

    Remove the Spindle Lock, button and compression spring Remove the blade shaft assembly retaining screws Using a flat screwdriver of a small pry bar, carefully separate the Blade Shaft Assembly from the Gear Housing Assembly 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 14 Remove the Blade Shaft Assembly Check the needle bearing for completeness If required, remove the needle bearing using inner bearing puller and slide hammer tool 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 15: Control Module Removal And Disassembly (Early Version)

    2. Disconnect all the electrical wire connection from the Printed Circuit Board and remove the Printed Circuit Board hold down screw and remove the Printed Circuit Board from the Control Module 3. Remove the Vacuum Power Cord Clamp 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 16 4. Remove the Main Handle top retaining screws 5. Remove the Main Handle Bottom retaining screws 6. Lift the Main Handle Top up and away from the Main Handle Bottom. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 17 7. Disconnect all the electrical connection from the switches 8. Route the wire through the Main Handle channel 9. Continue routing the electrical wires through the Control Module channel and remove 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 18 10. Remove the Control Module Base retaining screws 11. Route the saw motor, main power and vacuum power cords through the opening at the base of the Control Module and remove the Control Module base 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 19: Control Module Removal And Disassembly (Newer Version)

    Printed Circuit Board 2. Disconnect all the electrical wire connection from the On/Off Switch and to access the Printed Circuit Board (PCB) 3. Disconnect the wires from the Printed Circuit Board 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 20 4. Remove the Printed Circuit Board retaining screw 5. Remove the Printed Circuit Board 6. Remove the Control Module Base retaining Screw 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 21 7. Remove the Ground retaining screw 8. Lift the Control Module Base UP and away from the Gear Housing 9. Route the Saw Motor electrical wires thru the Control Module base 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 22 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 23: Saw Motor Removal And Disassembly

    Saw Motor Removal and Disassembly Remove the Saw Motor Brush Cover Remove the Saw Motor Brush Remove the Saw Motor retaining Screws (There is a total of 4, 1 at each corner) 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 24 Pull the Saw Motor Cover and Stator away form the gear housing Remove the Armature from the Gear Housing 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 25: Saw Motor Stator Disassembly

    Remove the armature NOTE: if the armature is still with the stator, Tapping the case against a surface may be required to free the armature from the stator Disconnect saw motor brush connectors 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 26 Loosen and remove the saw motor stator retaining screws Remove the saw motor stator NOTE: Tapping the case against a surface may be required to free the stator from the motor case 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 27: Gear Housing Removal And Disassembly

    Gear Housing Removal and Disassembly Route the Main and Vacuum power cords through the opening in the Gear Housing Loosen and remove the Gear Housing Locking Knob Allow the Gear Housing to open fully 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 28 Remove the Pivot Shaft Mount front retaining screws Remove the Pivot Shaft Mount Rear retaining screws Remove the Gear Housing and Pivot Shaft Mount from the Support Arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 29 Lay the Gear Housing and Pivot Shaft Mount on its side on a workbench and using a punch and a soft mallet, Tap the Pivot Shaft out Remove the Torsion Spring from the Gear Housing 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 30 10. Remove the Pivot Shaft 11. Separate the Gear Housing from the Pivot Shaft Mount 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 31: Support Arm Removal And Disassembly

    Support Arm Removal and Disassembly Disconnect the Vacuum Power Cord Remove the Support Arm retaining Screws Remove the Support Arm from the Table 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 32 Remove the Support Arm upper Cord Clamp Remove the Support Arm lower Cord Clamp Remove the Support Arm Vacuum and Main Power Cord Clamps at the base of the Support Arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 33 Using strain relief pliers, remove the Main Power cord strain relief Using strain relief pliers, remove the Vacuum Power cord strain relief Route the Main and Vacuum Power cord through the Cord Ring at the base of the Support Arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 34 10. Remove the Cord Ring at the base of the Support Arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 35: Vacuum Inlet Removal

    Vacuum Inlet Removal Unlock the Sliding Table Remove the Sliding Table to gain access to the vacuum inlet Loosen the jamb nut while holding the Allen screw secure 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 36 Unscrew both front and rear allen screws to remove the vacuum inlet suction. Remove the jamb nut from the adjustment screw. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 37: Vacuum Motor Removal

    Vacuum Motor Removal 1. Unplug the vacuum power cord 2. Remove the vacuum retaining screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 38 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 39: Vacuum Brushes Removal (Early Version)

    Vacuum Brushes Removal (Early Version) Remove the brush end caps Remove the carbon brushes 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 40 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 41: Vacuum Brushes Removal (New Version)

    Vacuum Brushes Removal (New Version) Remove vacuum motor end cap. Lift the brush holders up to gain access to the brushes. Remove the brushes from the brush holders. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 42 Disconnect the brushes and replace. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 43: Filter Removal

    Filter Removal Spin the filter knob counterclockwise to loosen Remove the filter knob Remove the filter cover retaining screws and remove the cover 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 44 Remove the filter Remove the Filter tab 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 45: Iqts244 Assembly

    Vacuum Filter Installation Apply lubricant and Insert filter in the filter housing. Ensure it is aligned with the vacuum suction tube and seat firmly. Install cover and secure with cover retaining screws. Install filter knob. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 46 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 47: Vacuum Suction Installation

    2. Install the vacuum suction on the vacuum. 3. Adjust vacuum suction and rolling table clearance to 1/32” and tighten jamb nut once achieved 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 48 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 49: Vacuum Motor Brushes Installation (Early Version)

    Vacuum Motor Brushes Installation (Early Version) Insert the carbon brush in the brush holder Install brush covers 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 50 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 51: Vacuum Brushes Installation (New Version)

    Vacuum Brushes Installation (New Version) Connect the vacuum brush to the connectors and insert into the vacuum brush holders. Lower the brush holders up to secure the brushes in place. Install the vacuum end cover 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 52 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 53: Vacuum Motor Installation

    Vacuum Motor Installation 1. Mount and align the vacuum and install the vacuum retaining screws 2. Route and secure the vacuum power cord on to the table arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 54 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 55: Support Arm Assembly And Installation

    Install the Cord Ring at the base of the Support Arm Route the Main and Vacuum Power cord through the Cord Ring at the base of the Support Arm Using strain relief pliers, install the Vacuum Power cord strain relief 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 56 Using strain relief pliers, install the Main Power cord strain relief Install the Support Arm Vacuum and Main Power Cord Clamps at the base of the Support Arm Install the Support Arm lower Cord Clamp 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 57 Install the Support Arm upper Cord Clamp Install the Support Arm from the Table Secure the Support Arm to the table with the retaining Screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 58 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 59: Pivot Shaft Mount And Gear Housing Assembly

    Pivot Shaft Mount and Gear Housing Assembly Insert the Gear Housing into the Pivot Shaft Mount Slide the Pivot Shaft partially, allowing the installation of the torsion spring install the Torsion Spring into the Gear Housing 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 60 Mount on its side on a workbench and using a punch and a soft mallet, Tap the Pivot Shaft into place Tighten the set Pivot Mount Shaft Set Screw Mount the Gear Housing and Pivot Shaft Mount from the Support Arm 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 61 Install the Pivot Shaft Mount Rear retaining screws Install the Pivot Shaft Mount front retaining screws Route the vacuum power cord thru the rear opening on the top of the support 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 62 10. Route the main power cord thru the front opening on the top of the support 11. Lower the Gear housing and install the Gear Housing Locking Knob 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 63: Saw Motor Armature Installation

    Saw Motor Armature Installation Apply general purpose grease on the armature output shaft end 2. Insert the armature into the coupling opening on the support 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 64 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 65: Saw Motor Stator Installation

    Saw Motor Stator Installation Carefully slide the saw motor stator into the saw motor housing Secure the stator to the saw motor housing with the retaining screws Route the conductors through the saw motor housing assembly 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 66 Slide the motor over the armature so its flush against the support arm Secure the saw motor housing assembly on to the gear housing with screws on all corners Install the saw motor brushes 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 67 Install motor brush end cap and tighten. DO NOT OVER TIGHTEN 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 68 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 69: Control Module Installation (Early Version)

    Control Module and remove the Control Module base Secure the Control Module Base using the retaining screws Continue routing the electrical wires through the Control Module channel 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 70 Route the wire through the Main Handle channel Connect all the electrical connection on to the switches Lower the Main Handle Top down on to the Main Handle Bottom. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 71 Install the Main Handle Bottom retaining screws Install the Main Handle top retaining screws Install the Vacuum Power Cord Clamp 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 72 10. Install the Circuit Board and connect all electrical connections using the correct electrical diagram. 11. Connect all connections on to the On/Off Switch 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 73: Control Module Installation (Newer Version)

    1. Route the saw motor, main and vacuum power cords through the opening at the base of the Control Module and remove the Control Module base 2. Secure the Control Module Base using the retaining screws 3. Install the Ground wires 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 74 5. Make the electrical connection on the Printed Circuit Board 6. Make the electrical connections on the On/Off switch 7. Install the Module Cover and secure with retaining screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 75: Blade Shaft (Arbor) Assembly Installation

    Blade Shaft (Arbor) Assembly Installation Insert Lock Guide Apply Multi-Purpose Lithium grease in the gear cavities Install the Blade Shaft Assembly in the Gear Housing 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 76 Install the Spindle Lock, button and compression spring Remove the blade shaft assembly retaining screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 77: Blade Guard Assembly And Installation

    Blade Guard Assembly and Installation 1. Route the laser wire in the channel and seal with silicon 2. Place the laser assembly in the space provided in the inner blade guard and secure loosely with the retaining screw. . 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 78 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 79: Blade Guard Dust Seal Installation

    Place the rubber dust seal on inner dust guard. Repeat for the outer Blade Guard Place the seal plate on top of the rubber dust seal and secure with retaining screws. Repeat for the outer Blade Guard 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 80 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 81: Blade Guard Installation

    Blade Guard Installation 1. Attach the inner dust guard on to the support arm with retaining screw Connect the Laser connection Secure Control Module Cover with retaining screws 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 82 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 83: Blade Installation

    Blade Installation Install the blade Install the hex nut and tighten using the wrench provided. Depress the Spindle Lock Button and engage the Spindle Lock to prevent the blade from rotating freely 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 84 Install the Outer Guard up to expose the tile blade Lower the Outer Blade Guard and tighten the locking knob 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 85: Iqts244 Adjustments

    Sliding Table Lower and Upper Rollers Adjustments Remove the sliding table from the track and lay it on the stand with the rollers facing up Clean the rolling table wheels with Scotch Brite Clean the table track with Scotch Brite 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 86 Wipe the table track with a lightly damp cloth Insert the sliding table back into the stand Check the table for stability by depressing all four (4) corners 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 87 Push the sliding table to the forward mechanical stops Depress the area still supported by the table track to check for wobble Pull the sliding table back to the table stop 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 88 (3) lower guide rollers and moving the straight edge back and forth. Verify all three (3) lower guide rollers rotate simultaneously 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 89 Verify all three (3) lower guide rollers rotate simultaneously. Repeat previous step until satisfied 17. Flip the rolling table so the front (POINTY END) of the table is now on the left side 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 90 20. Adjust each lower roller so the lower guide roller is at its lowest position when the table is installed in the saw stand 21. Verify all three (3) lower guide rollers are on the same plane. Repeat previous step until satisfied 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 91 REPEAT for ALL Six (6) sliding table upper rollers 24. Push the sliding table forward to the mechanical stop and check adjustment by depressing rear section of the table. Play should be very minimal 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 92 Play should be very minimal 26. Remove the table and tighten all six (6) upper guide wheels, making sure the eccentric stays in the same position 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 93: Sliding Table Travel Check And Adjustment

    If NO Adjustments are required, GOTO Pivot Arm Squareness Check Loosen all six retaining screws that secure the rail to the stand Insert the short arm of a square into the gap between the stand and the sliding table 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 94 Tighten the inner most retaining screws for the rail to the stand starting with the retaining screw just behind the vacuum motor Then tighten the screw just in front of the vacuum motor 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 95 7. Then tighten the screw just behind the first screw tightened Then tighten the screw in front of the second crew tightened Push the sliding table forward so the front lower guide wheel is on the edge of the rail guide 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 96 10. Tighten the retaining screw on the front edge 11. Pull the sliding table back so the rear lower guide wheel is on the edge of the rail guide 12. Tighten the retaining screw on the back edge 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 97 13. Re-Check the gap on the left side by rolling the table back and forth 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 98 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 99: Pivot Arm Squareness Check

    Place the inside edge of the long arm of the square against the edge of the saw blade and the outer edge of the short arm of the square along the back fence of the sliding table 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 100 0.4 millimeter. Flip the square so that it is on the Check the gap on the corner of the sliding table fence. The gap should be less than 1/64 inches or .016 inches or 0.4 millimeter. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 101 7. Verify the blade has proper clearance on both sides of the channel 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 102 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 103 Adjust so that gap between table and vacuum suction is about 1/32 inch or .03125 inch or .79375 millimeter It should appear as though the sliding table and the vacuum suction are touching 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 104 1/32” Push and pull the sliding table back and fourth to check for smoothness. Make necessary adjustments Tighten final setting on both screws by holding the set jamb nut and tightening the set screw. 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 105: Laser Check And Adjustments

    Laser Check and Adjustments 1. Turn laser on 2. Verify the laser beam runs along the center of the louvers on the sliding table If the laser is not straight, loosen the laser adjustment locking screw 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 106 Tighten the laser adjustment locking screw If the laser beam is does not fun along the center of the louvers, loosen the retaining screw securing the laser to the inner blade guard 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 107 Adjust the laser left to right as needed to align the laser beam Once the laser beam is at the desired location, tighten the retaining screw 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
  • Page 108 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
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  • Page 110 888-274-7744 iQTS244 www.iqpowertools.com Repair Manual...
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