EXakt Saw EC310N - Gear fault repair - take it apart

I've got one of these Exact Saw things. I've had it about six years and mainly used it for cutting wall tiles. I've done plenty but even so, the carbide blade is still as good as new. The important thing, it seems, is to make sure that the dust extraction system is always used. Failure to do so means the gearbox on it fills with crap and eventually something goes wrong. In my case, it was the (deliberately soft?) brass bevel gear that stripped. This was something I discovered on taking it apart the other night. Before starting, I did a bit of googling for a "How To Take An Exakt Saw Apart" tutorial but couldn't find anything. So, I took a step into the unknown and, lucky for you, I took some pictures of what I did. I've already ordered the new parts and once they arrive, I'll cover the replacement and rebuild in another post.

Here is my saw:

Remove the guard using the tool that came with the saw. If, like me, you have long since misplaced that tool, a T25 star bit will work instead:

Remove the cutting disc. Again, a T25 star bit and a pair of pliers will do:

The body is held together with five screws. Make a mental note of where the long screw comes from. The fifth screw is hidden under the guard lever mechanism (arrowed), which lifts away once the long screw is removed:

Next, cut through the label on the underside. This will void your warranty (if you still have one):

Unscrew and remove the depth-gauge knob and pull the collar off. Note the placement of the rubber seal before doing so:

The tool should now break apart. I had to stick a flat screwdriver into the join to get it started.
Et voila:

Some close ups of the internals for your enjoyment. In the first picture, I've highlighted a nut which fell out, and where it needs to go on re-assembly:

Now its time to open the gearbox. There are four screws which need to be undone. In the picture below they are already partially undone:

With the screws undone and removed, lift the gearbox plate away. This will reveal the internals.In the first picture, I've highlighted a small metal bush which will fall out and where it needs to go on re-assembly:

In mine, the gear and disc mechanism came away with the gearbox plate. It seems to be held in place with grease and dirt, but I won't know for sure until I take the final drive apart to replace the gear. I'll cover it in my next post. The pictures below clearly show the damage to the brass gear.

As I say, I'll do another post once the new parts have arrived. I thought I might as well do the brushes whilst I've got the tool open.

More soon, no doubt....


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