IQ Power Tools iQ360XR Repair Manual Download Page 51 | Manualshive

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Repair Manual

51

888

-

274

-

7744

iQ360XR

Control Module Assembly and Installation

1.

Route the saw motor, main power cord,
and vacuum power cord thru the control

module base

2.

Secure the control module base on to the
support arm with retaining screws

3.

Secure the main power cord ground wire

on to the support arm with retaining
screw

1. Install the printed circuit board

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Summary of Contents for iQ360XR

Page 1: ...assembly and Removal 29 Vacuum Brushes Removal 30 IQ360XR ASSEMBLY 32 Vacuum Brushes Installation 32 Vacuum Motor Installation 34 Pivot Arm Assembly and Installation 37 Saw Mount and Gear Housing Assembly 40 Saw Armature Installation 47 Saw Stator Assembly and Installation 48 Control Module Assembly and Installation 51 Arbor Installation 53 Blade Guard Installation 55 Blade Installation 56 Wiring ...

Page 2: ...www iqpowertools com Repair Manual 2 888 274 7744 iQ360XR ...

Page 3: ...www iqpowertools com Repair Manual 888 274 7744 iQ360XR IQ360XR DISASSEMBLY Filter Removal 1 Remove filter cover retaining screws 2 Remove filter knob 3 Remove filter cover ...

Page 4: ...www iqpowertools com Repair Manual 4 888 274 7744 iQ360XR 4 Remove filter ...

Page 5: ...www iqpowertools com Repair Manual 888 274 7744 iQ360XR Blade Removal 1 Raise saw arm to ease removal of saw blade 2 Depress blade lock 3 Loosen blade lock nut ...

Page 6: ...www iqpowertools com Repair Manual 6 888 274 7744 iQ360XR 4 Remove blade lock nut and washer 5 Remove outer blade flange 6 Remove blade ...

Page 7: ...www iqpowertools com Repair Manual 888 274 7744 iQ360XR 7 Remove inner blade flange ...

Page 8: ...www iqpowertools com Repair Manual 8 888 274 7744 iQ360XR Blade Guard Removal 1 loosen blade guard cover retaining screws 2 remove blade guard cover retaining screws 3 remove blade cover ...

Page 9: ...wertools com Repair Manual 9 888 274 7744 iQ360XR Blade Shaft Assembly Removal 1 remove blade arbor retaining screws 2 Remove the arbor gearbox be aware of the blade locking device 3 Remove blade locking device ...

Page 10: ...www iqpowertools com Repair Manual 10 888 274 7744 iQ360XR 4 Clean and inspect the arbor gear box housing ...

Page 11: ...iqpowertools com Repair Manual 11 888 274 7744 iQ360XR Control Module Disassembly 1 Remove the control module cover retaining screws 2 Lift top cover 3 Disconnect all wire connections from the circuit board ...

Page 12: ...www iqpowertools com Repair Manual 12 888 274 7744 iQ360XR 4 Remove the circuit board retaining screw 5 Lift and remove the circuit board 6 Disconnect the Main Power connection from the On Off switch ...

Page 13: ...www iqpowertools com Repair Manual 13 888 274 7744 iQ360XR 7 Separate and remove the control module top cover 8 Remove the control module retaining screws 9 Remove the Main Power Ground wire ...

Page 14: ...epair Manual 14 888 274 7744 iQ360XR 10 Route the saw and vacuum motor wire conductors through the control module base 11 Route the Main Power wire conductors through the control module base 12 Remove the control module base ...

Page 15: ...w iqpowertools com Repair Manual 15 888 274 7744 iQ360XR Saw Motor Removal 1 Remove the saw motor brush covers 2 Remove the saw motor brushes 3 Remove the saw motor case retaining screws from the saw arm ...

Page 16: ...www iqpowertools com Repair Manual 16 888 274 7744 iQ360XR 4 Pull the saw motor cover with the stator directly out Beware of the armature The armature may remain attached to the saw support arm ...

Page 17: ...om Repair Manual 17 888 274 7744 iQ360XR Saw Motor Stator Disassembly 1 Remove the saw motor end cover retaining screws 2 Remove the saw motor end cover 3 Disconnect the stator brush connectors from the brush connectors ...

Page 18: ...ww iqpowertools com Repair Manual 18 888 274 7744 iQ360XR 4 Route the stator conductors through the saw motor stator case 5 Remove the stator retaining screws 6 Remove the stator from the saw motor case ...

Page 19: ...www iqpowertools com Repair Manual 19 888 274 7744 iQ360XR 7 Check the saw motor case to ensure the armature bearing bushing has been removed ...

Page 20: ...www iqpowertools com Repair Manual 20 888 274 7744 iQ360XR Saw Motor Armature Removal 1 Firmly pull the armature from the support arm ...

Page 21: ...www iqpowertools com Repair Manual 21 888 274 7744 iQ360XR Support Arm Disassembly and Removal 1 Remove the support arm stop from the arm pedestal 2 Unlock the support arm 3 Raise the support arm fully ...

Page 22: ...www iqpowertools com Repair Manual 22 888 274 7744 iQ360XR 4 Loosen and remove the cord clamps 5 Pull the main power and vacuum cords through the support arm holes 6 Lower the support arm ...

Page 23: ...8 274 7744 iQ360XR 7 Lock the support arm 8 With a pair of strain relief pliers remove the vacuum cord strain relief with the vacuum cord 9 with a pair of strain relief pliers remove the main power cord strain relief with the main power cord ...

Page 24: ...8 274 7744 iQ360XR 10 unlock and raise the support arm fully 11 remove the support arm locking device retaining screws and remove the locking device 12 gently tap the support arm pivot shaft out Tap towards the direction of the locking device ...

Page 25: ...www iqpowertools com Repair Manual 25 888 274 7744 iQ360XR 13 Remove the pivot shaft 14 Remove the pivot shaft spring and bushing 15 Separate the support arm from the pivot shaft ...

Page 26: ...al 26 888 274 7744 iQ360XR Pivot Shaft Disassembly and Removal 1 Remove the back panel retaining screws 2 Pull the back panel away from the saw main body to expose the band clamp securing the vacuum output hose 3 Loosen the band clamp ...

Page 27: ...88 274 7744 iQ360XR 4 Remove the back panel 5 Disconnect the vacuum power cord 6 Remove the nut securing the pivot arm to the saw body from the blade chamber 7 Remove the both nuts securing the pivot arm to the saw body in the vacuum chamber ...

Page 28: ...www iqpowertools com Repair Manual 28 888 274 7744 iQ360XR 8 Lift and remove the pivot arm ...

Page 29: ... and Removal 1 Loosen and remove the nuts securing the vacuum to the saw body 2 Remove the vacuum from the saw body 3 Remove and collect all the securing hardware 4 Verify you have 3 sets with 1 each bolt 1 each rubber bushing 2 each flat washer 1 each plastic spacer 1 each nylock nut ...

Page 30: ...274 7744 iQ360XR Vacuum Brushes Removal 1 Depress the vacuum plastic cover tabs 2 Lift the plastic cover from the vacuum 1 With a flat head screw driver push the brush connector away from the brush housing towards the center of the vacuum motor ...

Page 31: ...www iqpowertools com Repair Manual 31 888 274 7744 iQ360XR 2 Remove the brush housing retaining screws 3 Lift and remove the brush housing retainers 4 Remove the vacuum motor brush ...

Page 32: ...wertools com Repair Manual 32 888 274 7744 iQ360XR IQ360XR ASSEMBLY Vacuum Brushes Installation 1 Install new vacuum brushes 2 Slide brush connector on to the brush socket 3 Place brush retainer over the brush ...

Page 33: ...owertools com Repair Manual 33 888 274 7744 iQ360XR 4 Tighten brush retainer screws 1 Check brush connection by pushing into the socket with a flat head screw driver 2 Place plastic cover over the vacuum motor ...

Page 34: ...rtools com Repair Manual 34 888 274 7744 iQ360XR Vacuum Motor Installation 1 Slide the vacuum retaining bolts through the saw body 1 Slide the rubber bushing over the bolt 2 Next slide a flat washer over the bolt ...

Page 35: ...pair Manual 35 888 274 7744 iQ360XR 3 Next slide the plastic spacer over the bolt 4 Slide the second flat washer over the bolt Ensure to repeat steps 1 5 for all 3 vacuum bolts 5 Install the vacuum in the vacuum housing area ...

Page 36: ...www iqpowertools com Repair Manual 36 888 274 7744 iQ360XR 6 Secure the vacuum with the nylock nut 7 Install the vacuum flex hose and tighten the band clamp ...

Page 37: ...60XR Pivot Arm Assembly and Installation 1 Slide the vacuum power cord thru the pivot stand 2 With a pair of strain relief pliers pull the strain relief through the opening provided and ensure it engages 3 Route the vacuum power cord thru the vacuum table ...

Page 38: ... 888 274 7744 iQ360XR 4 Slide the pivot stand on to the saw table 5 Secure the pivot stand on to the saw table with flat washer and nylock nut on the vacuum chamber side 6 Loosely tighten the nylock nut to allow for final adjustment later ...

Page 39: ...www iqpowertools com Repair Manual 39 888 274 7744 iQ360XR 7 Secure the pivot stand on to the saw table with flat washer and nylock nut on the vacuum filter side ...

Page 40: ...360XR Saw Mount and Gear Housing Assembly 1 Slide the gear housing on to the saw mount 2 Start the saw mount shaft by sliding into the saw mount 3 Allow the gear housing to couple with the saw mount but allow space to insert the torsion spring and bushing ...

Page 41: ...torsion spring and bushing into the gear housing cavity It should sit easily in the space provided without tension 6 While holding the torsion spring and bushing in place tap the saw mount shaft thru the saw stand and gear housing spring bushing and on thru the other side 7 Tap the gear housing shaft until it is thru ...

Page 42: ... 274 7744 iQ360XR 8 Verify the saw mount shaft is flush on both sides of the saw stand 9 Apply RED Loctite on the gear housing shaft retainer plate locking screws 10 Install the gear housing shaft retainer plate lock screws on to the saw stand ...

Page 43: ...e gear housing arm 12 Lock the gear housing shaft retainer in the down position 13 Route the saw motor power cord thru the rear of the gear housing 14 With a pair of strain relief pliers insert the strain relief with the vacuum power cord into the rear of the gear housing ...

Page 44: ... Route the saw motor power cord thru the rear of the gear housing 16 With a pair of strain relief pliers install the strain relief on the saw power cord and secure on to the rear of the gear housing 17 Unlock the gear housing lock pin 18 Raise gear housing fully ...

Page 45: ...360XR 19 Route vacuum power cord thru the top of the gear housing 20 Route the saw power cord thru the top of the gear housing 21 Secure both the saw and vacuum power cord with a plastic clamp on the underside of the gear housing 22 Lower the gear housing ...

Page 46: ...www iqpowertools com Repair Manual 46 888 274 7744 iQ360XR 23 Lock the gear housing by engaging the lock pin knob 24 Install the gear housing stop ...

Page 47: ...com Repair Manual 47 888 274 7744 iQ360XR Saw Armature Installation 1 Lubricate the armature gear housing O ring and install 2 Firmly insert the armature into the gear housing 3 Install the armature rear bearing bushing ...

Page 48: ...w Stator Assembly and Installation 1 Insert the stator into the plastic motor case The winding conductors should line up with the hole provide on the plastic case 2 Secure the stator with the retaining screws 3 Route the stator wires through the opening provided ...

Page 49: ...49 888 274 7744 iQ360XR 4 Attach the brush conductors located on the rear end of the motor case 5 Install the motor case end cap 1 Secure the motor end cap with retaining screws 2 Slide the stator and plastic motor case over the armature ...

Page 50: ...www iqpowertools com Repair Manual 50 888 274 7744 iQ360XR 3 Secure the motor case and stator with retaining screws ...

Page 51: ...llation 1 Route the saw motor main power cord and vacuum power cord thru the control module base 2 Secure the control module base on to the support arm with retaining screws 3 Secure the main power cord ground wire on to the support arm with retaining screw 1 Install the printed circuit board ...

Page 52: ...ecure the printed circuit board with retaining screw 3 Make all the proper connections on the printed circuit board and On Off switch using the correct wiring diagram as a guide 4 Secure the control module cover on to the control module base with retaining screws ...

Page 53: ...ar housing is clean 2 Assemble the arbor stop button spring and bushings and partially slide into position 3 Maneuver the arbor gear so the arbor stop and arbor gear slides into the support arm housing 4 Check the arbor stop by rotating the arbor output shaft and depressing the arbor stop push button ...

Page 54: ...www iqpowertools com Repair Manual 54 888 274 7744 iQ360XR 5 Secure the arbor gear onto the support arm housing with retaining screws 6 Tighten the arbor gear retaining screws ...

Page 55: ...www iqpowertools com Repair Manual 55 888 274 7744 iQ360XR Blade Guard Installation 1 Align and slide the blade guard over the arbor 2 Secure the blade guard onto the support arm with retaining screws ...

Page 56: ...ols com Repair Manual 56 888 274 7744 iQ360XR Blade Installation 1 Slide the inner flange onto the arbor shaft 2 Check the blade for rotation direction 3 Install the blade ensure the blade rotation arrow is correct ...

Page 57: ...www iqpowertools com Repair Manual 57 888 274 7744 iQ360XR 4 Install the outer blade flange 5 Insert the outer retaining washer and lock nut 6 Tighten lock nut ...

Page 58: ...www iqpowertools com Repair Manual 58 888 274 7744 iQ360XR Wiring Diagram 360XR ...

Page 59: ...ls com Repair Manual 59 888 274 7744 iQ360XR IQ360X TO IQ360XR CONVERSION GUIDE iQ360X Removal 1 Remove the blade 2 Remove the backplate retaining screws 3 Loosen the vacuum exhaust hose clamp 4 Remove the backplate ...

Page 60: ...m Repair Manual 60 888 274 7744 iQ360XR 5 Disconnect the wires from the relay 6 Unplug both power and vacuum quick disconnects 7 Disconnect the ground Green wire from the vacuum 8 Disconnect the ground Green from the case ...

Page 61: ... com Repair Manual 61 888 274 7744 iQ360XR 9 Disconnect the ground Green wire from the backplate 10 Remove the power cord strain relief from the backplate 11 Route all conductors thru the back plate 12 Remove the relay ...

Page 62: ...XR NOTE This is what the backplate should look like once all items have been removed 1 Remove the strain relief from located at the base of the stand 2 Remove the divot lock 3 Remove the gear housing stop and raise the gear housing to the fully open position ...

Page 63: ...ertools com Repair Manual 63 888 274 7744 iQ360XR 4 Tap the gear housing shaft half way out 5 Remove the tension spring and bushing 6 Pull the gear housing shaft all the way out 7 Remove the iQ360X gear housing ...

Page 64: ...e the iQ360XR Gear housing onto the stand and insert the gear housing pivot shaft 2 Install the tension spring and bushing and tap the gear housing pivot shaft thru 3 Rotate the gear housing to the down and cutting position and insert the gear housing stop 4 Tighten the gear housing stop ...

Page 65: ...r cord into the vacuum chamber 6 Connect the vacuum power cord to the vacuum 7 Insert the rubber plug into the opening previously used for the power cord on the backplate 8 Attach the vacuum exhaust on to the backplate and tighten the hose clamp 9 Install the backplate on to the tub ...

Page 66: ...www iqpowertools com Repair Manual 66 888 274 7744 iQ360XR 10 Install the blade ...

Page 67: ...ols com Repair Manual 67 888 274 7744 iQ360XR IQ360 TO IQ360XR CONVERSION GUIDE iQ360 Removal 1 Remove the blade 2 Remove the backplate retaining screws 3 Loosen the vacuum exhaust hose clamp 4 Remove the backplate ...

Page 68: ... Repair Manual 68 888 274 7744 iQ360XR 1 Disconnect the ground Green wire from the vacuum 8 Disconnect the ground Green from the case 9 Disconnect the wires from the relay 10 Unplug both power and vacuum quick disconnects ...

Page 69: ...wire from the backplate 12 Remove the power cord strain relief from the backplate NOTE This is what the backplate should look like once all items have been removed OPTIONAL Drill out the rivets to remove the relay and current sensor 13 Remove saw mount center nut 14 Remove saw mount side nut ...

Page 70: ...www iqpowertools com Repair Manual 70 888 274 7744 iQ360XR 15 Turn the saw on its side 16 Remove the final saw mount bolt 17 Remove the saw mount and 360 saw motor ...

Page 71: ...allation OPTIONAL 1 Place 360XR saw mount in table mount 2 Drill a inch hole on the blade side rear of the saw mount NOTE Just penetrate the table top to create a starter hole 3 Remove the saw mount 4 Using a step drill bit drill a 5 8 inch hole at the same location the inch hole was started ...

Page 72: ...www iqpowertools com Repair Manual 72 888 274 7744 iQ360XR 5 The finished hole should look like this 6 Place the rubber grommet into the inch hole on the saw mount ...

Page 73: ... table and secure the 3 bolts with nylock nuts 2 Slide the iQ360XR Gear housing onto the stand and insert the gear housing pivot shaft 3 Install the tension spring and bushing and tap the gear housing pivot shaft thru 4 Rotate the gear housing to the down and cutting position and insert the gear housing stop ...

Page 74: ...Q360XR 5 Tighten the gear housing stop 6 Install blade lock 7 Route the Vacuum power cord into the vacuum chamber 8 Connect the vacuum power cord to the vacuum 9 Insert the rubber plug into the opening previously used for the power cord on the backplate ...

Page 75: ...www iqpowertools com Repair Manual 75 888 274 7744 iQ360XR 10 Attach the vacuum exhaust on to the backplate and tighten the hose clamp 11 Install the backplate on to the tub 12 Install the blade ...

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