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3) Make sure that O ring 40 is assembled to Bearing box complete before assembling Internal gear 51. (Fig. 11)
4) Internal gear 51 is not reversible when assembled to Bearing box complete. Make sure that the stepped end of
Internal gear 51 is positioned on the Bearing box complete side. (Fig. 11)
5) Assemble Hammer case complete to Bearing box as illustrated in Fig. 12.
Fig. 10 Fig. 11
Hammer case complete
Internal gear 51
Hammering mechanism
Internal gear 51
stepped end
O ring 40
Bearing box complete
O ring 40
Bearing box complete
Fig. 12
Fit Hammer case complete over Internal gear 51 Fasten Hammer case complete to Bearing box
while aligning the four grooves on the inside of complete to the recommended torque of
Hammer case complete with the corresponding 30 - 40 N.m by turning counterclockwise
projections on Internal gear 51. using 1R224 and No.1R223,
Hammer case complete
four grooves on
the inside surface
Internal gear 51
four projections
134848-9
Bearing box complete
P 6 / 8
Repair
[3] -2. Disassembling/Assembling Motor Section
Fig. 13
DISASSEMBLING
1) Separate the assembly of Armature and
Yoke unit from the machine.
(Refer to 1) to 4) of [3] -1.)
2) Put the assembly of Yoke unit and Armature
on a work bench with the drive end of the
Armature down.
Separate Yoke unit from armature by pressing
down towards the work bench. (Fig. 13)
Yoke unit
ASSEMBLING
Do the reverse of disassembling steps.
Important:
1) Yoke unit is not reversible when assembled to Armature. Be sure to assemble with the notch in Yoke unit on the
drive-end of Armature. If assembled wrong, the Motor section cannot be assembled to Housing (L). (Fig. 14)
2) Because Yoke unit is a strong magnet, when assembling Armature to Yoke unit, be sure to hold the commutator portion
as illustrated to left in Fig. 15. Do not hold the Armature core as illustrated to right or your fingers will be pinched
between Yoke unit and the fan of Armature that is pulled strongly by the magnet force.
Fig. 14 Fig. 15
[Correct] [Wrong] [Correct] [Wrong]
Your fingers can be pinched
and injured.
Notch
3) When assembling the Motor section to Housing (L), Fig. 16
fit the notch in Yoke unit onto the projection on
notch projection Housing (L)
Housing (L) (Fig. 16)
[3] -3. Assembling F/R Change Lever to Switch
Fig. 17
Put the projection on Switch between the prongs of F/R change lever. (Fig. 17)
Prong
Projection
Hammer case complete side
P 7/ 8
Circuit diagram
Fig. 18
Brush holder complete
Color index of lead wires' sheath
Black
LED
Red
Light circuit
Orange
Blue
Switch
Terminal
Connector
Wiring diagram
A
[1] Lead Wire of Carbon Brush
As illustrated to left in Fig. 19, put each Carbon brush into
Brush holder so that its lead wire is placed outside.
Then route the lead wire of Carbon brush through the
outside slot in Brush holder as illustrated to left in Fig. 19.
(Illustrations in Fig. 19 are the Carbon brush section viewed from A.)
Fig. 19
[Correct] [Wrong]
Lead wire of Carbon brush
Route Lead wire of
Carbon brush through this
outside slot in Brush holder.
Tail of Torsion spring
Torsion spring
Tail of Torsion spring
Lead wire routed
wrong may interfere
Lead wire correctly routed
the tail of Torsion
spring.
P 8/ 8
Wiring diagram
[2] Wiring in Housing
Fig. 20
[2] -1. Lead Wires of LED
As illustrated below, fix the two lead wires (red and black) of LED
with lead wire holders, and route them between the pin and the boss.
lead wire holder
LED
LED
lead wire holder
Fit the corner of LED in this
corresponding corner of Housing (L).
pin
Be sure that the lead wires
boss
of LED are tight here.
Do not cross the lead wires of LED here.
Connector
Light circuit
[2] -2. Other Lead Wires
Brush holder complete
20 degrees
Assemble each Connecting
terminal to Switch at approx.
20 degrees to the vertical.
The lead wire (blue) from
Connector to Switch has to
lead wire holder
Switch
be routed inside of this pin.
With these lead wire holders,
pin
fix the lead wires connected
to each connector.
Light circuit
Connector (large)
Put Light circuit in place
Connector (small)
so that the orange lead wire
faces toward the Terminal side.
Put the following lead wires
between the rib and Light circuit.
Switch side
*Lead wires (red and black) from
Terminal to Connector (small)
*Lead wire (blue) from Switch
to Connector (small)
Lead wire
rib (orange)
Terminal side
Terminal
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