Makita LS003G Repair Manual
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Makita LS003G Repair Manual

Makita LS003G Repair Manual

Cordless slide compound miter saw
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OFFICIAL USE
For ASC
CORDLESS SLIDE COMPOUND MITER SAW
LS003G, LS004G
REPAIR MANUAL
August 2021
Ver.1

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Summary of Contents for Makita LS003G

  • Page 1 OFFICIAL USE For ASC CORDLESS SLIDE COMPOUND MITER SAW LS003G, LS004G REPAIR MANUAL August 2021 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................4 NECESSARY REPAIRING TOOLS ............................4 LUBRICANT AND ADHESIVE APPLICATION ........................5 TIGHTENING TORQUE SPECIFICATIONS ..........................6 REPAIR ......................................7 Battery and Saw blade section ............................. 7 6-1-1 Disassembling ................................7 Safety cover section ................................7 6-2-1 Disassembling ................................
  • Page 3 10-3 Flowchart for Troubleshooting ............................55 10-4 Wireless activation ................................56 10-4-1 Step 1: Preparation for Wireless activation ........................ 56 10-4-2 Step 2: Tool registration............................. 57 10-4-3 Step 3: Checking wireless activation ......................... 58 10-4-4 What to check and Corrective action ......................... 58 3 / 58...

  • Page 4: 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 5: Lubricant And Adhesive Application

    LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease R No.00 Apply a little unless specified in the figure. Makita grease FA No.2 Apply a little to Pin 4 and the keyway of Helical gear 14. Lubricant VG100 Apply to Felt 30 until it is soaked.

  • Page 6: Tightening Torque Specifications

    TIGHTENING TORQUE SPECIFICATIONS Tightening torque Parts to fasten Fastener (N∙m) Rod 6 ↔ Lever 25 complete Pan head screw M4x10 with WR 1.0 - 1.2 Upper fence L/ R ↔ Holder Tapping screw bind CT 4x12 1.0 - 1.2 Bearing box Bearing retainer 14-23 12 - 16 Bearing box...

  • Page 7: Repair

    Remove Tapping screw 4x14 [1] from Safety cover section [2]. Fig. 4 Remove Tapping screws 4x14 [1] (3 pcs), then disassemble Safety cover section to the following parts:  Safety cover A [2]  Safety cover B [3]  Leaf spring [4] (LS003G only) 7 / 58...

  • Page 8: Assembling

    Assemble the following parts with Tapping screws 4x14 [1] (3 pcs).  Safety cover A [2]  Safety cover B [3]  Leaf spring [4] (LS003G only: The orientation matters.) Fig. 6 Assemble Safety cover section [1] by reversing the disassembling procedure.

  • Page 9: Switch And Motor Section

    While pushing the locking tab of Connector to release the lock, pull it out. Fig. 10 Remove Pan head screws M5x20 [2] (2 pcs) for LS003G/ Pan head screws M5x25 [2] (2 pcs) for LS004G from Battery housing [1]. 9 / 58...
  • Page 10 Fig. 11 Remove Tapping screws 4x18 [1] (3 pcs), then disassemble Battery housing [2]. Fig. 12 Raise the saw head, then fix it at the top dead center. Remove Tapping screw 4x18 [1], then remove Lead cover holder [2], and then pull out Connector. Tips Push the locking tab of Connector to release the lock, then pull it out.
  • Page 11 Fig. 15 Remove Retaining ring S-17 [1] with 1R291. 1R291 Fig. 16 Remove Ball bearing 6003DDW [2] from the front portion of Rotor [1] with 1R401. 1R401 Fig. 17 Remove Ball bearing 607LLB [2] from the rear portion of Rotor [1] with 1R269. 1R269 Fig.
  • Page 12 Fig. 19 Remove the following parts from Motor housing section [1]:  Controller [2]  Power supply circuit [3]  Spacer [4] Fig. 20 Remove Tapping screws 4x18 [1] (2 pcs), then remove Baffle plate [2] and Plate [3] only for countries where the measurements of EMI are requires.

  • Page 13: Assembling

    Assembling 6-3-3 Press-fit Stator to Motor housing by reversing the disassembling procedure. Connect Connectors by crimping Closed end splices 5.5-SD (3 pcs) with 1R377. Fig. 22 Assemble Plate [2] (only for countries where the measurements of EMI are required) to Baffle plate [1], then tighten Tapping screws 4x18 [3] (2 pcs).
  • Page 14 Fig. 25 Insert Rotor [1]. As for Model LS003G, the LS003G orientation of its Motor bracket [3] does not matter. Insert Rotor [1] into the bottom of Motor housing [2] by tapping the end of Rotor [1] with a plastic hammer.
  • Page 15 Fig. 29 Assemble Battery housing [2] to Motor housing section [1] with Pan head screws M5x20 [3] (2 pcs) for LS003G/ Pan head screws M5x25 [3] (2 pcs) for LS004G. Fig. 30 Connect Connector and Lead wires to Switch [1].

  • Page 16: Led Section

    LED section Disassembling 6-4-1 Fig. 32 Loosen Tapping screw CT 4x16 [1], then remove Lens [2]. Remove Tapping screw CT 4x16 [3], then remove LED cover [4] and Lead cover [5]. Tips Remove LED cover [4] by releasing its tabs with a slotted screwdriver.

  • Page 17: Gear Section

    Gear section Disassembling 6-5-1 Note Proceed with disassembly until Rotor is removed. (6-3-1) Pull out Rotor first, or Gear cannot be pulled out because it is hooked with Rotor. Fig. 37 Remove Tapping screws CT4x16 [1] (3 pcs), then remove Logo plate [2]. Fig.
  • Page 18 Fig. 40 Loosen Bearing retainer 14-23 with 1R361. Tips It is recommended to tilt the saw head 45 degrees to 1R361 the right to prevent the grease from falling out. Fig. 41 Remove Pan head screws M5x16 [1] (3 pcs) and + Countersunk head screws M5x16 [2] (2 pcs), then remove Bearing retainer 51 [3].
  • Page 19 Fig. 44 Remove Retaining rings S-12 [1] and S-15 [2] with 1R291, then remove the following parts:  Flat washer 12 [3]  Rubber washer 12 [4] 1R291  Flat washer 12 [5]  Spiral bevel gear 32 [6]  Woodruff key 4 [7] ...

  • Page 20: Assembling

    Assembling 6-5-2 Fig. 48 Press-fit Ball bearing 6002DDW [2] to Spindle [1] with 1R029. 1R029 Fig. 49 Insert Spindle into Bearing box [1], then press-fit Helical gear 28 [2] with 1R031. And then assemble 1R291 Retaining ring S-15 [3] with 1R291. Note 1R031 Press-fit the convex side of Helical gear 28 [2] to...
  • Page 21 Fig. 52 Insert Helical gear 14 [1] into Ball bearing 608DDW, then manually tighten Bearing retainer 1R361 14-23 [2] with 1R361. Assemble Flat washer 5 [3] and Spring washer 5 [4], then hold the flats of Helical gear 14 [1] with an adjustable wrench, and then tighten Hex nut M5 [5] with a socket bit 8.
  • Page 22 Fig. 56 Assemble Gasket, Bearing box [1] and Bearing retainer [2] to Blade case [3] with Pan head screws M5x16 [4] (3 pcs) and + Countersunk head screws M5x16 [5] (2 pcs). And then tighten Bearing retainer 14-23 [6] with 1R361. Tips ...

  • Page 23: Blade Case Section

    H.S.H.bolt M6x16 [2] for LS003G/ Hex socket head bolt M6x20 [2] for LS004G for adjusting spring force of Torsion spring 40 for LS003G/ Torsion spring 45 for LS004G by about 10mm. Note  Be sure to hold Blade case section [1] at the top dead center.
  • Page 24 35 [3] for LS004G and Sleeves 17 (2 pcs) upward straightly. Note Be careful that Torsion spring 40 [3] for LS003G/ Torsion spring 35 [3] for LS004G and Sleeves 17 (2 pcs) are likely to fall onto Base, so it is recommended to lay cardboard or the like on Base.
  • Page 25 Fig. 65 Remove Pan head screws 4x10 [1] (2 pcs), then remove Guard plate section [2]. And then remove the following parts from Guard plate section [2]:  Tapping screw 4x12 [3]  Dust guide plate [4]  Guard plate [5] ...

  • Page 26: Assembling

    Pan head screws M4x10 with WR [6] (2 pcs). Fig. 69 Set Torsion spring 40 [2] for LS003G/ Torsion spring 35 [2] for LS004G and Sleeves 17 [3] (2 pcs) on Blade case [1], then apply the specified grease to the sliding surface, and then stand them upright to Front arm.
  • Page 27 H.S.H.bolt M6x16 [3] for LS003G/ Hex socket head bolt M6x20 [3] for LS004G. And then tighten Sleeve 6 [4] and Hex socket head bolt M5x30 [5] for LS003G/ Hex socket head bolt M5x18 [5] for LS004G. Fig. 72 Assemble Dust nozzle [2] to Blade case [1] with Pan head screw M4x14 [3].

  • Page 28: Front Arm Section

    Front arm section Disassembling 6-7-1 Fig. 74 Remove Dust nozzle [2] by removing Tapping screws CT 4x16 [1] (3 pcs). And then remove Dust guide [3]. Fig. 75 Remove Tapping screws CT 4x16 [1] (4 pcs), then remove Arm cover [2]. Note Be careful not to lose Compression spring 4 and Pin Fig.
  • Page 29 Fig. 78 Lock the flats of Grip 50B [1] with Wrench 17, and then remove Pulley 17-19.3 [2] by turning it counterclockwise with a 3mm thick Lock nut wrench for Angle grinder or the like. Fig. 79 Push out Ball bearing 6900LLB [1] by pushing with the shaft of Grip 50B [2], then remove Grip 50B [2].

  • Page 30: Assembling

    Assembling 6-7-2 Lock Arm section at 0 degrees bevel by turning Pulley 17-87.8 counterclockwise. Fig. 82 Slide Front arm [1] onto Slide pipes [2]. Install Holder [3], then fasten it with Set screws M8x12 [4] (2 pcs). Tips  Apply the specified lubricant to Felt rings 30 on the rear of Front arm [1] until they are soaked.

  • Page 31: Arm Section

    Fig. 85 Tighten + Flat head screw M5 [2] to Pulley 17-19.3 [1]. Tips Support Grip 50B [3] by hand or prevent it from rotating with Wrench 17 [4]. Fig. 86 Fit Synchro belt 15-810 [3] to Pulley 17-19.3 [1] and Pulley 17-87.8 [2] first, then fit it to Sleeve 20 [4].
  • Page 32 Fig. 90 Remove Retaining ring S-17 [1] with 1R291 (LS003G only), then remove Hex nut M10-19 [3] from Pulley 17-87.8 [2]. 1R291 Fig. 91 While pressing Center shaft with 1R361, remove Hex lock nut M10-17 (left-handed) [1] by turning it clockwise with a socket wrench 17.
  • Page 33 Fig. 92 Remove Arm [1] rearward, then remove Washer 94 [6] [8] [2]. Remove Retaining ring S-12 [3] with 1R291, 1R291 then remove Flat washer 12 [4], Torsion spring 14 [5] and Stopper [6]. Note  Do not tilt Arm [1] when removing it. ...

  • Page 34: Assembling

    Assembling 6-8-2 Fig. 95 Assemble Stop ring E-7 [1] with long-nose pliers, then assemble Knob 22 [2], Stopper pin [3] and [4] [3] Compression spring 10 [4]. Fig. 96 Assemble Compression spring 12 [2] to Release [1] [2] button [1], then assemble them to Arm [3]. Note If Compression spring 12 [2] is not firmly assembled, Stopper will out of order.
  • Page 35 Adjust Hex lock nut M10-17 [4] so that you can tilt Arm [5] smoothly, but with resistance a little, and without looseness. Fig. 101 Pass Hex nut M10-19 [2] through Pulley 17-87.8 [1], then assemble Retaining ring S-17 (LS003G only) [3] with 1R291. 1R291 35 / 58...

  • Page 36: Base, Turn Base Section

     Flat washer 10 [3] (small outer diameter)  Pulley 17-87.8 section [4]  Sleeve 5 [5]  Flat washer 5 [6]  Hex socket head bolt M5x40 (LS003G) [7]/ M5x30 (LS004G) [7] Tips Pulley 17-87.8 [4] can move back and forth. To fix Arm [9], set the pulley to the back and tighten Hex nut M10-19 [8] with a socket 19 [10].
  • Page 37 Fig. 104 Rotate Turn base left or right, then remove Kerf boards [2] (2 pcs) by removing Tapping screws bind CT 4x12 [1] (LS003G/ 6 pcs, LS004G/ 4 pcs). Fig. 105 Remove H.S.H.bolt M8x35 with WR [1] (4 pcs), then remove Guide fence [2].
  • Page 38  Lock plate [8]  Flat washers 5 [9] (2 pcs) [10]  Rings 5 [10] (2 pcs) (LS003G only) Remove Tapping screw bind CT 4x12 [11] and Leaf spring [12]. Fig. 111 Remove Pan head screw M3x8 [1], then remove Cam plate [2].

  • Page 39: Assembling

    Loosen Screws M5x16 [1] (2 pcs), then remove Stop rings E-9 [2] (2 pcs) with a slotted screwdriver, and then remove Sub base section [3] (LS003G)/ Holders 200 [3] (LS004G, 2 pcs). Remove Tapping screws bind CT 4x12 (4 pcs), then remove Foots [4] (4 pcs).
  • Page 40 Assemble Slide plate [2] to Base [1], then apply the specified grease to Slide plate [2] and Turn base. Fig. 118 < LS003G only> When assembling Bevel scale plate [1] to Turn base complete [2], first tighten the left Tapping screw 4x14 [3], then prevent Bevel scale plate [1] from rising up.

  • Page 41: Sub Base Section

    Rotate Turn base section fully left or right, then fasten Kerf boards [2] (2 pcs) with Tapping screws bind CT 4x12 [1] (6 pcs/ LS003G, 4 pcs/ LS004G). Note Be sure to place and fasten Kerf boards [2] (2 pcs) as far away from each other as possible.

  • Page 42: Assembling

    6-10-2 Assembling Fig. 124 < LS003G only > Assemble Sub base by reversing the disassembling procedure. Tips Decide the distance between Rods 12 [1] by tightening Pan head screws M4x10 [3] (2 pcs on one side) with Rods 12 [1] (2 pcs) passed through Base [2].

  • Page 43: Adjustment

    Adjustment Adjustment of lower limit position of the saw blade Fig. 125 Install the saw blade. Then, by turning Hex socket head bolt M8x25 [1], adjust the lower limit position of the blade so that the blade tip is positioned at the triangle mark on Kerf board as shown bottom.

  • Page 44: Adjustment Of Bevel Angle To 45 Degrees

    Adjustment of bevel angle to 45 degrees Tilt the saw head slightly to the left, then press Release button to tilt it to the right. Fig. 127 While attaching 1R207 to Saw blade [1], adjust it by turning Hex socket head bolt M8x25 [2] to be no gap.

  • Page 45: Adjustment Of Sub Fence

    Fig. 129 Attach 1R408-A (1 pc) to Saw blade [1], then set 1R208-A against Guide fence [2]. And then, adjust Turn base [3] by moving it left or right until there is 1R408-A no gap between 1R408-A and 1R208-A. Note 1R208-A ...

  • Page 46: Attaching Upper Fence Adjustment

    Attaching Upper fence adjustment Fig. 132 If there is a backlash when assembling Upper fence [2] to Guide fence [1], adjust H.socket head set screw M10x12 [3] of Guide fence [1] so that it can be attached and detached smoothly without a backlash.

  • Page 47: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 133 AWG14 Main switch AWG26 Controller B AWG22 Line filter AWG24 Line filter (if used) Connector Power supply circuit Switch unit LED circuit Connector for Wireless unit Capacitor Flag receptacle with lock (#250, t=0.8) Stator Terminal unit Closed end splice Controller Circuit diagram of Switch...

  • Page 48: Wiring Diagram

    WIRING DIAGRAM Motor housing Section 1 9-1-1 Fig. 134 The edge of Opening Motor housing Opening Stator Be careful not to slack Stator lead wires in Motor housing. Be careful not to damage Lead wires by the edge of Opening when passing Stator lead wires through Opening. Route Stator lead wires between these ribs.

  • Page 49: Handle Section

    Handle section Section 1 9-2-1 Fig.136 The end of Power supply circuit Handle The end of Rib A Capacitor Rib A Connector (3-pin) Power supply circuit Connector (2-pin) Be careful not to put Lead wires on these ribs. Pass Connector (2-pin) through this opening of Handle. Be careful not to put Lead wires on this rib.

  • Page 50: Section 2

    Section 2 9-2-2 Fig.137 Handle Line filter (if used) Switch Connector for Wireless unit Connector to Stator Rib E Connector to Power supply circuit Rib F Power supply circuit Switch unit Connector to Switch unit Place Connector to Switch unit, Connector to Power circuit, Connector to Stator and Line filter in this space. Fix Lead wires to Connector housing in this groove.

  • Page 51: Battery Housing Section

    Battery housing section Fig.138 Closed end splice Route Lead wires between these ribs. Pass Controller lead wires (Blue, White, Orange) to Stator through Line filter (if used). Put Closed end splices and Line filter in this space. 51 / 58...

  • Page 52: Led Circuit Section

    LED circuit section Fig.139 Rib A Boss Rib B Blade case LED circuit Ribs LED cover Lead cover Be careful not to put LED circuit lead wires on Boss. Fix LED circuit lead wires in this groove. Route LED circuit lead wires between Rib A and Rib B. Be careful not to put LED circuit lead wires on these shaded portion.

  • Page 53: Handle Lower Section

    Handle lower section Fig.140 Lead cover Be careful not to put Lead wires on the mating surface (shaded portion) with Lead cover holder. Place Connector (2-pin) in this space. 53 / 58...

  • Page 54: Troubleshooting

    10 TROUBLESHOOTING Whenever you find any trouble in your machine, first, see this list to check the machine for solution. 10-1 Note for Repairing The content may vary depending on the model. Use a full charged battery which has a star mark. When Housing is disassembled, check the conditions of the electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc.

  • Page 55: Flowchart For Troubleshooting

    10-3 Flowchart for Troubleshooting Check the items in the following flowchart in order from the top to bottom. Description of the item is referred to CIRCUIT DIAGRAM. After corrective action, return to the start of Troubleshooting and re-check again. Symptom Cause Corrective action Tester indicates proper figure.

  • Page 56: Wireless Activation

    10-4 Wireless activation  Be sure to prepare non-defective AWS-supported tool and vacuum cleaner for efficient defect inspection.  Check Step 1 to Step 3 in order and if some troubles happen, see 10-4-4.  During the inspection, do not use microwave oven nearby. AWS-supported tool AWS-supported vacuum cleaner Wireless activation lamp...

  • Page 57: Step 2: Tool Registration

    10-4-2 Step 2: Tool registration AWS-supported tool AWS-supported vacuum cleaner Press and hold down Wireless activation button, Press and hold down Wireless activation button, then make sure that Wireless activation lamp blinks then make sure that Wireless activation lamp blinks in green.

  • Page 58: Step 3: Checking Wireless Activation

    10-4-3 Step 3: Checking wireless activation The tool and cleaner should be about 5m apart from each other. AWS-supported tool AWS-supported vacuum cleaner Make sure that, when the tool is activated, Wireless Make sure that, when the tool is activated, Wireless activation lamp lights up in blue.

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Ls004g

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