Makita DDF489 Repair Manual
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Makita DDF489 Repair Manual

Makita DDF489 Repair Manual

Cordless driver drill/cordless hammer driver drill
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OFFICIAL USE
For ASC
CORDLESS DRIVER DRILL
DDF489
CORDLESS HAMMER DRIVER DRILL
DHP489
REPAIR MANUAL
June 2023
Ver.1

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  • Page 1 OFFICIAL USE For ASC CORDLESS DRIVER DRILL DDF489 CORDLESS HAMMER DRIVER DRILL DHP489 REPAIR MANUAL June 2023 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS (FOR TOOLS) ........................3 LUBRICANT AND ADHESIVE APPLICATION (FOR TOOLS) ..................... 3 TIGHTENING TORQUE SPECIFICATIONS (FOR TOOLS) ....................4 REPAIR (for Tools) ..................................5 Housing section ..................................5 6-1-1 Disassembling ................................5 6-1-2 Assembling ..................................

  • Page 3: Caution

    CAUTION Repair the machine in accordance with "Instruction manual" or "Safety instructions". Follow the instructions described below in advance before repairing:  Wear gloves.  In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what the parts are. It is also recommended to have boxes ready to keep disassembled parts by group.

  • Page 4: Tightening Torque Specifications (For Tools)

    TIGHTENING TORQUE SPECIFICATIONS (FOR TOOLS) Tightening Parts to fasten Fastener and parts Q'ty torque Adhesion [N∙m] Gear assembly ↔ Housing Tapping screw 4x18 1.3 - 1.8 Gear assembly ↔ Keyless drill chuck 13 Gear assembly 90 - 95 Keyless drill chuck 13 ↔ Gear assembly - Flat head screw M6x22 3.1 - 6.3 *1 Wipe off the adhesive portion on both new and reused bolts with carburetor cleaner and apply a small amount of...

  • Page 5: Repair (For Tools)

    REPAIR (for Tools) Housing section Disassembling 6-1-1 Fig. 2 Remove Tapping screws bind PT 3x16 [1] (2 pcs), then remove Rear cover [3] from Housing [2]. Fig. 3 Tap Housing [1] with 1R479 to lift up Rotor section [2], then pull it out. 1R479 Fig.
  • Page 6 Fig. 5 Remove Tapping screws bind PT 3x16 [1] (7 pcs), then remove Housing R [2]. Tips Put the removed Tapping screws bind PT 3x16 [1] (7 pcs), Tapping screws bind PT 3x16 (2 pcs) and Tapping screws 4x18 (4 pcs) into Rear cover to prevent loss.

  • Page 7: Assembling

    Fig. 7 Remove Leaf springs [2] (2 pcs) and Compression springs 4 [3] (2 pcs) from Speed change lever [1]. Note Compression springs 4 [3] may be deformed if they are forced to the side and removed, so use an awl to remove them by inserting it fully.
  • Page 8 Fig. 10 Assemble the electrical parts in accordance with Circuit diagram and Wiring diagram, then assemble the following parts to Housing L [1]:  LED circuit [2]  Stator [3]  Terminal [4]  Controller [5] Assemble F/R change lever [7] to the protrusion of Switch [6], then assemble them to Housing L [1].

  • Page 9: Drill Chuck Section

    Fig. 13 Insert Rotor [2] into Housing [1]. Tips Turn Rotor [2] to engage the gears, then insert it to the bottom. Note Be careful not to pinch your fingers between Stator [3] and Fan [4] of Rotor [2] because they are pulled by a strong magnetic force.

  • Page 10: Repair For Keyless Drill Chuck 13

    Pinion gear D 1R467/467-A: Compatible models (as of December 1, 2022) 7-1-2 Side of use Illustration Compatible model DF001G/DDF441/DDF448/DDF451/DDF454/DDF458/ 1R467 (Lock cam A side*) DDF481/DDF486/DDF489 * where Rubber pins are fixed HP001G/DHP441/DHP448/DHP451/DHP454/ DHP458/DHP481/DHP486/DHP489 DF002G/DDF343/DDF347/DDF446/DDF453/DDF456/ DDF457/DDF459 1R467 (Lock cam B side*) DDF470/DDF480/DDF482/DDF484/DDF485/DDF488...

  • Page 11: Pinion Gear/Spacer For 1R473 By Model (As Of December 1, 2022)

    DHP481/DHP486/HP001G DDF484/DF002G Pinion gear B (1R473-D) Spacer B (1R473-E) DHP484/HP002G DDF487 Pinion gear C (1R473-F) DHP487 DDF489 Pinion gear D (1R473-G) Spacer B (1R473-E) DHP489 TIGHTENING TORQUE SPECIFICATIONS Parts to fasten Fastener Tightening torque (N∙m) See specified torque for each...

  • Page 12: Disassembling

    Disassembling Disassembly of Keyless drill chuck 13 [1] (removal with an cordless impact wrench and 1R298) 7-3-1 * This method is not available in case of failure that the gear co-rotates in Drill mode. Set the machine to Low speed mode and Drill mode. Fig.
  • Page 13 Fig. 18 [For models with Keyless drill chuck 13 adhered to Gear assembly] 1R298 By heating the tip of Drill chuck [2] and 1R298 with a heat gun [1] for approx 3 minutes, dissolve the adhesive bonding the threads of Gear assembly and Drill chuck.

  • Page 14: Disassembly Of Keyless Drill Chuck 13 [2] (Removal With 1R473)

    Disassembly of Keyless drill chuck 13 [2] (removal with 1R473) 7-3-2 * This method is not available in case of failure that the gear co-rotates in Drill mode. * See 7-1-2 for the compatible models. Set the machine to Low speed mode and Drill mode in order to maximize the reaction force when loosing Gear assembly as much as possible and prevent damage to Gear assembly.
  • Page 15 Fig. 22 Turn the end of Hex socket head bolts M8x55 [1] (2 pcs) to raise Plate [2] until Speed change ring [4] (whose name varies by model) of Gear assembly [3] is pushed fully up to the low speed side, then tighten the thumb screw [5] to fix Pinion gear [6].
  • Page 16 Fig. 24 Attach an appropriate steel pipe [2] to the hex wrench [1], then remove Keyless drill chuck 13 [3] by turning it counterclockwise. Tips Turn the pipe [2] with one hand, while holding down Gear assembly [4] with the other hand to prevent it from falling off from 1R473.

  • Page 17: Disassembly Of Keyless Drill Chuck 13 [3] (Removal With 1R467/1R467-A)

    Disassembly of Keyless drill chuck 13 [3] (removal with 1R467/1R467-A) 7-3-3 * In case of failure that the gear co-rotates in Drill mode, disassemble the machine in this way. * See 7-1-2 for the compatible models. Disassemble the machine, then remove Gear assembly together with Keyless drill chuck 13. Fig.
  • Page 18 Fig. 27 Hold 1R467 or 1R467-A by clamping its flats in Vise, then align the spindle portion of Gear assembly [1] with the hole of 1R467 or 1R467-A, 1R467/467-A then insert the spindle portion into the hole. Remove - Flat head screw M6x22. (Fig.

  • Page 19: Assembling

    Assembling Assembly of Keyless drill chuck 13 (with 1R473) 7-4-1 * Compatible model: See 7-1-2. Fig. 29 Hold 1R473 in Vise. (Fig. Set Gear assembly [1] onto 1R473, while adjusting the position of Speed change ring or Spacer. (Fig. Fig. 1R473 Fig.
  • Page 20 Fig. 32 Set 1R223 to the specified torque, then insert 1R224 1R224 (1R223) into 1R298, and then turn 1R223 1R223 (1R224) clockwise to tighten Keyless drill chuck 13 [1] to the specified torque. Note 1R298  Be careful not to break the pins press-fitted to Set 1R223 plates by turning the pipe with Gear assembly [2] being raised off Set plate.

  • Page 21: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 34 AWG14 Flag receptacle with lock (#187, t=0.8) AWG22 Stator Flag receptacle with lock (#250, t=0.8) Terminal unit Switch Sensor board Connector LED circuit Straight receptacle with lock (#250, t=0.8) Controller Terminal 21 / 26...

  • Page 22: Wiring Diagram

    WIRING DIAGRAM Switch, LED section Fig.35 Switch LED circuit Connector Connect Flag receptacle to Switch as shown. Place Connector in this space. Fix LED circuit lead wires in these grooves. 22 / 26...

  • Page 23: Electrical Parts Section

    Electrical parts section Fig.36 Stator Boss B LED circuit Capacitor Switch Controller Rib C Terminal Boss A Put the thick lead wires (Blue, White) for Stator on the other lead wires in this space. Route Lead wires for Switch between Rib C and Boss B. Route Lead wires for Stator/ LED circuit between Rib C and Boss A.

  • Page 24: Troubleshooting

    10 TROUBLESHOOTING Whenever you find any trouble in your machine, first, see this list to check the machine for solution. 10-1 Note for Repairing The content may vary depending on the model. Use a full charged battery which has a star mark. When Housing is disassembled, check the conditions of the electrical parts (Mechanical lock, Adherence of iron powder to Motor section, Disconnection of Connectors, Pinching and braking of Lead wires, Assembling of Stator, Connection of Terminal and Battery, etc.).

  • Page 25: Flowchart For Troubleshooting

    10-3 Flowchart for Troubleshooting Check the items in the following flowchart in order from the top to bottom. 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 Tester indicates proper figure.
  • Page 26 (Continued from previous page) Rub marks are on Controller is broken. Replace Stator complete. Rotor. Rotor is broken. Replace Rotor. Stator is broken. Replace Stator complete. The machine shows same symptom in spite of Replace Stator complete. Controller is broken. the above corrective actions.

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