Makita JR3051T Repair Manual
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Makita JR3051T Repair Manual

Makita JR3051T Repair Manual

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OFFICIAL USE
For ASC
RECIPRO SAW
JR3051T
REPAIR MANUAL
May 2020
Ver.1

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Summary of Contents for Makita JR3051T

  • Page 1 OFFICIAL USE For ASC RECIPRO SAW JR3051T REPAIR MANUAL May 2020 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 TIGHTENING TORQUE SPECIFICATIONS ..........................4 REPAIR ......................................5 Hook section ..................................5 6-1-1 Disassembling ................................5 6-1-2 Assembling .................................. 5 Shoe section ..................................6 6-2-1 Disassembling ................................

  • Page 3: Caution

    CAUTION Repair the machine in accordance with "Instruction manual" or "Safety instructions". Follow the instructions described below in advance before repairing:  Wear gloves.  In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what the parts are. It is also recommended to have boxes ready to keep disassembled parts by group.

  • Page 4: Lubricant And Adhesive Application

    LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease FA. No.2 Apply a little unless specified in the figure. Makita grease R No.00 Apply a little unless specified in the figure. Fig.1 TIGHTENING TORQUE SPECIFICATIONS Tightening torque Q’ty Parts to fasten Fastener (N∙m)

  • Page 5: Repair

    REPAIR Hook section 6-1-1 Disassembling Fig.2 Remove Pan head screws M5x10 [1] (2 pcs), then remove Hook [2] and Square nuts [3] (2 pcs). 6-1-2 Assembling Fig.3 Assemble Square nuts M5 [2] (2 pcs) and Hook [3] to Motor housing [1] with Pan head screws M5x10 [4] (2 pcs).

  • Page 6: Shoe Section

    Shoe section 6-2-1 Disassembling Fig.4 Remove Hex. socket head bolt M6x20 [2] and Flat washer 6 [3] with Hex. wrench 5 [1], then remove Shoe [4]. 6-2-2 Assembling Fig.5 Assemble Shoe [1] with Flat washer 6 [2] and Hex. socket head bolt M6x20 [3]. Note Apply the specified adhesive to the thread of Hex.

  • Page 7: Blade Clamp Section

    Blade clamp section 6-3-1 Disassembling Remove Shoe. (6-2-1) Fig.6 It is easy to disassemble by holding the machine [1] with the tip faced upward with 1R312. 1R312 Fig.7 Plug the cord in the outlet and move Blade clamp section to the most forward position by pulling Switch slightly.
  • Page 8 Fig.9 Insert the blade, then turn Driving sleeve [1] to lock it, and then remove the following parts:  Driving sleeve [1]  Shoulder pin 5 [2]  Compression spring 6 [3]  Push pin [4] Note Be careful not to drop or lose Shoulder pin 5 [2] and [3] [2] Compression spring 6 [3].

  • Page 9: Assembling

    Fig.12 When removing Torsion spring 17 [2] from Slider [1], Compression spring 2 [3] is also come off. Note Be careful not to drop or lose Compression spring 2 [3]. 6-3-2 Assembling Fig.13 Hold the machine with 1R312 with the tip faced upward.
  • Page 10 Fig.15 Assemble Guide sleeve [1], then align the holes, and then insert Pin 3 [2]. Fig.16 Assemble Compression spring 6 [2] to Shoulder pin 5 [1], then insert them into Guide sleeve [3]. Note Apply the specified grease to the outer surface and the head of Shoulder pin 5 [1].
  • Page 11 Fig.18 Hold Slider [1] in 1R049 so as not to lower. Assemble Driving sleeve [2]. Fig.19 While inserting the blade, turn Driving sleeve [1] counterclockwise until it is fully turned. Fig.20 While holding Driving sleeve [1] to turn it counterclockwise all the way, turn Connecting sleeve clockwise with Wrench 22.
  • Page 12 Fig.21 Remove the blade from Slider [1]. Fit Retaining ring (EXT) 18 [2] into the groove of Guide sleeve [3] while rotating it from the end in order. Fig.22 Assemble Protector [1]. Remove 1R049 from Blade clamp section. Tips Check that Driving sleeve is locked by inserting the blade, then check that the blade is pushed out by turning Protector [1] counterclockwise.

  • Page 13: Carbon Brush Section

    Carbon brush section 6-4-1 Disassembling Remove Blade clamp section. (6-3-1) Fig.23 Remove Holder caps [2] (2 pcs) and Carbon brushes [3] (2 pcs) from each side of Motor housing [1]. 6-4-2 Assembling Fig.24 Assemble Carbon brushes [2] (2 pcs) and Holder caps [3] (2 pcs) to each side of Motor housing [1].

  • Page 14: Insulation Cover Section

    Insulation cover section 6-5-1 Disassembling Fig.25 While protecting Handle section [1] with a waste cloth, hold them in Vise. Remove Insulation cover [3] from Gear housing [2]. Tips Insulation cover [3] can be easily removed by spraying parts cleaner between Insulation cover [3] and Gear housing [2].

  • Page 15: Switch/ Motor Section

    Switch/ Motor section 6-6-1 Disassembling Remove Hook, Shoe, Carbon brushes and Insulation cover. (6-1-1, 6-2-1, 6-4-1, 6-5-1) Tips The above disassembly is not necessary if only Switch and Power supply cord are replaced. Fig.27 Remove Tapping screws 4x18 [1] (5 pcs), then remove Handle R [2].
  • Page 16 Fig.30 When removing Lead wires from Switch [1], insert a thin pin through the hole near Switch lead wire insertion port. Attach 1R296 to 1R461, then pull out Lead wire while inserting 1R296 into the hole. Tips If it is hard to insert 1R296 into the bottom, tap 1R461 with a plastic hammer to pierce the hole.
  • Page 17 Fig.33 Remove Baffle plate [1] from Motor housing [2]. Fig.34 Remove Ring terminal [1] with a slotted screwdriver. Fig.35 Remove Tapping screws 5x45 [2] (2 pcs) from Motor housing [1], then tap Motor housing [1] with a plastic hammer to remove Field [3]. Note Do not tap the thin portion of Motor housing [1] because it is fragile.

  • Page 18: Assembling

    6-6-2 Assembling Fig.36 Insert Field [2] straight down into Motor housing [1]. Tips If it is hard and does not fit into the bottom, tap the back of Motor housing [1] with a plastic hammer. Fig.37 Tighten Tapping screws 5x45 [1] (2 pcs). Fig.38 Set Ring terminals [1] (2 pcs) in place with 1R370.
  • Page 19 Fig.39 Assemble Baffle plate [2] to Motor housing [1]. Fig.40 Assemble Gear housing [2] to Motor housing [1]. Tighten Tapping screws 5x25 [3] (4 pcs). Fig.41 Assemble Handle L [2] to Motor housing [1]. 19 / 32...
  • Page 20 Fig.42 Assemble Switch [2] to Handle L [1], then insert Lead wires. Fig.43 Loosen the screws on Switch [1], then insert Lead wires of Power supply cord [2], and then tighten the screws. Fig.44 Hold Power supply cord with Strain relief [1] and Tapping screws 4x18 [2] (2 pcs).

  • Page 21: Armature/ Gear Section

    Fig.45 Assemble Handle R [1] with Tapping screws 4x18 [2] (5 pcs). Note Check the operation of Switch [3]. Armature/ Gear section 6-7-1 Disassembling Remove Handle section. (6-6-1) Fig.46 Remove Hex. socket head bolts M4x12 [1] (2 pcs). Fig.47 Remove Pan head screws M5x35 [1] (2 pcs) and Pan head screws M5x25 [2] (2 pcs), then remove Gear housing cover [3].
  • Page 22 Fig.48 Remove Pan head screws M5x16 [1] (4 pcs), then remove the following parts:  Gear plate A [2]  Gear plate [3]  Gear complete [4] Fig.49 Remove Armature [2] from Gear housing [1] with a slotted screwdriver. Fig.50 Remove Flat washer 18 [2] and Needle bearing 708 [3] from Gear complete [1].
  • Page 23 Fig.51 Remove Retaining ring S-12 [2] from Armature [1] with 1R291. 1R291 Fig.52 Remove Ball bearing 6001LLU [2] from Armature [1] with 1R269, then remove Bearing retainer 80 [3]. 1R269 Fig.53 Remove Ball bearing 608ZZ [2] from Armature [1] with 1R269 and Water pump pliers, then remove 1R269 Insulation washer [3].

  • Page 24: Assembling

    6-7-2 Assembling Fig.54 Assemble the following parts to Armature [1], then hold Armature [1] with 1R034, and then press-fit them.  Bearing retainer 80 [2]  Ball bearing 6001LLU [3]  Insulation washer [4]  Ball bearing 608ZZ [5] Tips Press-fit Armature [1] while turning it.
  • Page 25 Fig.57 Assemble Gear plate [2] and Gear plate A [3] to Gear housing [1] with Pan head screws M5x16 [4] (4 pcs). Note  Apply the specified adhesive to the thread of Pan head screws M5x16 [4] (4 pcs).  Apply the specified grease to the sliding portion of Gear housing [1] and Gear complete [5].

  • Page 26: Slider Section

    Fig.59 Tighten Hex. socket head bolts M4x12 [1] (2 pcs). Note Apply the specified adhesive to the thread of Hex. socket head bolts M4x12 [1] (2 pcs). Fig.60 Assemble Gear housing cover [2] to Gear housing [1] with Pan head screws M5x25 [3] (2 pcs) and Pan head screws M5x35 [4] (2 pcs).
  • Page 27 Fig.62 Remove Pan head screws M5x16 [2] (4 pcs) from Gear housing cover [1], then remove Plates [3] (2 pcs). Fig.63 Remove the following parts from Gear housing cover [1]:  Plane bearings 14 [2] (2 pcs)  Slider [3] ...

  • Page 28: Assembling

    6-8-2 Assembling Fig.65 Assemble the following parts to Gear housing cover [1]:  Block [2]  Collared pin 6 [3]  Stop ring E-5 [4] Fig.66 Assemble the following parts to Gear housing cover [1]:  Slide plate [2]  Plane bearings 14 [3] (2 pcs) ...
  • Page 29 Fig.67 Assemble Plates [2] (2 pcs) to Gear housing cover [1] with Pan head screws M5x16 [3] (4 pcs). Note  Apply the specified adhesive to the thread of Pan head screws M5x16 [3] (4 pcs).  Check the operation of Slider [4]. Fig.68 Assemble Seal ring [2] to Gear housing cover [1].

  • Page 30: Circuit Diagram

    CIRCUIT DIAGRAM Fig.69 Color index of lead wires' sheath White Black AWG18 View of Field from Commutator side Black or Brown Line filter (ø10-30/ if used) White or Blue Non-insulated splice [SPC-1.0T] Power supply cord Switch Non-insulated splice (Handle L side) Noise suppressor (if used) Non-insulated splice (Handle R side) Switch circuit diagram...

  • Page 31: Wiring Diagram

    WIRING DIAGRAM Field section Fig.70 Field Opening B Lead wire of Field (White) Motor housing Lead wire of Field (Black) Lead wire holder Opening A Assemble Field to Motor housing in the orientation as shown. Pass Lead wire of Field (white) through Opening A and Lead wire of Field (black) through Opening B as shown. Assemble Lead wire of Field (black) from Motor housing between Field and Lead wire holder and Lead wire holder and Lead wire holder without slack.

  • Page 32: Handle Section

    Handle section Fig.71 Handle L Switch Rib A Noise suppressor (if used) Rib B Range C Rib C Range B Boss Power supply cord Lead wires of Field Range A Motor housing Line filter (if used) Fix Lead wires of Field connect to Switch in this groove. Put Lead wire of Filed (White) on Lead wire of Field (Black). Put the slack of Lead wires of Field connect to Switch in Range C.

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