Difficulty

Moderate

Steps

3

Time Required

                          1 hour

Sections

2

  • Outer Casing
  • 1 step
  • Electric Motor
  • 2 steps

Flags

1

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Introduction

The electric motor in this tool is what rotates the gearbox assembly in your Hackzall, which makes the blade on the end of your Hackzall reciprocate back and forth. A worn-out or failed electric motor can be indicated if: A) the tool is operating at a hotter temperature and performing worse than in previous uses, B) the blade on the end of the Hackzall can be moved by hand but not when the trigger is engaged and a battery is connected to the tool, or C) the Hackzall produces smoke whenever the trigger is pulled and the tool is working properly.

Reasons for the electric motor failing can vary from the elements the tool was exposed to (submerged, burned, buried, etc.), to the amount of maintenance performed throughout the tools life (lubricating bearings, etc.), to even the age of the tool (as the brushes on brushed electric motors eventually wear out).

The following steps will help in disassembling the Hackzall and removing the electric motor from the tool’s PC board. The use of a soldering iron is required to remove wiring around the trigger so soldering skills and knowledge are needed. Be sure to remove any source of power to the tool prior to beginning this repair.

What you need

Step 1

              Outer Casing
  • Remove the screws holding the shell of the device together. Each screw size varies; you will use a T9 Torx screwdriver for one size 7.0 mm.
  • Use a T10 Torx screwdriver to remove one 14.0 mm screw.
  • Use a T15 Torx screwdriver for the remaining eight screws that are 16.0 mm.
  • Remove the casing to reveal all of the internal components.

Remove the screws holding the shell of the device together. Each screw size varies; you will use a T9 Torx screwdriver for one size 7.0 mm.

Use a T10 Torx screwdriver to remove one 14.0 mm screw.

Use a T15 Torx screwdriver for the remaining eight screws that are 16.0 mm.

Remove the casing to reveal all of the internal components.

1024

Step 2

              Electric Motor
  • Find the red and black wire running from the back of the motor to the trigger mechanism.
  • With a soldering iron remove the two solders on the trigger mechanism.

Find the red and black wire running from the back of the motor to the trigger mechanism.

With a soldering iron remove the two solders on the trigger mechanism.

Step 3

  • Remove the two screws connecting the motor to the gear box with a T15 torx screwdriver.
  • The motor is now free and can be removed from the tool.

Remove the two screws connecting the motor to the gear box with a T15 torx screwdriver.

The motor is now free and can be removed from the tool.

To reassemble your device, follow these instructions in reverse order.

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Author

                                      with 6 other contributors 


                    Mason Jones

Member since: 09/18/2019

572 Reputation

                                      5 Guides authored                  



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Team

                       Western Carolina University, Team S1-G1, Virtue Fall 2019                        

                                                  Member of Western Carolina University, Team S1-G1, Virtue Fall 2019 



                    WCU-VIRTUE-F19S1G1                     


                                            5 Members                     


                                            9 Guides authored

Marcin Kędzior - Jan 8, 2021

Reply

Is there any chance to change only brushes in this motor?

Anthony DeSanto - Jun 1, 2021

Reply

That’s my exact question as well, nobody seems to cover this..