Hitachi CR 13VC Technical Data And Service Manual

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POWER TOOLS

TECHNICAL DATA

AND

SERVICE MANUAL

RECIPROCATING SA W

CR 13VC

SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT

LIST No. 0792 Aug. 2002

MODEL

CR 13VC

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REMARK: Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s) is(are) used in the place of company name(s) and model name(s) of our competitor(s). The symbol(s) utilized here is(are) as follows:

Symbols Utilized

Competitors

Company Name

Model Name

FLEX

SK2902VV

MAKITA

JR3030T

DEWALT

DW307MK

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1. PRODUCT NAME............................................................................................................................. 1

2. MARKETING OBJECTIVE ............................................................................................................... 1

3. APPLICA TIONS................................................................................................................................ 1

4. SELLING POINTS ............................................................................................................................ 1

4-1. Selling Point Descriptions ..................................................................................................................2

5. SPECIFICATIONS ............................................................................................................................ 6

5-1. Specifications.....................................................................................................................................6

5-2. Optional Accessories .........................................................................................................................7

6. COMPARISONS WITH SIMILAR PRODUCTS ................................................................................ 9

7. COMPARISONS IN CUTTING TIME .............................................................................................. 10

7-1. Cutting Steel Pipes ..........................................................................................................................10

7-2. Cutting Wood ...................................................................................................................................11

7-3. Cutting Operation for Long Blade Life .............................................................................................12

8. PRECAUTIONS IN SALES PROMOTION ..................................................................................... 13

8-1. Handling Instructions .......................................................................................................................13

8-2. Caution on Name Plate....................................................................................................................13

9. REPAIR GUIDE .............................................................................................................................. 14

9-1. Precautions in Disassembly and Reassembly.................................................................................14

9-2. Lubrication .......................................................................................................................................23

9-3. Tightening Torques ..........................................................................................................................23

9-4. Wiring Diagram ................................................................................................................................23

10. CONFIRMATION AFTER REASSEMBLY .................................................................................... 25

10-1. Lead Wire Precautions .................................................................................................................25

10-2. Insulation Tests ..............................................................................................................................25

10-3. No-Load Current Value ..................................................................................................................25

11. STANDARD REPAIR TIME (UNIT) SCHEDULES........................................................................ 26

Assembly Diagram for Model CR 13VC

CONTENTS

Page

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1. PRODUCT NAME

Hitachi 130 mm (5") Reciprocating Saw, Model CR 13VC

2. MARKETING OBJECTIVE

The new Model CR 13VC is an upgraded version of the current Model CR 12V to satisfy the market demand for a lightweight and high-speed saber saw. Thanks to the powerful motor, the Model CR 13VC offers the class-top cutting performance. The weight is equivalent to that of the current Model CR 12V. The Model CR 13VC is easy to operate and maintain thanks to the various convenient functions such as Hitachi-original tool-less blade detachable mechanism.

3. APPLICA TIONS

Cutting metal, wood and plastics etc.

4. SELLING POINTS

Saw blade can be mounted in either upward or downward direction

Fast cutting speed thanks to the high-power motor

[about 2 times faster than the current Model CR 12V]

Speed selectable dial scale and switch trigger (same as the Model CR 13VA)

Dust- and water-resistant triple-sealing construction (same as the Model CR 13VA)

Nonskid and comfortable soft grip handle

Easy-to-operate/maintain tool-less blade detachable mechanism (The Model CR 13VC is serviceable without removing the front cover.)

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4-1. Selling Point Descriptions

(1) Fast cutting speed

The Model CR 13VA can cut various construction materials fast and efficiently thanks to the high-power motor whose maximum output is over 1000 W (Model CR 12V: 720 V).

(2) New tool-less blade detachable mechanism

Recently, most saber saws on the market are equipped with a mechanism that requires no tool such as hexagonal wrench for mounting and removal of saw blades. The Model CR 13VC is also equipped with such a mechanism in order to replace saw blades speedily.

[ Features of the tool-less blade detachable mechanism ]

Easy to mount and remove saw blades

Saw blades can be easily mounted and removed just by pressing the lever.

Easy to maintain

The tool-less blade detachable mechanism can be disassembled and reassembled without removing the

front cover. <How to mount a saw blade> (a) Push the lever in the direction of the arrow

mark marked on the lever.

(b) Insert the saw blade all the way into the small slit of the plunger tip with the lever pushing.

(c) Release the lever and pull the back of the saw blade two or three times by hand to check that the blade is securely mounted. When pulling the blade, you will know it is properly mounted if it clicks and the lever moves slightly.

Lever

Saw blade

Click

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< Construction of the tool-less blade detachable mechanism >

Blade holder

Holder pin to secure the blade

Spring to pull back the holder pin

Saw blade

Lever to mount and remove saw blades

Bolt

Spring

Plunger (reciprocating shaft)

Heat- and dust-resistant rubber cap

< Maintenance of the tool-less blade detachable mechanism >

After use, clean the blade mount with a brush to ensure that the tool-less blade detachable mechanism can function smoothly. In addition to the regular maintenance, perform the following effective maintenance occasionally.

Cleaning the inside of the tool-less blade detachable mechanism Pull the rubber cap provided on the lever in the direction of an arrow mark shown below. Then the rubber cap can be removed from the lever easily. Remove dust from the inside of the blade holder with air or the like.

Rubber cap

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< Disassembly and cleaning of the tool-less blade detachable mechanism >

The tool-less blade detachable mechanism can be easily disassembled or reassembled because the fixing bolt can be loosened or tightened without removing the front cover. To disassemble the tool-less blade detachable mechanism, remove the fixing bolt and pull out the blade holder.

(Caution) This is a special bolt comprised of an M4 thread and an M5 hexagonal socket. Be careful not

to break the bolt by overtightening.

In case the saw blade is apt to come off The saw blade is apt to come off if the blade hole is worn out. Replace the saw blade with new one. If the new saw blade comes off even after replacement, the holder pin may be worn out. Replace the holder pin with new one.

Front cover

Fixing bolt

Blade holder

(3) Saw blade can be mounted in either direction, upward or downward

The Model CR 13VC is convenient for cutting materials on the floor or near the wall, and also for plunge cutting on plywood panels because the saw blade can be mounted in reverse.

Blade hole

Refer to the Handling Instructions for detailed information about plunge cutting on plywood panels.

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(4) Dust-and water-resistant triple-sealing construction

The Model CR 13VC has a triple-sealing construction to protect from the large amount of dust generated when cutting construction materials, autoclaved lightweight concrete, etc., and also from waste water when cutting pipes.

Dust-resistant felt ring It prevents dust from entering by way of the plunger (reciprocating shaft). Dust-and water-resistant seal ring (made of heat-resistant rubber) It prevents dust and waste water from entering by way of the plunger (reciprocating shaft). Dust- and water-resistant o-ring (made of heat-resistant rubber) It prevents dust and waste water from entering by way of the plunger (reciprocating shaft).

Plunger

O-ring

Seal ring

Felt ring

< Triple-sealiing construction >

(5) Comfortable double-molded (leostomer and polyamide resin) handle

The handle is nonskid and comfortably fits in the palm of a hand thanks to the double-molded construction (glassfiber reinforced polyamide resin at the handle main body and leostmer at the grip). You can see the excellence especially when you operate the Model CR 13VC wearing working gloves.

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5. SPECIFICATIONS

Max. cutting size Steel pipe outer diameter 130 mm (5")

Wood thickness (for Europe) 300 mm

(for USA) 5"

Mild steel plate 19 mm (3/4")

Power source AC single phase 50 or 60 Hz

Type of switch

Enclosure

Type of motor

Full load current

Weight

Stroke

Number of strokes

Max. output (reference)

Power input

AC single phase series commutator motor

Variable trigger switch

Blade No. 103 *

•••••••••••••••

Plastic case

••••••••••••••••••••

Hexagonal bar wrench

•••••

Net

•••••••••••••••••••

3.3 kg (7.3 lbs.) [without cord]

Gross

•••••••••••••••

6.1 kg (13.4 lbs.)

29 mm (1-1/7")

1,180 W

1,010 W

110 V

•••••••••••••••••••••••••

9.7 A

120 V

•••••••••••••••••••••••••

8.9 A

220 V

•••••••••••••••••••••••••

4.8 A

230 V

•••••••••••••••••••••••••

4.6 A

240 V

•••••••••••••••••••••••••

4.4 A

Packaging

No load

•••••••••••••••••••

0 to 2,800/min.

Full load

••••••••••••••••••

2,100/min. [dial setting 5]

Standard accessories

Capacities

5-1. Specifications

Housing

••••••••••••••••••••••••••••••••

Glassfiber reinforced polyamide resin

Handle

••••••••••••••••••••••••••••••••••

Glassfiber reinforced polyamide resin + Leostmer

Front cover

•••••••••••••••••••••••••••

Leostmer

Gear cover and inner cover

••••

Aluminum alloy die casting

Plastic case (in corrugated cardboard sleeve)

Cord length

2.5 m (8.2 ft)

*: This blade is sold separately as an optional accessory in some areas.

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5-2. Optional Accessories

The cutting speed of the Model CR 13VC is substantially higher than that of the current Model CR 12V, however, the conventional HCS blades may be broken in heavy applications such as house demolition, etc. To cope with this problem, the BI-METAL blades shown in Table 2 are provided. The BI-METAL blades are tough and rarely break since they are made by electron-beam welding together of two different types of steels. A very hard steel called "DM05" (JIS: SKH51 or equivalent molybdenum containing high speed tool steel) or "Matrix II" (JIS: SKH59 or equivalent cobalt containing high speed tool steel) is used at the cutting edges, and a flexible steel for spring material is used for the blade main body. So these BI-METAL blades are remarkably stronger than the HCS blades.

(1) HCS blades The blade numbers of HCS blades in Table 1 are engraved in the vicinity of the mounting position of each blade. Select appropriate blades by referring to Tables 1 and 3 below. Table 1: HCS blades

For cutting and roughing lumber

Blade No. Uses Thickness (mm)

For cutting steel pipes less than 105 mm in outer diameter 2.5 --- 6

No. 1

No. 3

No. 96

No. 95

No. 9

No. 8

No. 5

No. 4

No. 2

For cutting steel pipes less than 30 mm in outer diameter

For cutting and roughing lumber For cutting vinyl chloride pipes less than 105 mm in outer

diameter For cutting and roughing lumber

For cutting steel pipes less than 130 mm in outer diameter For cutting steel and stainless pipes less than 105 mm in

outer diameter For cutting steel and stainless pipes less than 30 mm in

outer diameter

2.5 --- 6

50 --- 70

2.5 --- 6

Below 2.5

Below 3.5

Below 30

Below 105

2.5 --- 15

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(2) BI-METAL blades The blade numbers of BI-METAL blades in Table 2 are engraved in the vicinity of the mounting position of each blade. Select appropriate blades by referring to Table 2 and 3 below. Table 2: BI-METAL blades

Below 3.5

(3) Selection of blades for other materials Table 3

Material to be cut

Material quality

2.5 --- 19

No. 1, 2, 101, 102, 103, 104, 105, 106, 131, 132

No. 3, 6, 107, 108

Iron plate

Synthetic resin

Nonferrous metal

Mild steel plate

Aluminum Copper Brass

Vinyl chloride Acrylic resin etc.

Phenol resin Melamine resin etc.

Thickness (mm)

Below 5

No. 3, 6, 107, 108

No. 1, 2, 101, 102, 103, 104, 105, 106, 131, 132

5 --- 20

5 --- 30

10 --- 50

5 --- 30

10 --- 60

No. 3, 5, 8, 105, 106, 107, 108

No. 1, 2, 4, 101, 102, 103, 104, 131, 132

No. 3, 5, 8, 105, 106, 107, 108

No. 1, 2, 4, 101, 102, 103, 104, 131, 132

Blade No. Uses

Thickness (mm)

2.5 --- 6

For cutting steel and stainless pipes less than 60 mm in outer diameter

No. 101

For cutting steel and stainless pipes less than 60 mm in outer diameter

No. 103

For cutting steel and stainless pipes less than 130 mm in outer diameter

No. 102

For cutting steel and stainless pipes less than 130 mm in outer diameter

No. 104

For cutting steel and stainless pipes less than 130 mm in outer diameter

No. 108

For cutting steel and stainless pipes less than 60 mm in outer diameter

No. 107

For cutting steel and stainless pipes less than 130 mm in outer diameter

No. 106

For cutting steel and stainless pipes less than 60 mm in outer diameter

No. 105

For cutting and roughing lumber

No. 121

All purpose

No. 131

All purpose

No. 132

2.5 --- 6

Below 3.5

2.5 --- 6

Below 3.5

300

Blade No.

2.5 --- 6

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(2) Cut-off guide (L)

Cut-off guide (L) permits easy cutting of mild steel pipes.

Cut-off guide (L) is applicable to the above specified saw blades only. Do not use it for the other short saw blades. Check that the saw blade is not disengaged from the guide bar before operation. During cutting, be careful not to disengage the saw blade from the guide bar. If the saw blade is disengaged from the guide bar, the saw blade can be damaged.

Cut-off guide (L)

Code No. Cutting application

321113

Outer diameter 75 mm - 165 mm

Blade used

No. 9, No. 131

6. COMPARISONS WITH SIMILAR PRODUCTS

Maker HITACHI Model CR 13VC

230 1,010 29 0 -- 2,800 1,180 435 165 95

3.3

124.0

87.5 *T&D

Plastic & Rubber

Triple-seal

CR 12V

P Q C 230

850 1,050 900

28 0 -- 2,600

------ 460 158 100

3.5

119.8

82.7 T

Plastic

28 0 -- 2,600

------ 460 170 103

3.9

123.1

90.2 T

Plastic

32 0 -- 2,800

430 178 97

3.1

124.2

86.6 T

Plastic

720 30 800 -- 2,500 680 422 140 86

3.2

116.2

86.0 D

Plastic

1. Voltage V W mm /min. W

kg dB dB

2. Power input

3. Stroke

4. No-load speed

5. Max. output

6. Dimensions

7. Net weight

8. Vibration

9. No-load noise

10. Features

L H

Variable speed Blade tool-less Base tool-less

Handle Sealing

construction

Double-seal

-------

* Vibration of the handle in to-and-fro direction * T: Variable speed control with trigger D: Variable speed control with dial

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30 40

CR 13VC

CR 12V

Cutting time (sec./cut)

Cutting speed

7. COMPARISONS IN CUTTING TIME

Following test data should be used for reference purposes since the cutting time may vary depending on the operating conditions such as the cutting function, pressing force, type of blade, etc. The graph means the time (in sec.) required for cutting a piece of each material.

7-1. Cutting Steel Pipes

A steel pipe less than 42 mm (1.65") in inner diameter and 3.2 mm (0.13") in thickness

Pressing force about 5 kgf (11 lbs.)

HITACHI genuine blade No. 103 for cutting steel pipes

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A piece of hemlock fir 230 mm (9") in width and 40 mm (1.57") in thickness

Pressing force about 5 kgf (11 lbs.)

7-2. Cutting Wood

HITACHI genuine blade No. 121 for cutting wood

30 40

CR 13VC

CR 12V

Cutting time (sec./cut)

Cutting speed

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7-3. Cutting Operation for Long Blade Life

The service life of a saw blade may vary depending on the operating conditions such as the type of cutting action, pressing force, etc. Observing the following instructions can lengthen the service life of a saw blade, for reference.

< Explanation > Heat generated in the cutting operation can significantly affect the service life of the saw blade. Continued cutting operation with the saw blade heated to red hot can decrease the hardness of the saw blade because the cutting edge is annealed. The saw blade is then worn out in a short time and nothing can be cut. The merits of moving the saber saw up and down are described below. The seesaw motion of the saw blade can minimize heating. The effective cutting length of the blade is longer than that of an ordinary cutting operation. Thus, the service

life of the saw blade can be lengthened and the cutting speed becomes faster. Cutting wood in the same manner can also make the cutting speed faster.

1 2

Application of undue force to the workpiece during the cutting operatation can heat up the saw blade and the number of strokes can decrease, causing reduction of speed. Appropriate pressing force is about 4 to 5 kgf (8.8 to 11 lbs.).

Do not apply undue force to the workpiece2

1 Move the saber saw handle up and down repeatedly during the cutting operation The service life of a saw blade can be lenghtened by moving the saber saw handle up and down repeatedly once or twice per second during the cutting operation.

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8. PRECAUTIONS IN SALES PROMOTION

In the interest of promoting the safest and most efficient use of the Model CR 13VC Reciprocating Saw by all of our customers, it is very important that at the time of sale, the salesperson carefully ensures that the buyer seriously recognizes the importance of the contents of the Handling Instructions, and fully understands the meaning of the precautions listed on the Name Plate attached to each tool.

8-1. Handling Instructions

Although every effort is made in each step of design, manufacture and inspection to provide protection against safety hazards, the dangers inherent in the use of any electric power tool cannot be completely eliminated. Accordingly, general precautions and suggestions for the use of electric power tools, and specific precautions and suggestions for the use of the Reciprocating Saw is listed in the Handling Instructions to enhance the safe and efficient use of the tool by the customer. Salespersons must be thoroughly familiar with the contents of the Handling Instructions to be able to offer appropriate guidance to the customers during sales promotion.

8-2. Caution on Name Plate

Each tool is provided with a Name Plate which contains the following basic safety precautions in the use of the tool. (1) For Australia, New Zealand and China

(2) For Taiwan

CAUTION

Read thoroughly HANDLING INSTRUCTIONS before use.

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9. REPAIR GUIDE

9-1. Precautions in Disassembly and Reassembly

The [Bold] numbers in the description below correspond to the item numbers in the Parts List and exploded assembly diagram for the Model CR 13VC. Before disassembly or replacement of saw blades, disconnect the power cord plug from the outlet.

1. Disassembly (1) Removal of Front Cover (C) [2] (Fig. 1)

Remove the Hex. Socket Hd. Bolt (W/Flange) M5 x 12 [22] and remove Base (B) [1]. Remove the Cover Clip [13] with a flat-blade screwdriver and remove Front Cover (C) [2] from the main body.

(2) Removal of Gear Cover (B) [5] (Figs. 2 and 3)

Hold the fan of the armature and loosen the Nylock Bolt (W/Flange) M6 x 35 [20] about two turns previously. Remove four Machine Screws (W/Washers) M5 x 60 (Black) [45] and pull out Gear Cover (B) [5] from the main body. Remove the Nylock Bolt (W/Flange) M6 x 35 [20] and Washer (G) [21]. Then Second Shaft (B)

[30] and Sub Shaft (B) [25] can be removed from Gear Cover (B) [5] in an assembly state.

Fig. 1

Fig. 2

[13]

[1]

[2]

[22]

[5]

[45]

[22]

[21]

[20]

[30]

[25]

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Remove the Pin D6 [12] and the Swing Roller [11] then remove Plunger (B) [4] assembly from Gear Cover (B)

[5]. At this time, be careful not to scratch the Felt Washer [6], V-ring [8] and O-ring [9]. Push out Metal (B) [10] press-fitted in Gear Cover (B) [5] with a press. Remove the V-ring [8], Washer (H) [7] and Felt Washer [6]. Remove the O-ring [9] from Metal (B) [10] with a small flat-blade screwdriver. Remove three Nylock Bolts (W/Flange) M4 x 12 [60] and the Ball Bearing 6002DDCMPS2L [23].

Fig. 3

(3) Removal of the saw blade mount (Fig. 4)

Slide the Cap [15] (made of rubber) out of Lever (A) [16] with fingers horizontally. Remove the Special Bolt M4 [14]. Then Blade Holder (A) [3], Lever (A) [16], Spring (D) [17], Holder Pin (B) [18] and Spring (B) [19] can be removed from Plunger (B) [4]. At this time, be careful not to lose Spring (B) [19].

Fig. 4

[4]

[11]

[12]

[5]

[11]

[23]

[60]

[8]

[9]

[6]

[10]

[7]

[3]

[17]

[19]

[16]

[4]

[14]

[15]

[18]

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(4) Removal of Second Shaft (B) [30] (Fig. 5)

Remove the Ball Bearing 608VVC2PS2L [32] from Second Shaft (B) [30]. Push the end surface of Second Shaft (B) [30] with a press supporting the side of Gear (B) [31] to remove Second Shaft (B) [30] from Gear (B) [31]. Remove the Retaining Ring for D17 Shaft [26] from Second Shaft (B) [30]. Push the end surface of Second Shaft (B) [30] (parallel surface to the side of the Recipro Plate [27]) with a press supporting the side of Recipro Plate [27] to remove the Recipro Plate [27] in an assembly state. Remove the Retaining Ring for D35 Hole [29] and remove two Ball Bearings 6003VVCMPS2L [28] from the Recipro Plate [27].

Fig. 5

Fig. 6

Removal of Inner Cover (B) [33] and Housing (Green) [40] (Fig. 6) Remove two Brush Caps [41] and two Carbon Brushes [42]. Tap the air vent of the Housing (Green) [40] lightly with a plastic hammer. Then Inner Cover (B) [33] can be removed together with the Armature [35] from the Housing (Green) [40]. At this time, do not hit the fan with the plastic hammer. Remove the Fan Guide [36] from the Housing (Green) [40].

[26]

[28]

[29]

[30]

[31]

[32]

[27]

[28]

[33]

[34]

[24]

[35]

[36]

[40]

[41]

[42] [43]

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(5) Removal of Inner Cover (B) [33] and Armature [35] (Fig. 7)

Push the pinion end surface of the Armature [35] with a press supporting the end surface of Inner Cover (B) [33] to remove the Armature [35]. Remove two Slotted Hd. Screws (Seal Lock) M4 x 10 [24] and the Ball Bearing 6001VVCMPS2L [34].

Fig. 7

(6) Removal of Handle (A) [53] and Handle (B) [48] (Fig. 8)

Remove five Tapping Screws (W/Flange) D4 x 25 (Black) [47] and Handle (B) [48]. Then the Switch Trigger

[50] can be removed.

Fig. 8

[33]

[34]

[24]

[35]

[39]

[53]

[50]

[48]

[47]

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(7) Removal of Handle (A) [53] and Switch [51] (Fig. 9)

Loosen the machine screws securing two internal wires coming from the Stator Ass'y [38] and two internal wires coming from the Cord [59]. Then the Switch [51] can be removed from Handle (A) [53]. Remove two Tapping Screws (W/Flange) D4 x 16 [56] and remove the Cord Clip [57], Cord [59] and Cord Armor [58] from Handle (A) [53].

Fig. 9

Fig. 10

(8) Removal of Housing (Green) [40] and Brush Holder [43] (Fig. 10)

Remove the brush terminal coming from the Stator Ass'y [38] from the Brush Holder [43]. Push out the Brush Holder [43] from the inside of the Housing (Green) [40] with a flat-blade screwdriver (no screw nor adhesive is used).

[53]

[56]

[52]

[51]

[38]

[58]

[57]

[59]

[38]

[40]

[43]

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Fig. 11-a

2. Reassembly Reassembly can be accomplished by following the disassembly procedures in reverse. However, particular attention should be given to the following items.

(1) Mounting Second Shaft (B) [30] to the Recipro Plate [27] (Fig. 11)

Use the special jigs (J-330 and J-315) for press-fitting. First, mount two Ball Bearings 6003VVCMPS2L [28] and the Retaining Ring for D35 Hole [29] to the Recipro Plate [27] to make an assembly of the Recipro Plate [27].

(a) When Gear (B) [31] and Ball Bearing 608VVC2PS2L [32] are not mounted: Mount the assembly of the Recipro Plate [27] to the jigs as shown in Fig. 11-a and push it in the arrow direction with a press. (b) When Gear (B) [31] and Ball Bearing 608VVC2PS2L [32] are mounted: Mount the assembly of the Recipro Plate [27] to the jigs as shown in Fig. 11-b and push it in the arrow direction with a press. Be careful of the direction when press-fitting the assembly of the Recipro Plate [27].

J-330

J-315

Fig. 11-b

[28]

[27]

[32]

[28]

[27]

[31]

[29]

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(2) Mounting the saw blade mount (Figs. 12, 13 and 14)

Insert Spring (B) [19] and Holder Pin (B) [18] into Plunger (B) [4]. Apply Nippeco SEP-3A to the slanted portion of Lever (A) [16]. Mount the shorter end of Spring (D) [17] into Lever (A) [16] then mount Lever (A) [16] into Blade Holder (A) [3]. Keeping this state, insert the tip of Plunger (B) [4] into Blade Holder (A) [3]. At this time, fit Spring (D) [17] in the groove of Plunger (B) [4] securely. Tighten the Special Bolt M4 [14] at the specified torque. Push the Cap [15] to Lever (A) [16] from the side so that the arrow mark on the Cap [15] points downward. At this time, check that there is no gap between the Cap [15] and Blade Holder (A) [3]. Be careful not to break the Special Bolt M4 [14] by overtightening with an M5 hexagonal wrench. Finally, mount and dismount the saw blade to check for operation.

[16]

Fig. 12

[19]

[18]

[4]

[17]

[3]

Fig. 13

[4]

[18]

[16]

[15]

[14]

[17]

[19]

[3]

[15]

Fig. 14

[14]

[17]

[4]

Groove of plunger (B)

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(3) Mounting Metal (B) [10] to Gear Cover (B) [5] (Fig. 15)

Apply Nippeco SEP-3A to the inner circumferences of Metal (B) [10] and the O-ring [9]. Mount the O-ring [9] to the inside groove of Metal (B) [10]. Mount the Felt Washer [6], Washer (H) [7] and the V-ring [8] to Gear Cover (B) [5] in order. Press-fit Metal (B) [10] (an inspection hole is provided at one side) all the way with a press. At this time, carefully mount the Felt Washer [6], Washer (H) [7] and the V-ring [8] to the proper positions in Gear Cover (B) [5] respectively. If Metal (B) [10] is press-fitted without mounting these parts properly, they may be damaged or Plunger (B) [4] may be improperly mounted or the water-resistance may be degraded.

Fig. 16

Fig. 15

[10]

[9]

[8][7]

[5]

[6]

[5]

[24]

[23]

[4]

(4) Mounting the Ball Bearing 6002DDCMPS2L [23] to Gear Cover (B) [5] (Fig. 15)

Mount the Ball Bearing 6002DDCMPS2L [23] to Gear Cover (B) [5] securely. Tighten three Slotted Hd. Screws (Seal Lock) M4 x 10 [24] at the specified torque two times respectively. Improper mounting of the Ball Bearing 6002DDCMPS2L [23] or improper tightening of the Slotted Hd. Screws (Seal Lock) M4 x 10 [24] may cause malfunction of the Model CR 13VC.

Page 25

--- 22 ---

(5) Mounting Plunger (B) [4] to Gear Cover (B) [5] (Fig. 17)

Apply Nippeco SEP-3A to the polished portion of Plunger (B) [4] (the saw blade mount has already been mounted). Insert it into Gear Cover (B) [5]. When inserting, turn the Felt Washer [6], V-ring [8] and O-ring [9] slowly to prevent scratching them. Especially be careful of the Felt Washer [6] because it is apt to be caught by Plunger (B) [4]. After insertion of Plunger (B) [4], apply Nippeco SEP-3A to the Pin D6 [12] and the inner circumferences of two Swing Rollers [11] then mount them to Plunger (B) [4].

Fig. 18

Fig. 17

(6) Others

* Caution when reinstalling the Armature [35] to the Housing (Green) [40]

The Armature [35] may come off the Ball Bearing 6001VVCMPS2L [34] when removing the Armature [35] from the Housing (Green) [40]. To prevent it, press-fit the Armature [35] to the Ball Bearing 6001VVCMPS2L [34] before reinstalling the Armature [35] to the Housing (Green) [40] (Fig. 7).

* Be careful of the mounting direction of the Cord Clip [57]. (Fig. 18)

[4]

[6]

[8]

[9]

[12]

[11][5]

[56]

[57]

Cord dia.: More than 6.4 mm dia.,

8.5 mm dia. or less.

Cord dia.: More than 8.5 mm dia.,

10.8 mm dia. or less.

Page 26

--- 23 ---

9-3. Tightening Torques

Slotted Hd. Screw (Seal Lock) M4 x 10 [24] ••••••••••••••••••••••• 1.8 0.4 N•m (18 4 kgf•cm) Tapping Screws (W/Flange) D4 [47] [56] ••••••••••••••••••••••••••• 2.0 0.5 N•m (20 5 kgf•cm) Nylock Bolt (W/Flange) M4 [60] •••••••••••••••••••••••••••••••••••••••••• 3.6 0.7 N•m (37 7 kgf•cm) Special Bolt M4 [14] ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4.4 0.5 N•m (45 5 kgf•cm) Machine Screws (W/Washers) M5 x 60 (Black) [45] •••••••••••• 2.5 0.5 N•m (25 5 kgf•cm) Hex. Hd. Tapping Screw D5 x 60 [37] ••••••••••••••••••••••••••••••••• 3.4 0.7 N•m (35 7 kgf•cm) Hex. Socket Hd. Bolt (W/Flange) M5 x 12 [22] •••••••••••••••••••••5.9 1.5 N•m (60 15 kgf•cm) Nylock Bolt (W/Flange) M6 x 35 [20] •••••••••••••••••••••••••••••••••••••••• 11.8 2.0 N•m (120 20 kgf•cm)

9-4. Wiring Diagram

Carefully ensure that wiring is accomplished as illustrated below. As incorrect wiring will result in lack of rotation, reverse rotation or other malfunctions, close attention is absolutely necessary. (Figs. 19, 20, 21 and 22)

O-ring [9] Spherical portion of the Recipro Plate [27] Polished portion of Plunger (B) [4] Inner circumference of Metal (B) [10]

9-2. Lubrication

Nippeco SEP-3A

Slanted portion of Lever (A) [16] Inner circumference of the Swing Roller [11] Teeth of Gear (B) [31] Pinion of the Armature [35] Apply 45 g of Nippeco SEP-3A to the Swing Roller [11], Plunger (B) [4] and Gear (B) [31] in Gear Cover (B) [5].

Fig. 19

Switch body

Noise suppressor

Noise suppressor earth wire

Dial resistor

Triac ass'y

Page 27

--- 24 ---

For stator ass'y, or for stator ass'y and noise suppressor

For triac ass'y, or for triac ass'y and noise suppressor

For cord

For stator ass'y

Noise suppressor

Tube (D)

Cord

Terminal

Triac ass'y

Dial resistor

Tube (D)

For cord

Fig. 20

Armature

Stator

Fig. 21

Fig. 22

Fig. 23

Stator

Armature

Stator

Dial resistor

Triac ass'y

Switch body

Cord

Tube (D)

Switch body

With noise suppressor type

Other type

120 V type

Page 28

--- 25 ---

10. CONFIRMATION AFTER REASSEMBLY

10-1. Lead Wire Precautions

When connecting lead wires, be very careful not to remove the insulation covering of each lead wire more than needed. Also, ensure that the lead wires are not pinched between the mating surfaces of the handle.

10-2. Insulation Tests

On completion of disassembly and repair, measure the insulation resistatance and conduct dielectric strength test. Insulation resistance: 7 MΩ or more with DC 500 V Megohm Tester Dielectric strength: AC 4000 V/1 minute, with no abnormalities … 220 V to 240 V

AC 2500 V/1 minute, with no abnormalities … 110 V to 127 V

10-3. No-Load Current Value

After no-load operation for 30 minutes, the no-load current value should be as specified below at a frequency of 50/60 Hz.

110 V … 4.4 A max. 115 V … 4.2 A max. 120 V … 4.1 A max. 127 V … 4.3 A max. 220 V … 2.1 A max. 230 V … 2.2 A max. 240 V … 2.1 A max.

Page 29

--- 26 ---

11. STANDARD REPAIR TIME (UNIT) SCHEDULES

MODEL 10 20 30 40

Fixed

Variable

CR 13VC

Work Flow

Handle (A) Handle (B) Switch Cord Switch Trigger

Front Cover (C)

Inner Cover (B) Armature Ball Bearing

(6001VV)

Ball Bearing

(608VV)

Ball Bearing

(6002DD) Sub Shaft (B) Recipro Plate Ball Bearing

(6003VV) x 2

Second Shaft

(B) Gear (B) Ball Bearing

(608VV)

Plunger (B) Metal (B) O-ring Gear Cover (B)

General Assembly

Housing Stator Ass'y

Base (B)

Page 30

ELECTRIC TOOL PARTS LIST

LIST NO.

RECIPROCATING SAW Model CR 13VC

2002• 8 •30

(E1)

0792

501

502

503

42 43

Page 31

ALTERNATIVE PARTS

--- 2 ---

ITEM

NO.

CODE NO.

DESCRIPTION REMARKS

NO.

USED

PARTS

8 -- 02

CR 13VC

1 321-116 BASE (B) 1 2 321-125 FRONT COVER (C) 1 3 321-132 BLADE HOLDER (A) 1 4 321-120 PLUNGER (B) 1 5 321-123 GEAR COVER (B) 1 6 318-458 FELT WASHER 1 7 321-117 WASHER (H) 1 8 318-459 V-RING 1

9 321-118 O-RING 1 10 321-214 METAL (B) 1 11 321-136 SWING ROLLER 2 12 318-491 PIN D6 1 13 321-126 COVER CLIP 1 14 321-133 SPECIAL BOLT M4 1 15 321-130 CAP 1 16 321-131 LEVER (A) 1 17 321-135 SPRING (D) 1 18 321-134 HOLDER PIN (B) 1 19 318-483 SPRING (B) 1 20 318-451 NYLOCK BOLT (W/FLANGE) M6X35 1 21 318-452 WASHER (G) 1 22 996-399

HEX. SOCKET HD. BOLT (W/FLANGE) M5X12 1

23 600-2DD BALL BEARING 6002DDCMPS2L 1 24 314-430

SLOTTED HD. SCREW (SEAL LOCK) M4X10

5 25 321-129 SUB SHAFT (B) 1 26 967-261 RETAINING RING FOR D17 SHAFT 1 27 321-121 RECIPRO PLATE 1 28 600-3VV BALL BEARING 6003VVCMPS2L 2 29 939-556

RETAINING RING FOR D35 HOLE (10 PCS.)

1 30 321-128 SECOND SHAFT (B) 1 31 321-127 GEAR (B) 1 32 608-VVM BALL BEARING 608VVC2PS2L 1 33 321-124 INNER COVER (B) 1 34 600-1VV BALL BEARING 6001VVCMPS2L 1

* 35 360-581C ARMATURE 110V 1 * 35 360-581U ARMATURE ASS’Y 120V 1 INCLUD.34,39 * 35 360-581E ARMATURE 220V-230V 1 * 35 360-581F ARMATURE 240V 1

36 321-122 FAN GUIDE 1 37 961-501 HEX. HD. TAPPING SCREW D5X60 2

* 38 340-479H STATOR ASS’Y 110V-115V 1 INCLUD.37 * 38 340-479G STATOR ASS’Y 120V-127V 1 INCLUD.37 * 38 340-479E STATOR ASS’Y 220V-230V 1 INCLUD.37 * 38 340-479K STATOR ASS’Y 240V 1 INCLUD.37 * 38 340-479J STATOR ASS’Y 220V-230V 1

INCLUD.37 FOR NZL,FIJ,GBR,EUROPE,NOR,SWE, DEN,FIN

39 608-VVM BALL BEARING 608VVC2PS2L 1 40 318-506 HOUSING (GREEN) 1 41 945-161 BRUSH CAP 2 42 999-043 CARBON BRUSH (1 PAIR) 2 43 958-900 BRUSH HOLDER 2

Page 32

ALTERNATIVE PARTS --- 3 ---

ITEM

NO.

CODE NO.

DESCRIPTION REMARKS

NO.

USED

PARTS

8 -- 02

CR 13VC

44 NAME PLATE 1 45 307-224

MACHINE SCREW (W/WASHERS) M5X60 (BLACK)

4 46 HITACHI LABEL 1 47 307-028

TAPPING SCREW (W/FLANGE) D4X25 (BLACK)

* 48 321-140 HANDLE (B) 1 * 48 321-141 HANDLE (B) 1 FOR NZL,FIJ,AUS * 49 981-373 TUBE (D) 2 EXCEPT FOR USA,CAN

50 318-499 SWITCH TRIGGER 1

* 51 318-505 SWITCH 1 * 51 318-817 SWITCH 1 FOR TPE,GBR (110V) * 51 318-504 SWITCH 1 FOR USA,CAN * 51 320-142

SWITCH (1P SCREW TYPE) W/SAFETY LOCK 1 FOR NZL,FIJ,AUS

52 981-373 TUBE (D) 2 53 321-139 HANDLE (A) 1

* 54 938-108 TERMINAL 1 FOR NOISE SUPPRESSOR * 55 994-273 NOISE SUPPRESSOR 1

FOR NZL,FIJ,AUS,GBR,EUROPE,NOR,SWE,DEN, FIN

56 984-750 TAPPING SCREW (W/FLANGE) D4X16 2

57 937-631 CORD CLIP 1 * 58 953-327 CORD ARMOR D8.8 1 * 58 938-051 CORD ARMOR D10.1 1 * 59 500-245Z CORD 1 (CORD ARMOR D8.8) * 59 500-201Z CORD 1

(CORD ARMOR D10.1) FOR TPE,THA,PHI,PER, BRN,BAN,BOL,TUN,MOZ

* 59 500-234Z CORD 1

(CORD ARMOR D8.8) FOR EUROPE,INA,EGY, TUR, NGR,SAU,MAR,VIE

* 59 500-247Z CORD 1 (CORD ARMOR D8.8) FOR NOR,SWE,DEN,FIN * 59 500-439Z CORD 1 (CORD ARMOR D8.8) FOR NZL,FIJ,AUS * 59 500-423Z CORD 1 (CORD ARMOR D8.8) FOR SIN,MAL,SRI * 59 500-434Z CORD 1 (CORD ARMOR D8.8) FOR USA,CAN * 59 500-435Z CORD 1 (CORD ARMOR D8.8) FOR GBR (230V) * 59 500-237Z CORD 1 (CORD ARMOR D8.8) FOR GBR (110V)

Page 33

ALTERNATIVE PARTS --- 4 ---8 -- 02

ITEM

NO.

CODE NO.

DESCRIPTION

REMARKS

NO.

USED

CR 13VC

OPTIONAL ACCESSORIES

STANDARD ACCESSORIES

ITEM

NO.

CODE NO.

DESCRIPTION

REMARKS

NO.

USED

Printed in Japan (020830N)

501 944-458 HEX. BAR WRENCH 4MM 1

* 502 318-613

SABER SAW BLADES NO.103 150L P.14 (5 PCS.)

* 502 318-621

SABER SAW BLADES NO.132 203L (5 PCS.)

1 FOR USA,CAN

503 321-142 CASE 1

601 959-610 SABER SAW BLADES NO.1 (5 PCS.) 1 602 958-182 SABER SAW BLADES NO.2 (5 PCS.) 1 603 958-183 SABER SAW BLADES NO.3 (5 PCS.) 1 604 959-611 SABER SAW BLADES NO.4 (5 PCS.) 1 605 958-185 SABER SAW BLADES NO.5 (5 PCS.) 1 606 958-188 SABER SAW BLADES NO.8 (5 PCS.) 1 607 318-611

SABER SAW BLADES NO.101 150L P.10 (5 PCS.)

608 318-612

SABER SAW BLADES NO.102 228L P.10 (5 PCS.)

609 318-614

SABER SAW BLADES NO.104 228L P.14 (5 PCS.)

610 318-615

SABER SAW BLADES NO.105 150L P.18 (5 PCS.)

611 318-616

SABER SAW BLADES NO.106 228L P.18 (5 PCS.)

612 318-617

SABER SAW BLADES NO.107 150L P.24 (5 PCS.)

613 318-618

SABER SAW BLADES NO.108 228L P.24 (5 PCS.)

614 318-619

SABER SAW BLADES NO.121 305L P.6 (5 PCS.)

615 318-620

SABER SAW BLADES NO.131 305L P.10/14 (5PC.)

616 318-621

SABER SAW BLADES NO.132 203L (5 PCS.) 1

Page 34