Makita DTD155 Repair Manual
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Makita DTD155 Repair Manual

Makita DTD155 Repair Manual

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OFFICIAL USE
For ASC
CORDLESS IMPACT DRIVER
DTD155
REPAIR MANUAL

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Summary of Contents for Makita DTD155

  • Page 1 OFFICIAL USE For ASC CORDLESS IMPACT DRIVER DTD155 REPAIR MANUAL...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ..................................2 CAUTION..................................3 NECESSARY REPAIRING TOOLS ..........................3 LUBRICANT AND ADHESIVE APPLICATION......................3 TIGHTENING TORQUE SPECIFICATIONS ........................ 4 DISASSEMBLING/ ASSEMBLING ..........................5 Advance preparation ..............................5 Bit sleeve ................................... 5 6-2-1 Disassembling ..............................5 6-2-2 Assembling ............................... 6 Hammer case ................................

  • Page 3: Caution

    Extension bar (Square drive 12.7mm) removing Hammer case complete LUBRICANT AND ADHESIVE APPLICATION Apply the following lubricants and adhesives. Lubricant Amount Gear portion Makita grease FA No.2 Except Gear portion a little Fig. 1 Anvil shaft Whole surface of Gear portion: 1g...

  • Page 4: Tightening Torque Specifications

    TIGHTENING TORQUE SPECIFICATIONS Tightening Torque Parts to fasten Parts description (N･m) Housing L  1.1-1.3 Housing R complete 3x16 Tapping screw complete  0.2-0.3 Sensor board Stator PT 2x6 Tapping screw  40.0-45.0 Hammer case Bearing box Bearing box 4 / 26...

  • Page 5: Disassembling/ Assembling

    DISASSEMBLING/ ASSEMBLING Advance preparation Fig. 2 Remove Battery [1]. Bit sleeve 6-2-1 Disassembling Fig. 3 Using 1R003 with 1R212-A and 1R212-B attached to it, remove Ring spring 10 [1] by widening the end gap of 1R212-A Ring spring 10 [1]. Note Press the top of Bit sleeve with your thumb and index finger so that Ring spring [1] and Flat washer 11[2] do not pop out.

  • Page 6: Assembling

    Anvil M [2] and then install Bit sleeve [3], Compression spring 13 [4] and Flat washer 11 [5] in place. Apply Makita grease FA No 2 to the two holes of Anvil M [2] to prevent Steel ball 3 [1] from falling off.
  • Page 7 Fig. 8 Remove Hammer case [1] and Motor section [2] together from Housing L [3], and then pull out Motor section [2] from Hammer case [1]. Fig. 9 Insert a slotted driver between Bumper [1] and Hammer case cover [2] to pry off Bumper [1]. Fig.
  • Page 8 Fig. 12 Remove Internal gear 43 [1] and Hammer section [2] from Hammer case. Fig. 13 Push out Anvil M [1] from Hammer case [2]. Fig. 14 Remove Nylon washer 19 [1] with a slotted screwdriver. 8 / 26...

  • Page 9: Hammer

    Hammer 6-4-1 Disassembling Fig. 15 Turn the handle of 1R045 clockwise to push Spindle [1] and compress Compression spring 21[2]. 1R045  Set 1R045 on Hammer [3] so that the protrusions of Hammer [3] and the claws of 1R045 cross at a right angle.

  • Page 10: Assembling

    Fig. 21 Install Flat washer 20, Compression spring 21 [2], Washer 21 [3] and Spindle [4] on Hammer [1]. Apply Makita grease FA No.2 to Cam grooves on Spindle [4] where Steel balls 4.8 are put. Fig. 22 Turn the handle of 1R045 clockwise to push Spindle [1] and compress Compression spring 21.
  • Page 11 After removing 1R045, install two Spur gears 17 [1] and two Pins 3.5 [2] on Spindle [3]. Fig. 25 Install Flat washer 12 [1] on Spindle [2]. Apply Makita grease FA No 2 to Flat washer 12 [1] to prevent it from falling off. 11 / 26...

  • Page 12: Hammer Case

    Assembling Fig. 26 Assemble Nylon washer 19 [1] and Anvil M [2] to Hammer case [3]. Apply Makita grease FA No.2 to the groove on the surface of Anvil M [2]. Groove Fig. 27 Install Internal gear 43 [1] on Bearing box [2], and then install Hammer section [3] on Internal gear 43 [1].

  • Page 13: Rotor And Other Electric Parts

    Fig. 29 Clamp the flats of Hammer case [1] in a vise. Attach Hex socket 27-50 to 1R224. And then fasten Bearing box [2] to 1R224 Hammer case [1] with 1R223 to a tightening torque of 40.0- 45.0 N･m. 1R223 Turn Bearing box [2] counterclockwise.
  • Page 14 Fig. 32 Remove Rotor [1] from Stator [2]. Push Rotor [1] against workbench. Push down Stator [2] to remove Rotor [1] from Stator [2]. Fig. 33 Note When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors. Because Rotor has strong magnet force, failure to follow this instruction could result in: ...
  • Page 15 Fig. 36 Remove LED circuit [2] from Controller by disconnecting Connector [1]. If LED does not light up, check it with 1R412. Fig. 37 Remove Terminal [1] from Controller by disconnecting three Flag receptacles [2]. Remove Flag receptacles [2] while releasing lock with a slotted screwdriver or the like.

  • Page 16: Assembling

    6-6-2 Assembling Assemble by reversing the disassembly procedure. Fig. 38 Fix Sensor board [1] of Controller with three PT 2x6 Tapping screws. Projection of Statorl  The orientation of Sensor board [1] matters. The black sensor element side should face towards Stator [2]. ...
  • Page 17 Fig. 41 Connect three Straight terminals between Controller and Stator correctly. Connect wires of similar colors Note Insert three Straight terminals firmly because loose connection leads to abnormal rotation. Fig. 42 Flip the cover of Switch [3], then insert Connector into Connector socket [1] and then connect two Flag terminals [2] to Switch;...
  • Page 18 Fig. 45 Install Controller [1], Terminal [2], Switch plate [3] on Housing L [4]. Put each Lead wire into the grooves of Housing and Lead wire holders with 1R411. Fig. 46 Install Switch [1] with F/R change lever [2] on Housing L [3].
  • Page 19 Fig. 48 Fatsten Housing R [2] to Housing L by tightening nine 3x16 Tapping screws [1]. Note Check the following points before fastening Housing R:  Lead wires are not pinched between Housings L and R.  F/R change lever [3] moves normally. ...

  • Page 20: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 49 Flag receptacle LED circuit (with lock #187 t=0.8mm) Sensor Stator board Orange/AWG16 Blue/AWG16 White/AWG16 Switch Straight terminal Red/AWG18 White/ AWG18 Orange/AWG18 Blue/AWG18 White/AWG18 Controller Red/AWG22 Fuse Flag receptacle (with lock #187 t=0.8mm) Red/AWG18 Terminal Yellow/AWG22 Black/AWG18 Flag receptacle AWG= American wire gauge (with lock #250 t=0.8mm)

  • Page 21: Wiring Diagram

    WIRING DIAGRAM Fig. 50 Route Lead wire connected to Sensor board between Rib C and Rib D. Don’t put Lead wires on Boss B. Sensor board Rib B Boss A Rib D LED circuit Rib C Boss B Route LED Lead wires between Rib A Rib A and Boss A and then between Rib B and Rib A-C.
  • Page 22 Fig. 51 Stator Sensor board Route Lead wires of Sensor board and LED circuit under those of Stator. Route Lead wires of Stator, Sensor board and LED LED circuit circuit between Rib E and Rib F then between Rib F and Boss C.

  • Page 23: Trouble Shooting

    TROUBLE SHOOTING Note in Repairing (1) Use a fully charged CXT battery. (2) When Housing is disassembled, check the conditions of small electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc. (3) Do the running test at the lowest speed (with the trigger being pulled just a little bit) to check the function of the following parts: F/R change lever, Switch plate, Variable speed control trigger.

  • Page 24: Flowchart Of Troubleshooting

    Flowchart of Troubleshooting Check the items from the top to the bottom of the following list. (Description of the item is referred to Circuit diagram) After corrective action, return to the start of Troubleshooting and re-check again. Symptom Cause Corrective action Does Tester indicate within the range of 0.7-0.9V? If Tester is not available, go to Controller is broken.
  • Page 25 Symptom Cause Corrective action Connectors are poorly Connect Connectors firmly. connected. LED job light is Check Lead wires and Lead wires are broken. replace them. Replace Switch. Switch is broken. Replace LED circuit. LED circuit is broken. There are scrape Controller is broken.

  • Page 26: Short-Circuit Test On Fet (Field Effect Transistor) Of Controller

    Short-circuit test on FET (Field Effect Transistor) of controller Trouble on Controller can be checked with Digital tester as follows. Fig. 52 Set Digital tester (1R402-A) to the Diode mode. Fig. 53 After removing the battery from the machine, pull Switch trigger and hold it in the “ON”...

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