19
MAINTENANCE SECTION
18. Remove the Clutch Pilot Rod (38) and the Cam Guide
(24). Remove the two Cam Guide Balls (25) from the
Guide.
19. Lift the Gear Case from the Gear Case Jig and push the
Spindle Bearing (30) and Cam (27) from the Case.
20. Lift the Cam from the Spindle Bearing and remove the
Cam Rollers (28).
21. Slide the Spindle Washer (29) from the Spindle
Bearing.
Cleaning and Inspection of the Tool
1. Clean all of the mechanical parts in an approved safety
solution in a well–ventilated area. Inspect for damage
or wear.
2. Inspect the Fan. If the four corners of the hole are
worn, replace the Fan.
3. Inspect the Fan Pinion Gear and Fan Pilot Rod. If they
are damaged or cracked, replace them.
4. If the taper on the Pilot is worn, replace the Pilot and
the two Pilot Cam Balls.
5. Inspect the Cam Guide Balls. If they are worn, replace
them.
6. Inspect the Cam Guide. If its holes are worn, replace
it.
7. Inspect the Taper Ring Assembly. If the internal taper
is worn, replace it.
8. Inspect the Cam Rollers. If they are worn, replace
them.
9. Inspect the Spindle Washer. If the surface is worn,
replace it.
10. Inspect the Spindle Bearing. If it does not rotate
smoothly, replace it.
11. Inspect the Gears and the Gear Case. If the teeth are
worn, replace them.
Disassembly of the Electrical Components
1. Remove the Reverse Switch Circuit Board (69 or 71)
from the Housing.
Do not touch any circuit paths if using pliers.
2. Loosen the Receptacle Assembly (73).
3. Using a #0 phillips screwdriver, remove the two
Switch Base Screws (63) mounted on the
Microswitch Circuit Board (58).
The Switch Base Screws are coated with thread
adhesive. Unscrew gradually to prevent damage to
the threads.
4. Remove the Motor Assembly and the Controller
Assembly (68) from the Housing Package while
holding both of them together.
Be careful not to damage the Motor Pilot Rod (42).
5. To remove the Controller Assembly, pull the three–pin
connector from the Reverse Switch Circuit Board.
6. Remove the two–pin connector from the Microswitch
Circuit Board.
7. Using needle nose pliers, remove the three wires from
the Shut–off Switch (60).
Be careful not to damage the Shut–off Switch
Terminals.
8. Set the Controller Assembly aside.
9. Grasp the Microswitch Circuit Board using needle nose
pliers and squeeze the ends of the two white Switch
Base Spacers (65). Lift the Brush Light
Circuit Board (67) from the Switch Base Spacers.
10. Using needle nose pliers, squeeze the Switch Base
Spacers and remove the Insulating Film (66).
11. Using the pliers, remove the Switch Base Spacers from
the Brush Light Circuit Board.
12. Remove the two Shut–off Switch Screws (62).
13. Remove the two Start Switch Screws (62).
14. Remove the Switch Plate (59) and the Switch Pilot
Rod (56) from the Switch Plate.
15. Inspect the tip of the Switch Pilot Rod. If it is bent or
worn, replace it.
16. Check the Shut–off Switch for continuity. Replace it if
defective.
17. Check the Start Switch (61) for continuity. If it is
defective, desolder and remove it from the
Microswitch Circuit Board.
18. If the Brush Light Circuit Board is defective, desolder
and remove the red and blue wires.
19. If the components on the Reverse Switch Circuit Board
are damaged or defective, desolder and remove the red
and blue wires.
20. If the Reserve Switch (70) is damaged, desolder and
replace.
21. Using an Ohm meter, check the Resistor (72) on the
Reverse Switch Circuit Board. Readings should be
20 Ohm for 115V Tools and 80 Ohm for 230V Tools.
Desolder and replace Resistor if necessary.
22. If the Capacitor (71) is damaged, desolder and replace
it.
23. Inspect the Noise Suppressor Assembly EP4004E–232
for any components that might be damaged. Replace if
necessary.
