Regular Maintenance; Replacing Carbon Brushes - Makita DPP200 Instruction Manual

MAINTENANCE
CAUTION:
Always be sure that the tool is
switched off and the battery cartridge is removed
before attempting to perform inspection or
maintenance.
NOTICE:
Never use gasoline, benzine, thinner,
alcohol or the like. Discoloration, deformation or
cracks may result.
To maintain product SAFETY and RELIABILITY,
repairs, any other maintenance or adjustment should
be performed by Makita Authorized or Factory Service
Centers, always using Makita replacement parts.

Regular maintenance

Keep the air hole at the end of the C frame clear of dirt
and obstructions. The air hole has to be open in order to
control the hydraulic pressure.
► Fig.15: 1. Air hole
Do not undo or remove the three screws as shown in
the figure. Doing so will cause oil to leak from the tool.
► Fig.16
Addling oil
This tool is electro-hydraulic. When shipped from the
factory, it was filled with the oil. Do not attempt to add oil
as long as the tool performs well. When the oil-pressure
is not enough for proper operation, add oil in the follow-
ing procedures.
NOTICE:
Make sure that the work area and all
equipment is clean so that no dirt, dust or other
foreign materials can get into the hydraulic oil or
pump area.
NOTICE:
Only use pure hydraulic oil recom-
mended by Makita. To prevent damage to the seals
and other internal machine parts, do not use other oil
listed below.
Recommended oil:
• Makita hydraulic oil
• Super Hyrando #46 (JXTG Nippon Oil & Energy
Corp.)
• Shell Tellus Plus #46 (U.S. Shell)
• Hydraulic oil with equivalent spec anti-wear, ISO
Viscosity Grade 46.
1. Install the battery cartridge to the tool.
2. Lay the tool on its left side so that the oil port is
facing up.
3.
Operate the tool to move the punch position
almost to the bottom of its stroke.
NOTE: If necessary, run the tool for several strokes.
Doing so allows you to determine the bottom of stroke
and also position the punch piston correctly. In the
correct position, the maximum amount of oil has been
drawn from the pump and the appropriate amount of
oil for refill can be obtained.
4. Remove the battery cartridge from the tool.
5. Carefully remove the socket head cap screw to
open the oil port.
► Fig.17: 1. Socket head cap screw
6. Fill the reservoir with hydraulic oil using the small
squeeze bottle which is supplied with the tool.
7.
Rock the tool back and forth slightly several times
to free any trapped air bubbles. After that, add addi-
tional oil as necessary.
8. Replace the socket head cap screw and wipe up
any excess oil.
9. Install the battery cartridge and run the tool for
several strokes with the return lever is in open position.
After that, run the tool again with the return lever is in
closed position.
Doing this purges trapped air out of the system. Repeat
this procedure to make sure that the punch piston is
almost at the bottom of its stroke.
10. Add additional oil as necessary by repeating step
3 to 9.
If the oil is depleted excessively, you need to repeat this
procedure several times.

Replacing carbon brushes

Replace the carbon brushes when they wear down to
the limit mark.
NOTICE:
Keep the carbon brushes clean and
free to slip in the holders.
NOTICE:
Both carbon brushes must be replaced
at the same time.
NOTICE:
Use only identical carbon brushes.
► Fig.18: 1. Limit mark
1. Remove two screws on the rear cover using a
screwdriver and then remove the rear cover.
► Fig.19: 1. Rear cover 2. Screw
2.
Raise the arm part of the spring and then place
it in the recessed part of the housing with a slotted bit
screwdriver or the like.
► Fig.20: 1. Arm 2. Spring 3. Recessed part
3. Remove the carbon brush caps of the carbon
brushes using pliers and then take out the worn carbon
brushes. Insert the new carbon brushes and attach the
carbon brush caps.
► Fig.21: 1. Carbon brush cap
4. Make sure that the carbon brush caps have fit into
the holes in brush holders securely.
► Fig.22: 1. Hole 2. Carbon brush cap
5. Reinstall the rear cover and tighten two screws
securely.
15 ENGLISH