Part #

Part Name

# Req’d

Material

Mfg Process

Image

1

Rear motor mount

1

Steel

Sheet metal bending, punching, riveting

2

Front motor mount

1

Steel

Sheet metal bending, punching

3

Brush mounts

2

Polymer

Injection molding

See black pieces on above photo

4

Motor brushes

2

Graphite and binder

Compression molding of graphite powder and binder (powder metallurgy)

6

Motor brush springs

2

Copper

Wound wire

7

Motor fan

1

Polymer

Injection molding

8

Rotor

1

See below

See below

8.1

Iron cores  

8

Ferrous iron

Die casting

8.2

Rotor wire coils

1

Copper w/ polymer insulation

Wire drawing

8.3

Core insulators (red)

8

Insulating fish paper

Die cut

8.4

Commutator

1

Copper and resin

“Molding copper to a synthetic resin cylinder” - from example

8.5

Motor shaft sleeve

1

Polymer

Injection molding

8.6

Threaded output shaft

1

Steel

Thread rolling and CNC turning

9

Stator

1

Ferrous iron

Die casting

10

Stator wire coils

1

Copper w/ insulation

Wire drawing

11

Insulating washers

5

Polyimide

Die cutting

12

Wave washer

1

Steel

Die Punch

13

Ordinary washers

2

Steel

Die punch

14

Motor screws

2

Steel

Thread rolling, cold press (heads)

15

Motor to blade assembly screws

2

Steel

Thread rolling, cold press (heads)

16

Blade (one with pin one with hole)

2

Steel

Sheet metal bending, punching, riveting

CNC Machining/grinding

17

Blade grip

2

Polymer

Injection molding

18

Blade arm left

1

Polymer

Injection molding

19

Blade arm right

1

Polymer

Injection molding

20

Blade arm casing top

1

Steel

Sheet metal bending, punching

21

Blade arm casing bottom

1

Steel

Sheet metal bending, punching

22

Helical gear

1

Nylon

Injection molding

23

Motor subassembly to blade subassembly interface

1

Steel

Sheet metal bending, punching

24

Gear axle

1

Steel

Die extrusion with knurling

25

Tension spring

2

Metal

Die extrusion and bent

26

Blade fastener

2

Steel

Die casting and cold working (bend)

27

Trigger lever

1

Steel

Sheet metal shearing/punching

28

Case top

1

Acrylic - guess based on “A” on inside

Injection molding

29

Case bottom

1

Acrylic

Injection molding

30

Case screw

1

Steel

Thread rolling, cold working

31

Trigger

1

Polymer

Injection molding

32

Blade release button

1

Polymer

Injection molding

33

Blade release button plate

1

Steel

Sheet metal punching and bending

34

Blade release spring

1

Steel

Wound wire and heat treated

35

Blade release screw and washer

1

Steel

Thread rolling, cold working

36

Switch

1

Polymer, copper, and aluminum

CNC machining, sheet metal punching, and riveting

37

Switch mounting screw

1

Steel

Thread rolling, cold working

38

Cord clamp

1

Steel

Die punch

39

Cord mounting screws

2

Steel

Thread rolling, cold working

40

Insulating cord washer

1

Fish paper

Die punch

41

Trigger lever guide

1

Polymer

Injection molding

42

Motor mounting screws and washers

3

Steel

Thread rolling, cold working

43

Cord cover

1

Flexible polymer

Injection molding

Step #

Procedure

Part #s removed

Image

1

Remove blade by pulling release switch

16,17

2

Separate blades and remove blade grip screws

26

3

Remove screw from case and lift top case out

30

4

Remove release screw and release mechanism

35

5

Remove release spring and metal plate from release switch

32,33,34,

6

Cut wires to motor (black) and switch (red) and remove screws fastening power supply cord. Remove cord cover.

39,40,38,43

7

Remove four screws fastening blade arms and remove blade arm casing

20

8

Remove three screws fastening motor and blade mechanism to bottom case.

42

9

Remove blade fasteners and springs

25,26

10

Remove trigger lever and trigger lever guide

21,27,41

11

Remove switch screw and remove switch from bottom case

37

12

Squeeze trigger latches and remove trigger from bottom case

31

13

Remove screws attaching reciprocating mechanism to motor subassembly and remove tabs connecting to brush springs - Can’t disassemble reciprocating mechanism further because helical gear axle can’t be removed

15,18,19,22,24

14

Depress motor tabs. Remove tabs, brush springs and brushes

36,4,6

15

Remove screws holding motor sub assembly together and separate stator, rotor, fan, mounting plates, and washers

7,8,9,10,11,12,13,14