T ECHNICAL INFORMATION PRODUCT P 1 / 20 Models No. LH1040, LH1040F Description Table Top Miter Saw 260mm (10-1/4") CONCEPT AND MAIN APPLICATIONS Models LH1040 and LH1040F have been developed as multi-purpose miter saws. Installation of a table on Model LS1040 has enabled miter saw and table saw to be packed in one tool for great versatility. LH1040F features LED built-in job light for accurate tracing of ink line in dark places. H Dimensions: mm (") Length (L) 530 (20-7/8) Width (W) 476 (18-3/4) Height (H) 535 (21) L W Specification Voltage (V) Current (A) Cycle (Hz) 110 120 220 230 240 15 15 7.9 7.5 7.2 50 / 60 50 / 60 50 / 60 50 / 60 50 / 60 Continuous Rating (W) Input Output 1,650 1,000 1,650 1,000 1,650 1,000 1,650 1,000 1,650 1,000 LH1040 Model No. 2,300 2,300 2,300 2,300 2,300 LH1040F 4,800 No load speed: min-1 = rpm. Diameter Saw blade: mm (") Max. Output(W) 255 - 260 (10 - 10-1/4 ) 15.88 (5/8) 30.0 ( for European countries) 40 (1-9/16 ) Hole diameter Table saw Capacity: mm (") (with 260 mm saw) Miter saw Protection against electric shock See the table below. Double insulation Yes Electric brake LED job light Cord length: m (ft) Net weight: kg (lbs) No Yes 2.5 ( 8.2 ) 13.7 (30.2 ) Cutting capacity as Miter Saw Bevel angle Miter angle 90° 45° Left bevel 90° 69mm x 130mm (2-3/4" x 5-1/8") 93mm x 95mm (3-5/8" x 3-3/4") 35mm x 130mm (1-3/8" x 5-1/8") 53mm x 95mm (2-1/16" x 3-3/4") 45° Left 69mm x 85mm (2-3/4" x 3-3/8") 93mm x 67mm (3-5/8" x 2-5/8") 35mm x 65mm (1-3/8" x 2-9/16") 49mm x 42mm (1-15/16" x 1-5/8") 45° Right 69mm x 85mm (2-3/4" x 3-3/8") 93mm x 67mm (3-5/8" x 2-5/8") 35mm x 91mm (1-3/8" x 3-5/8") 49mm x 67mm (1-15/16" x 2-5/8") Standard equipment TCT saw blade 260mm .......... 1 pc Dust bag ................................. 1 pc Holder set ............................... 1 pc Sub plate ass'y ........................ 1 pc Socket wrench 13 ....................... 1 pc Ring 16 (adaptor for saw blades with 25mm hole diameter) ......... 1 pc Triangular rule ............................ 1 pc Note: The standard equipment listed above may differ from country to country. Optional accessories Vertical vise Horizontal vise Holder set Assorted TCT saw blades Set plate ................................... 1 pc Blade cover .............................. 1 pc Push stick ................................. 1 pc Guide rule rule ........................ 1 pc P 2 / 20 Repair CAUTION: For your safety, before maintenance or repair, be sure to; 1. Disconnect the machine from the power source. 2. Remove the saw blade from the machine.  NECESSARY REPAIRING TOOLS Tool No./ Description Use for 1R035/ Bearing Setting Plate 15.2 Press-fitting Ball bearings 1R045/ Gear Extractor (large) 1R208/ 90 Degrees Set Square Disassembling Gear housing cover and Bearing box Squaring Saw blade with Base 1R229/ 1/4" Hex shank bit for M5 1R235/ Round Bar for Arbor 6-100* (2 pcs) Removal/Installation of screws that fasten Bearing box Disassembling Blade case 1R269/ Bearing Extractor Removing Ball bearings 1R291/ Retaining Ring S and R Pliers 1R306/ Ring Spring Removing Jig** Removal/Installation of the Retaining ring Disassembling Blade case 1R340/ Wrench for Bearing Retainer Removal/Installation of Bearing retainer *Note: Disassembling can be done also using two Phillips screwdrivers of 6.5X100mm or larger size instead. **Note: Disassembling can be done also using 1R201/ Jig for Retaining Ring.  LUBRICATION 1) Apply 12g of Makita grease N No.1 to the gear portion. 2) Apply an appropriate amount of Makita grease N No.1 to each of the listed below. Although these slide surfaces are factory-greased with Makita grease N No.1, you apply other type of grease such as Makita grease N No.2 or the like. Position No. 1 Parts item Blade case 24 Center cover 99 Table support 101 Support plate Portion to be lubricated Gear portion Accepting hole for compression spring 27 The pivotal portion where arm contacts The appropriate amount is 12g. The portion where torsion spring 36 contacts The elliptic punched hole where lever 54 contacts, when table support is slidden up and down. The side where (1) Blade Case contacts, when table support is slidden up and down. The elliptic punched hole where pipe 9-126 contacts, when support plates are slidden up and down. Fig.1-1 Lever 54 Torsion spring 36 Lever 54 Safety cover Compression spring 27 Pipe 9-126 Switch box P 3 / 20 Repair  LUBRICATION Position No. Parts item Portion to be lubricated 124 Hex bolt M10 Threaded portion 126 Rod 16 The surface where (127) Arm Complete contacts. 127 Arm complete 129 Stopper pin The groove to which O ring 5 is mounted. 135 145 Slide plate Turn base The surface where (145) turn base contacts Accepting portion for pivoting (127) Arm Complete 147 Base complete Accepting boss for the shaft of (145) Turn Base 150 Knock spring Both edge which contacts its accepting portion of (145) Turn Base 151 Grip 32 Tip of the threaded portion with which (150) Knock spring is pushed toward (145) Turn Base Thumb screw Tip of the threaded portion A The portion where (145) turn base contacts, when arm complete pivoting. Accepting portion for pivoting (1) Blade Case Fig.1-2 O ring 5 Accepting portion for (150) Knock Spring Rip fence P 4 / 20 Repair < 3 > Removing table 1. Lift up table by loosening two 54 levers which are equipped under the table. See Fig.2-1. 2. Lift up the table to the highest level. See Fig.2-1. 3. Remove pan head screw M5x16 and remove cover complete from riving knife. See Fig.2-2. 4. Remove 8 M5x16 countersunk head screws. Then, table can be removed from blade case. See Fig.2-2. And remove compression spring 27 from blade case. See Fig.2-2. (In case of model LH1040 without fluorescent job light) 4A. While lifting up the table, remove light circuit from the table. Then, table can be removed from blade case. And remove compression spring 27 from blade case. See Fig.2-2. (In case of model LH1040F with fluorescent job light) Fig.2-1 Table Lever 54 Fig.2-2 Pan head screw M5x16 Hex lock nut M5-8 Cover complete Table Countersunk head screw M5x16 (8 pcs.) Riving knife Table Compression spring 21 < 4 > Mounting table 1. Secure table with 8 M5x16 countersunk head screws. Refer to Fig.2-2. 2. While lifting up table to the highest level, mount compression spring 21 by inserting it from the side. 3. Take the left step with referring to the above Figs. P 5 / 20 Repair < 5 > Removing blade case section 1. Remove living knife. See Fig.3-1. 2. Remove lever 54, support plate and pipe 9-126. See Fig.3-1. The pipe 9-126 removed in this step, is used as a jig for removing rod 16 which functions as a pivot for blade case. 3. Loosen lever 54 and press table support down to the surface of blade case. See Fig.3-2. Fig.3-1 Fig.3-2 Support plate Living knife Hex flange head bolt M8x20 Pipe 9-126 Table support Table support Lever 54 Lever 54 Rod 16 4. Remove two M5x16 pan head screws. Now guard with guard holder can be removed from blade case. See Fig.3-3. 5. Remove hex socket button head screw M6 (adhesive type), flat washer 7 and ring 7. Now the linkage of link plate with arm complete has been disconnected. See Fig.3-4. 6. Remove stop ring E-5, flat washer 6 and ring 6. then, link plate can be removed from blade case. See Fig.3-5. Fig.3-3 Fig.3-4 Guard holder Blade case Arm complete Blade case Link plate Pan head screw M5x16 Ring 7 Guard Flat washer 7 Hex socket button head screw M6 Fig.3-5 Stop ring E-5 Flat washer 6 Ring 6 Link plate P 6 / 20 Repair < 5 > Removing blade case section 7. Lower the blade case section to the possible lowest position, and lock it at the same position with stopper pin. See Fig.3-6. 8. While further pressing the blade case section, insert two screwdrivers into the side hole of blade case. See Fig.3-7. Or insert No.1R238 "Round Bar for Arbor" as illustrated in Fig.3-7A. 9. Loosen hex socket head bolt M6x10 with hex wrench. See Fig.3-7. 10. Apply pipe 9-126 on rod 16, and remove it by striking the pipe with plastic hammer toward the side of hex socket head bolt M6x10. See Fig.3-8. Now blade case section can be separated from arm complete. Fig.3-7 Fig.3-6 Hex wrench Screwdriver Hex socket head bolt M6x10 Stopper pin Screwdriver Fig.3-8 Fig.3-7A Hex wrench Hex socket head bolt M6x10 Hex socket head bolt M6x10 No.1R238 Round Bar for Arbor Pipe 9-126 <Note> In order to minimize scratch on the accepting holes for rod 16, remove it toward the side of hex socket head bolt M6x10. See Fig.3-8A. Fig.3-8A Direction for removing rod 16 Rod 16 Blade case Arm complete The scratch on the accepting holes is minimized to this area. Hex socket head bolt M6x10 The portion scratched with hex socket head bolt M6x10 Rod 16 P 7 / 20 Repair < 5 > Removing blade case section 11. Put the removed blade case section on the turn base of arbor press, And set 1R306 "Ring Spring Removing Jig" between the two screwdrivers, inserted in the step of Fig.3-7. See Fig.3-9. 12. Press down 1R306 "Ring Spring Removing Jig" with arbor press. So, spring holder is pressed down and the screwdrivers can be pulled out from blade case. Fig.3-9 No.1R306 Ring Spring Removing Jig Arbor press Screwdriver Blade case section 13. Put the removed blade case section on the turn base of arbor press, And set 1R306 "Ring Spring Removing Jig" between the two screwdrivers, inserted in the step of Fig.3-7. See Fig.3-9. 14. Press down 1R306 "Ring Spring Removing Jig" with arbor press in order to lower spring holder, while holding the blade case section firmly, so that it does not tilt or wobble. 15. Slowly lessen the pressure to 1R306 "Ring Spring Removing Jig", while holding the blade case section firmly, so that it does not tilt or wobble. See Fig.3-10. 16. Remove spring holder and compression spring 27 from blade case, when the jig gets free from the force of compression spring. See Fig.3-10. Fig.3-10 No.1R306 Ring Spring Removing Jig Slowly lessen the pressure to the jig. Spring holder Compression spring 27 Blade case section P 8 / 20 Repair < 5 > Mounting blade case section 1. Take the reverse step of removing, while paying attention to the following matters. A. Scrape off the scratched portion of rod 16 with file, before mounting. Mount rod 16 from the side of hex socket head bolt M6x10 . See Fig.4-1. B. When pulling out two screwdrivers in the final step, press the blade case section down to the possible lowest position. Then, at the same time, spring holder is mounted to the original position automatically. C. Apply the adhesive to hex socket button head screw M6 with which link plate is secured to arm complete. Refer to Fig.3-4. Fig.4-1 Hex socket head bolt M6x10 Blade case Direction for mounting rod 16 Arm complete The portion scratched with hex socket head bolt M6x10, has to be scraped off, before mounting. Rod 16 < 6 > Disassembling safety cover section 1. Loosen hex flange head bolt M8x12. Remove socket head flange screw M6 with hex wrench, inserted through the punched hole of safety cover. Now safety cover section can be separated from blade case. See Fig.5-1. 2. The safety cover section can be disassembled by unscrewing pan head screw M5x12. See Fig.5-2. Fig.5-1 Fig.5-2 Center cover Blade case section Center plate Torsion spring 36 Socket head flange screw M6 Hex flange head bolt M8x12 Safety cover Hex wrench Safety cover Flat washer 5 Pan head screw M5x12 Tapping screw bind PT3x8 No need to remove socket head flange screw M6 from center cover, for easy reassembling. < 7 > Assembling safety cover section 1. In case of the disassembling as illustrated in Fig.5-2, tapping screw bind PT3x8 has to be removed from safety cover before reassembling. 2. Drive tapping screw bind PT3x8 again, after mounting torsion spring 36, center cover and center plate. Refer to Fig.5-2. P 9 / 20 Repair < 8 > Disassembling motor section 1. Remove carbon brush. See FIg.6-1. And then, remove table from blade case section as illustrated in Fig.2-1 and Fig.2-2. 2. Remove lever 54 and support plate. See Fig.6-2. 3. After removing four M6x60 pan head screws, motor section can be separated from blade case. See Fig.6-3. <Note> Compression spring 9 for shaft lock falls off easily from the machine, when separating motor section from blade case. Be careful, not to lose this spring. Fig.6-2 Fig.6-1 Carbon brush Brush holder cap Support plate Lver 54 Brush holder cap Carbon brush Fig.6-3 Pan head screw M6x60 Shaft lock Pan head screw M6x60 Compression spring 9 < 9 > Assembling motor section 1. Putting shaft lock into the notch of motor housing, mount armature to motor housing. See Fig.7-1. 2. While pushing shaft lock to the direction designated with black arrow, mount the motor section to blade case in order to avoide piching of shaft lock between motor housing and blade case. See Fig.7-2. 3. Take the reverse step of disassembling after the above process. Fig.7-1 Fig.7-2 Notch for shaft lock slide Armature Shaft lock Shaft lock Compression spring 9 P 10 / 20 Repair < 10> Disassembling safety block mechanism 1. Lock the blade case section at the possible highest position, with stopper pin. 2. Remove lock lever by unscrewing 2 M4x10 pan head screws. Then, lock lever can be removed from lock pin. See Fig.8-1. 3. Remove motor section as shown in <8> Disassembling motor section, when removing lock pin 8. See Fig.8-2. Fig.8-1 Fig.8-2 Lock pin 8 Lock pin 8 Torsion spring 9 Pan head screw M4x10 Lock lever <11> Assembling safety block mechanism 1. Pass lock pin 8 through torsion spring 9, and hold its tail with switch box. See Fig.9-1. 2. While sliding lock lever to switch button side, tighten lock lever with one M4x10 pan head screw preliminarily. See Fig.9-2. 3. Nip the hooked tail of torsion spring 9 and put it on lock lever. See Fig.9-3. Switch box Fig.9-2 Fig.9-1 Lock pin 8 Switch box Hold this side with switch box. Slide lock lever to switch button side, when preliminary tightening. Switch box Switch button Preliminary tightening with one M4x10 pan head screw Torsion spring 9 Fig.9-3 Torsion spring 9 Lock pin 8 Lock lever Switch box Hooked tail of torsion spring 9, put on lock lever P 11 / 20 Repair <11> Assembling safety block mechanism 4. Adjust the position of lock lever so that the distance between lock lever and safety cover is approx. 1mm. See Fig.9-4. And then, finally tighten lock lever with 2 Mx10 pan head screws. Fig.9-4 Lock lever Safety cover Approx. 1mm <12> Removing turn base 1. Remove grip 32. From the bottom side of base, unscrew pan head screw M5x12. Now knock spring can be removed. See Fig.10-1. 2. After removing guide fence, lever up kerf board with screwdriver to remove them. See Fig.10-2. 3. Remove hex lock nut M8x13 and flat washer 8. Now turn base can be removed from base. See Fig.10-3. Fig.10-1 Fig.10-2 Hex bolt M8x30 Guide fence Hex bolt M8x30 Kerf board Grip 32 Turn base Knock spring Pan head screw M5x12 Screwdriver P 12 / 20 Repair <12> Removing turn base 3. Remove hex lock nut M8x13 and flat washer 8. Now turn base can be removed from base. See Fig.10-3. Fig.10-3 Hex lock nut M8x13 Socket wrench 13 which comes with the product. Turn base Flat washer 8 Base <13> Mounting turn base 1. Mount turn base and flat washer 8, and tighten hex lock nut M8x13 with socket wrench 13. The hex lock nut M8x13 has to be so tightened, that turn base can move without wobbling. 2 Take the reverse step of disassembling after the above process. <14> Angle adjustment of saw blade 1. Adjusting to 90° to turn base, While applying 1R208 "90-degree Set Square", turn Hex bolt M8x28 of motor housing side, until both saw blade and turn base contact the jig closely. See Fig.11-1. 2. Adjusting to 45° to turn base, While applying 1R207 "45-degree Set Square", turn Hex bolt M8x28 of saw blade side, until both saw blade and turn base contact the jig closely. See Fig.11-2. Fig.11-2 Fig.11-1 Hex bolt M8x28 of motor housing side 1R209 45-degree Set Square Turn base Turn base Hex bolt M8x28 of saw blade side 1R208 90-degree Set Square P 13 / 20 Repair <15> Squaring adjustment of guide fence 1. Set the bevel angle 90°. 2. Provisionally tighten M8x30 hex bolt (B) into the smaller screw hole on the left side of guide fence when viewed from operator's position. 3. While checking the angle of guide rule to saw blade using 90 Degrees set square (No.1R208), pivot the guide fence by moving its right end until the angle is 90 degrees. 4. After completion of squaring adjustment, securely tighten four M8x30 hex bolts; first A and D, then B and C. Fig.12-1 Screw hole smaller than the other 3 screw holes. Hex bolt M8x30 A Hex bolt M8x30 C B D Guide fence When adjusting, move this side. 90 Degrees set square (No.1R208) Saw blade Operator's position <16> Repairing switch section Handle cover can not be separated from switch box without removing lock lever of safety lock mechanism. Remove lock lever as illustrated in Fig.8-1. 1. Remove handle cover, Now relay can be replaced. See Fig.13-1. Fig.13-1 Handle cover Relay Switch box 2. Do not forget to mount clamp plate and felt ring 6, when assembling switch section. And do not remove sponge sheet from handle cover, when mounting it to switch box. Because these three parts protect the machine against saw dust. See Fig.13-2. Fig.13-2 Motor housing Handle cover Switch box Pin Felt rig 6 Pin Clamp plate Switch button OFF Switch button ON Sponge sheet P 14 / 20 Circuit diagram (1) LH1040F with fluorescent job light for * High voltage area in Europe, * High voltage area in Saudi Arabia * Cyprus * Kuwait * Bhutan Color index of lead wires' sheath Blue Purple Brown Gray Black White Red Yellow Orange Light switch box Switch for light Light circuit 41 31 1 3 Varnish tetron tube A1 Terminal block 42 32 2 4 A2 **Noise suppressor *Main switch (Relay) Sponge Brush holder (Turn base side) Switch box Circuit for soft start Power supply cord Brush holder (Table side) *Main switch (Relay): Its terminal No. 31, 3, 42, 2 and A2 are equipped with receptacle sleeves. **Noise suppressor: The product is supplied without equipping noise suppressor for some countries. Motor housing P 15 / 20 Circuit diagram (2) LH1040F with fluorescent job light for Low voltage in Great Britain Color index of lead wires' sheath Blue Purple Brown Yellow Black White Red Orange Noise suppressor Light switch box Switch for light Light circuit Line filter Varnish tetron tube 41 1 3 5 A1 Terminal block 42 2 4 6 *Main switch (Relay) A2 Sponge *Main switch (Relay): Its terminal No. 42, 4, 5 and A2 are equipped with receptacle sleeves. Brush holder (Turn base side) Circuit for soft start Power supply cord Switch box Brush holder (Table side) Motor housing P 16 / 20 Circuit diagram (1) LH1040 without fluorescent job light, for * High voltage area in Europe, * High voltage area in Saudi Arabia * Cyprus * Kuwait * Bhutan Color index of lead wires' sheath Orange Purple Gray Black White Red Yellow Varnish tetron tube 41 31 1 3 A1 Terminal block *Main switch (Relay) 42 32 2 4 A2 **Noise suppressor Sponge Brush holder (Turn base side) Circuit for soft start Power supply cord Switch box Brush holder (Table side) *Main switch (Relay): Its terminal No. 31, 3, 42, 2 and A2 are equipped with receptacle sleeves. **Noise suppressor: The product is supplied without equipping noise suppressor for some countries. Motor housing P 17 / 20 Circuit diagram (2) LH1040 without fluorescent job light for Low voltage in Great Britain Color index of lead wires' sheath Blue Purple Brown Yellow Black White Red Orange Noise suppressor Line filter Varnish tetron tube 41 1 3 5 A1 Terminal block 42 2 4 6 *Main switch (Relay) A2 Sponge *Main switch (Relay): Its terminal No. 42, 4, 5 and A2 are equipped with receptacle sleeves. Switch box Brush holder (Turn base side) Circuit for soft start Power supply cord Brush holder (Table side) Motor housing P 18 /20 Wiring diagram under Housing Cover Terminal block Insulated connector Motor housing Housing cover Lead wire of soft start circuit Punched hole Do not push insulated connector into motor housing through the punched hole. Lead holder Soft start circuit Lead wire of soft start circuit has to be held with the lead holder. Varnish tetron tube Motor housing The lead wires which are put on the edge of field, have to be bundled with varnish tetron tubes by separating in two groups. And max. four lead wires have to be in each bundle. Rib Field Varnish tetron tube P 19 /20 Wiring diagram Under clamp plate Clamp plate Rib A Field lead wire (orange) Before securing clamp plate, put the lead wires between rib A and B. Soft start lead wire (Purple) Rib B Line filter When line filter is used, pass the following lead wires through line filter. * Field lead wire (orange) * Soft start lead wire (Purple) Put line filter in the space illustrated above. (exclusively for low voltage in Great Britain) Field lead wire (orange) Soft start lead wire (Purple) In switch box Put the insulated connectors into the space between relay and inner wall, or push into the punched hole. Be careful, not to pinch the lead wires of light circuit between rib B and relay, when fluorescent job light is installed. When putting lead wires onto relay, do not put them on this area. Switch button Hole for pipe 9-126 Rib B Relay Inner wall Rib A Punched hole for lead wires Noise suppressor Boss Put the lead wires, connected to relay through punched hole, between boss and rib A. Put noise suppressor into the space between relay and inner wall, or push it into the punched hole, when it is used. P 20 / 20 Wiring diagram Light Switch Box Cord of light circuit Light switch box Switch for light circuit Put lead wires in the lead holder. Lead holder Insulated connector Put insulated terminal in the space shown in the above illustration.