Makita HS7100, HS7101 User Manual

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Page 1

ECHNICAL INFORMATION

PRODUCT

P 1/16

Model No.

Description

HS7100, HS7101

Circular Saw 190mm (7-1/2")

CONCEPT AND MAIN APPLICATIONS

Models HS7100, HS7101 have been developed as the successor models of the current model 5705R, featuring compact & lightweight design without riving knife.

Other features are:

• New aesthetic design with black blade case and rear cover

• Electronic brake for quick blade stop (for HS7101 only)

• Twin LED job light for easy tracing of cutting line in the dark place

(for HS7101 only)

These models are also available with plastic carrying case as “K” models; HS7100K, HS7101K.

Specification

Voltage (V) Cycle (Hz)

110 13 50/60 680 1,750

220 - 240 6.4 50/60

Current (A)

Continuous Rating (W)

Input Output

1,400 1,400 640 2,200

Dimensions: mm (")

Length (L)

Width (W)

Height (H)

Max. Output (W)

310 (12-1/4)

246 (9-11/16)

258 (10-1/8)

Specifications

Size of blade: mm (")

No load speed: rpm= min.

Max cutting capacity: mm (")

Electric brake No Yes

Power supply cord: m (ft)

Weight according to

EPTA-Procedure 2003/01*

*1: with TCT saw blade, Dust nozzle

Diameter

Hole diameter

ˉ¹

1: kg (lbs)

Model No.

0 degree

45 degrees

50 degrees

HS7100 HS7101

190 (7-1/2)

30 (1-3/16)

5,500

67.0 (2-5/8)

48.5 (1-15/16)

43.5 (1-11/16)

Double insulationProtection against electric shock

No Yes (twin LED)Job light

European countries: 4.0 (13.1), Australia, Brazil: 2.0 (6.6)

Other countries: 2.5 (8.2)

4.0 (8.8) 4.0 (8.9)

Standard equipment

TCT saw blade 190 ............. 1

Hex wrench ........................ 1

Guide rule (Rip fence) ....... 1

Dust nozzle ......................... 1

Guide rail adapter ............... 1 (for some countries only)

Note: The standard equipment for the tools shown above may vary by country.

Optional accessories

Saw blades Guide rail 1400 set Guide rail 1900 set Guide rail 3000 set

Position seat sets Rubber seat set Seat set Guide rail adapter

Bevel guide set

Guide rule (Rip fence) Clamp set Stopper

Page 2

P 2/16

Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

Code No. Description Use for

1R003 Retaining ring S pliers ST-2N Removing/mounting Retaining ring S-42, holding Safety cover

1R032 Bearing setting plate 8.2 Removing Spindle from Helical gear

1R207 45-degree set square Adjusting accuracy of 45 degrees

1R208 90-degree set square Adjusting accuracy of 90 degrees

1R217 Ring 22 Supporting Helical gear when removing Spindle

1R228 1/4” Hex shank bit for M4 Disassembling/assembling Rear angular guide

1R269 Bearing extractor Removing Ball bearing 607ZZ from Spindle

1R280 Round bar for arbor 6-50 Removing Spindle from Helical gear

1R340 Bearing retainer wrench Removing/mounting Bearing retainer 23-36

[2] LUBRICATION

Apply the following grease/ lubricant to the specific portions to protect parts and product from unusual abrasion.

Item No. Description Grease AmountPortion to lubricate

39 48 75

Fig. 1

Blade case Gear room approx. 6 g

Angular guide Contact surface where (39) Blade case pivots

Safety cover

a littleBearing box Drum portion where Safety cover pivots a little

Makita Grease SG No.0

VG100

Page 3

P 3/16

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -1. Base

DISASSEMBLING

Set the cutting depth of the machine to maximum, and remove saw blade. Then remove both Rear angular guide section and Angular guide section from Base. Base can now be replaced. (Fig. 2)

Fig. 2

Rear Angular Guide Section (on the rear of the machine)

1. Unscrew M6 Thumb nut, then remove Flat washer 6 and M6x20 Flat head square neck bolt.

M6 Thumb nut

Flat washer 6

M6x20 Flat head

square neck bolt

Angular Guide Section (on the front of the machine)

3. Loosen M6x20 Hex bolt using Lever 45, then remove E-8 Bow stop ring with a slotted screwdriver.

4. Remove M6x20 Hex bolt by using Lever 45 as a tool, then remove Flat washer 6.

2. Loosen M6x8 Hex socket set crew with Hex wrench, remove Shoulder pin 6-7 that functions as a hinge.

M6x8 Hex socket

set screw

Shoulder pin 6-7

5. Loosen M6x8 Hex socket set screw, then remove Shoulder pin 6-7 that functions as a hinge.

Lever 45

E-8 Bow stop ring

M6x20 Hex bolt

6. Base can now be separated from the machine.

Base

Flat washer 6

Lever 45

M6x20 Hex bolt

M6x8 Hex socket set screw

Shoulder pin 6-7

7. Base can be replaced after removing Top guide, Lock levers, and four M6x8 Hex socket set screws.

M5x8 Pan hd. screw

Lock lever

M6x8 Hex socket

set screw

(4 pcs.)

Top guide

Lock lever

Page 4

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -1. Base

ASSEMBLING

Base can be mounted to the machine by taking the reverse steps of Disassembling. Note: Follow the important instructions described in Fig. 2A. See Fig. 3 for Assembling and Adjustment of Lock lever for clamping Guide Rule.

Fig. 2A

P 4/16

Be sure to mount E-8 Bow stop ring as shown below for securely engaging Lever 45 with M6x20 Hex bolt.

Angular guide section,

Angular guide

Flat washer 6

Lever 45

E-8 Bow stop ring

M6x20 Hex bolt

viewed from top

Adjust Lever 45 so that it can be locked in the position shown below when the machine’s cutting angle is adjusted to 90 degrees.

Lever 45

[3] -2. Lock Lever for clamping Guide Rule

ASSEMBLING, ADJUSTMENT

Mount Lock lever to Base and adjust its locking position when Guide rule attaching. (Fig. 3)

Fig. 3

1. Fasten Guide rule to Base with M6x10 Hex bolt.

M6x10 Hex bolt

4 . Lift up Lock lever so that its upper surface is flush with that of M6x10 Hex bolt, then rotate Lock lever independently. Then adjust the Lock lever so that it can be locked in the position shown below.

30 degrees

Guide rule

2. Insert Torsion spring 11 into Lock lever with its short arm inserting in the square hole of Lock lever.

Torsion spring 11

short arm

Lock lever

3. Applying the Torsion spring's long arm to the tab of Base, put the Lock lever over M6x10 Hex bolt. But do not push Lock lever down until you engage it with the Hex bolt in the step 5.

long arm long arm

tab

30 degrees

5 . Push Lock lever down until it engages with M6x10 Hex bolt, then secure Lock lever with Stop ring E-6.

Stop ring E-6

6. Make sure that:

1) When Guide rule is clamped, Lock lever stops in the same position as you set in the step 4.

2) With Guide rule removed, Lock lever returns to its initial position smoothly and exactly from the locking position..

Page 5

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -3. Depth Guide

DISASSEMBLING

Disassemble Depth guide as described in Fig. 4.

Fig. 4

P 5/16

1. Set the cutting depth of the machine to minimum. Remove Lock plate from Lever 70 by unscrewing M4x8 Pan head screw.

M4x8

Pan head screw

3. Fix M4-7 Hex lock nut with Wrench 7, then remove M4x20 Hex bolt with 1R288.

Lock plate

2. From M6x18 Hex bolt, remove Lever 70, M6 Hex nut, Flat washer 6 and Sleeve 6.

M6 Hex nut

Lever 70

M6x18 Hex bolt

4. Depth guide and Flat washer 6 on Blade case side can now be removed.

Flat washer 6

Sleeve 6

M4-7 Hex lock nut

M4x20 Hex bolt

5. M6x18 Hex bolt can now be removed by loosening M5x8 Hex socket set screw a little bit.

M6x18 Hex bolt

Depth guide

Flat washer 6

M5x8 Hex socket

set screw

Page 6

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -3. Depth Guide

ASSEMBLING

Assemble Depth guide section by taking the reverse step of Disassembling. (Fig. 4)

Note: Follow the important instructions described in Fig. 5.

Fig. 5

1. M6x18 Hex bolt must be mounted to Blade case so that the concave surface of the bolt head faces M5x8 Hex socket set screw.

Blade case

M6x18 Hex bolt

Base

concave

surface

P 6/16

M5x8 Hex socket

set screw

2. M4x8 Pan head screw must be seen closest to Handle when Lever 70 is in the locking position with the cutting depth of the machine adjusted to minimum.

Handle

Lever 70 in the locking position, with the cutting depth of the machine adjusted to minimum

M4x8 Pan head screw

Page 7

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -4. Angular Guide

DISASSEMBLING

Angular guide can be disassembled as described in Fig. 6.

Fig. 6

P 7/16

1. Loosen M6x20 Hex bolt with Lever 45, then remove

E-8 Bow stop ring.

Lever 45

E-8 Bow stop ring

M6x20 Hex bolt

4. Hold M5-8 Hex lock nut with Wrench 8, then unscrew M5 Truss head screw O ring 9 and Stopper can now be removed.

2. Remove M6x20 Hex bolt by using Lever 45 as a tool, then remove Flat washer 6.

Flat washer 6

Lever 45

M6x20 Hex bolt

3. Loosen M6x8 Hex socket head set crew, then remove Shoulder pin 6-7 that functions as a hinge.

M6x8 Hex socket

Shoulder pin 6-7

5. Disassemble Angular guide.

set screw

Angular guide

O Ring 9

M5 Truss head screw

Stopper

Angular guide

ASSEMBLING

Assemble Angular guide by taking the reverse step of Disassembling. (Fig. 6)

Note:

1. E-8 Bow stop ring must be mounted as shown on the left in Fig. 2A.

2. Adjust Lever 45 as shown on the right in Fig. 2A.

M5-8 Hex lock nut

Page 8

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -5. Blade Case, Blade Cover, Safety Cover

DISASSEMBLING

(1) Separate Motor housing and Armature from Blade case section as described in Fig. 7.

Fig. 7

1. Remove Carbon brush. 2. Remove three M5x45 Pan head screws.

P 8/16

Brush holder cap

3. Separate Motor housing from Blade case section. 4. Remove Armature together with Shaft lock

Note: If Rubber washer 13 falls off Motor housing in this step, put it back into Bearing box of Motor housing.

(2) Remove both Angular guide section and Rear angular guide section from Base. (Fig. 2)

(3) Remove Depth guide and M6x8 Hex bolt from Blade case. (Fig. 4) (4) Remove Safety cover together with Tension spring 4, Bearing box and other parts from Blade case. (Fig. 8)

Fig. 8

Carbon brush

Rubber washer 13

Brush holder cap

and Compression spring 7.

Compression spring 7

Armature

Shaft lock

Tension spring 4

Safety cover

Retaining ring S-42

Use 1R003 for removing Retaining ring S-42.

M5x8 Hex socket

set screw

Bearing box

M5x16

Pan head screw

O Ring 44

Rubber sleeve 6

M6x20 Pan head screw

Page 9

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -5. Blade Case, Blade Cover, Safety Cover

DISASSEMBLING

(5) Remove Blade cover as described in Fig. 9.

Fig. 9

P 9/16

1. Remove two M4x12 Pan head screws.

Blade case

Blade cover

ASSEMBLING

(1) Mount Bearing box on Blade case. (See the right illustration in Fig. 8.) (2) Mount Tension spring 4 on Blade case and Safety cover as described in Fig. 10.

Fig. 10

2. Grab Blade cover at the tab and the bottom with your forefinger and thumb, then lift it up a little and put the rib portion of Blade case on the edge of Blade case.

tab

rib portion,

put on the edge

of Blade case

3. Pull off Blade cover from Blade case by sliding it in the direction of the arrow.

Insert the hook from Blade side to Motor housing side.

Blade case

Tension spring 4

Blade side Motor housing side

Safety cover

Insert the hook from Motor housing side to Blade side.

(3) Set Retaining ring S-42 in place with 1R003. (See the left illustration in Fig. 8)

(4) Take the reverse step of Disassembling. (Fig. 7)

Page 10

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -6. Helical Gear, Ball Bearing 6003DDW

DISASSEMBLING

(1) Remove Safety cover, then remove Bearing box from Blade case. (Fig. 8) Then separate Helical gear together with Spindle from Bearing box as described in Fig. 11.

Fig. 11

P 10/16

1. Separate Bearing box from Spindle and Helical gear using arbor press as drawn below.

Bearing box

Spindle

*Helical gear

Ball bearing 607ZZ

(2) Remove Spindle from Helical gear as described in Fig. 12.

Fig. 12

1. Put Helical gear section onto 1R217, then put 1R032 onto Spindle as drawn below.

2. Push Spindle down a little by giving impact to 1R032 using arbor press.

2. Remove Ball bearing 607ZZ with 1R269.

1R269

Ball bearing 607ZZ

* Helical gear 40 for HS6100, HS6101 * Helical gear 43 for HS7100, HS7101

3. Apply 1R280 to Spindle. Spindle can be removed by pushing 1R280 down using arbor press.

1R032

1R280

*Helical gear

Spindle

1R217

* Helical gear 40 for HS6100, HS6101 * Helical gear 43 for HS7100, HS7101

(3) In the step of Fig. 11, Ball bearing 6003DDW still remains in Bearing box. This Ball bearing can be removed as described in Fig. 13.

Fig. 13

Clamp Bearing box in vise. Engage 1R340 with Bearing retainer 23-36, then remove the Bearing retainer from Bearing box by turning 1R340 clockwise. Ball bearing 6003DDW can now be removed from Bearing box.

1R340

Bearing retainer 23-36

Bearing box

Ball bearing 6003DDW

Bearing box

Bearing retainer

23-36

Page 11

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -7. Handle Cover, Electrical Parts in Handle

DISASSEMBLING

Remove Handle cover from Motor housing as described in Fig. 14.

Note: No need to disassemble Blade case or Motor housing. Fig. 14

P 11/16

1. Lift up Handle cover in the direction of arrow .

2. Turn Handle cover in the direction of arrow . Then pull the Handle cover in the direction of arrow .

3. Electrical parts (Switch, Power supply cord, LED light circuit, Controller etc.) can now be replaced.

[4] ADJUSTMENT [4]-1 Angle of Saw Blade to Base

(1) Attach Saw blade to the unplugged machine, and set to the cutting depth to maximum. (2) Adjust the angle of saw blade to Base as described in Fig. 15.

Fig. 15

[Adjustment to 90 degrees]

[Adjustment to 45 degrees]

Power supply cord

Switch

LED light circuit

1. Set the cutting depth of the machine to maximum with the bevel angle adjusted to 90 degrees.

2. Tighten Lever 45, Lever 70 and M6 Thumb nut.

3. Open Safety cover fully, then apply 1R208 to the base metal of the saw blade as drawn below, Then adjust for 90 degree accuracy by turning M6x8 Hex socket set screw with hex wrench.

1R208

1. Set the cutting depth of the machine to maximum with the bevel angle adjusted to 45 degrees.

2. Tighten Lever 45, Lever 70 and M6 Thumb nut.

3. Open Safety cover fully, then apply 1R207 to the base metal of the saw blade as drawn below, Then adjust for 45 degree accuracy by turning M6x8 Hex socket set screw with hex wrench.

1R207

Page 12

Repair

[4] ADJUSTMENT [4]-2 Parallel Adjustment of Base to Saw Blade

(1) Attach saw blade to the unplugged machine, and set the cutting depth of the machine to maximum with the bevel angle adjusted to 90 degrees. (2) Make parallel adjustment of Base to saw blade as described in Fig. 16.

Fig. 16

1. Unlock Base from Blade case at the Cord guard side by loosening M5x8 Hex socket set screw a little.

2. Open Safety cover fully.

3. Move the Cord guard side of Base in the direction of large black arrows until the distance A is equal to B.

4. After the adjustment is finished, tighten M5x8 Hex socket set screw firmly with hex wrench.

M5x8 Hex socket

set screw

P 12/16

Cord guard

Page 13

Circuit diagram

Fig. D-1

HS6100 & HS7100 (without Electric brake and LED light)

Color index of lead wires' sheath

Black White

Blue Brown

P 13/16

Noise suppressor

Noise suppressor is not used for some countries.

Switch

Brush holder R

Field

Field,

viewed from

Blade case side

Brush holder F

This Lead wire is black for some countries instead of brown.

Power supply cord

This Lead wire is white for some countries instead of blue.

Terminal block

Page 14

Wiring diagram

Fig. D-2

HS6100 & HS7100 (without Electric brake and LED light)

P 14/16

Be careful not to put Lead wire (blue or white) of Power supply cord on Noise suppressor after connecting it to Terminal block.

Switch

Be careful not to put Lead wires on the boss and ribs A, B, C, D.

rib C rib D

Strain relief

rib A

Noise suppressor

(if used)

rib B

Terminal block

boss

Route Field lead wires into Handle section through this groove.

Field lead wires must be tight in Motor housing.

Field

Fix Field lead wires in these Lead wire holders.

If Noise suppressor is used, route Noise suppressor’s lead wires between rib A and rib B. Be careful not to put them on Noise suppressor, ribs A and B.

Set Terminal block in Handle section with each terminal positioned as follows: *On Strain relief side, the terminal with which the Lead wire of Power supply cord is connected must be positioned. *On Field side, the terminal with which the Field lead wire is connected must be positioned.

Field lead wires must be tight in Motor housing.

Page 15

Circuit diagram

Fig. D-3

HS6101 & HS7101 (with Electric brake and LED light)

Color index of lead wires' sheath

Black Brown Purple Yellow

Blue Orange White

P 15/16

Noise suppressor

Noise suppressor is not used for some countries.

Switch

Brush holder R

Field

Choke coil

Field,

viewed from

Blade case side

Brush holder F

This Lead wire is black for some countries instead of brown.

Power supply cord

This Lead wire is white for some countries instead of blue.

Terminal block

Choke coil

Controller

This Lead wire is blue for some countries instead of red.

Light Circuit

This Lead wire is blue for some countries instead of red.

Page 16

Wiring diagram

Fig. D-4

HS6101 & HS7101 (with Electric brake and LED light)

P 16/16

Be careful not to put Lead wire (blue or white) of Power supply cord on Noise suppressor after connecting it to Terminal block.

Be careful not to put Lead wires on the boss and ribs A, B, C, D.

Strain relief

rib A

Noise suppressor

(if used)

Route Field lead wires and Lead wires of LED Light circuit into Handle section through this groove.

Switch

rib C rib D

rib B

boss

Terminal block

Fix Lead wires of LED Light circuit in this Lead wire holder.

Field lead wires must be tight in Motor housing.

Fix Lead wires of LED Light circuit in these Lead wire holders.

Field

LED Light circuit

Fix Field lead wires in these Lead wire holders.

If Noise suppressor is used, route Noise suppressor’s lead wires between rib A and rib B. Be careful not to put them on Noise suppressor, ribs A and B.

Field lead wires must be tight in Motor housing.