Makita DBN900 Repair Manual
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Makita DBN900 Repair Manual

Makita DBN900 Repair Manual

Cordless framing nailer
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OFFICIAL USE
For ASC
CORDLESS FRAMING NAILER
DBN900, DBN901
REPAIR MANUAL
January 2025
Ver.1

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  • Page 1 OFFICIAL USE For ASC CORDLESS FRAMING NAILER DBN900, DBN901 REPAIR MANUAL January 2025 Ver.1...

  • Page 2: Table Of Contents

    OFFICIAL USE For ASC CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 TIGHTENING TORQUE SPECIFICATIONS ..........................5 REPAIR ......................................6 Battery, Nails section ................................6 6-1-1 Removing ..................................6 Magazine section.................................. 6 6-2-1 Disassembling .................................

  • Page 3: Caution

    OFFICIAL USE For ASC 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: Lubricant And Adhesive Application

    OFFICIAL USE For ASC LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease FA No.2 a little Isoflex NB52 a little Lubricant VG32 a little a little Makita grease GA No.2 Meanwhile, apply much grease to Driver [1] and Holder [2].

  • Page 5: Tightening Torque Specifications

    OFFICIAL USE For ASC TIGHTENING TORQUE SPECIFICATIONS For screws not specified, refer to the general tightening torque in Repair basic manual. Tightening torque Parts to fasten Fastener [N·m] ↔ Cylinder 5 - 15 ↔ Driver guide H.S.H.bolt M5x12 5.0 - 9.0 Nose ↔...

  • Page 6: Repair

    OFFICIAL USE For ASC REPAIR Battery, Nails section Removing 6-1-1 Remove Battery and remove the nails from Magazine. Magazine section Disassembling 6-2-1 Fig. 2 Remove H.S.H bolts M5x12 [4] (2 pcs) on Driver guide [3] and H.S.H.bolt M5x20 [2] on the center of Magazine section [1], then remove Magazine section [1] from the machine.
  • Page 7 OFFICIAL USE For ASC Fig. 4 Remove Hex.socket head bolt M5x12 [1], then remove Magazine cap [3] (with Hex.lock nut M5-8 [4]) from Magazine [2]. Pull out Nail rail [5] from Magazine [2]. Note If Hex.wrench 4 [6] is attached when you received the machine from the user, hold it so that it does not fall off.

  • Page 8: Assembling

    OFFICIAL USE For ASC Fig. 7 Face the assembled side of Urethane ring 3 [1] 1R495 upward and hold Pusher lever [2] so that it does not tilt, then push out Pin 4 [5] with an appropriate Round bar jig [3] and a metal hammer [4] to remove the following parts.
  • Page 9 OFFICIAL USE For ASC Fig. 9 Insert Compression spring 3 [2] into the round hole in Pusher lever [3] at the assembling position for Lock plate [1], then insert the bent side of Lock plate [1] into the assembling position. Assemble Urethane ring 3 [4] into the slit of Pusher lever [3], then insert Pin 4 [5] from the side with the step into the hole on the opposite side.
  • Page 10 OFFICIAL USE For ASC Fig. 11 Insert Pin 4 [3] from its stepped side into the hole of Pusher lever [1] on the opposite side of the space for assembling Urethane ring 3 [2], and while aligning the positions, push Pin 4 [3] until the stepped side protrudes from the space for Urethane ring 3 [2].
  • Page 11 OFFICIAL USE For ASC Fig. 13 Hook the hook portion of Spiral spring [2] to the end face of Magazine [1], then assemble Pusher lever [3]. Assemble the hook of Pusher cushion [5] to the notch of Under driver guide [4], then assemble Under driver guide [4] to Magazine [1].

  • Page 12: Electrical Parts Section

    Magazine section [1] obliquely to the main body.  Align the position of the upper threaded hole of Housing L [5] of DBN900 / the lower threaded hole of Housing L of DBN901 with the center hole of Magazine section [1].
  • Page 13 OFFICIAL USE For ASC Fig. 18 Remove Tapping screws 4x18 [1] (12 pcs), then remove Housing R [2]. Remove Leaf springs [4] (2 pcs) from Housing L [3]. Note  Be careful not to bend Leaf springs [4] (2 pcs). ...
  • Page 14 OFFICIAL USE For ASC Fig. 20 Disconnect the connector [1] of Sensor circuit. Lift up Cylinder section [2], then pull out Gear section [4] from Motor section [3] to remove Mechanical section [5]. Note When removing Mechanical section [5], be careful not to touch Driver guide [6] and lift up Cylinder section [2].
  • Page 15 OFFICIAL USE For ASC Fig. 22 Remove Holder cushions [3] (4 pcs) from Battery holder L [1] and Battery holder R [2]. Remove Tapping screws bind PT 3x16 [4] (2 pcs), then remove Battery holder L [1] and Battery holder R [2] from Terminal [5]. Note Check that four pcs of Holder cushion [3] are removed.

  • Page 16: Assembling

    OFFICIAL USE For ASC Assembling 6-3-2 Assemble the electrical parts in accordance with Circuit diagram and Wiring diagram. Fig. 26 Assemble Rotor [2] to Stator [1], then assemble the unit to Motor housing L [3]. Tips Set Ball bearing 608ZZ [5] and Ball bearing 607LLB [6] of Rotor [2] in place so that the lead wires [4] of Stator [1] come out from the notch of Motor housing L [3].
  • Page 17 OFFICIAL USE For ASC Fig. 29 Assemble the following parts to Housing L [1]:  Controller [2]  Battery holder section [3]  Motor section [4] Tips Assemble Controller [2] along the U-shape [5] of Housing L [1], then put Switch unit [6] lead wires so that they come to the lowest position.
  • Page 18 OFFICIAL USE For ASC Fig. 31 Assemble Switch circuit [2] to Housing L [1], then tighten Tapping screws bind PT 3x10 [3] (2 pcs). Note When assembling Switch circuit [2], be careful the assembling orientation of the upper and lower. Put the lead wires of Switch circuit [2] and Controller [4] in Housing L [1], then bundle the three connectors of Switch circuit [2], Switch unit...
  • Page 19 OFFICIAL USE For ASC Fig. 33 Assemble Gear section [2] to Motor section [1], then assemble the mechanical section [4] to Housing L [3]. Note Apply a small amount of the specified grease onto the top of Rotor [6] or the center of Gear assembly [5]. Fig.
  • Page 20 OFFICIAL USE For ASC Fig. 35 When repaired the mechanical section. Attach 1R511 to Top cap [1], then inflate to Chamber with slightly higher air pressure than the specified value (0.51MPa) with Cordless air inflator [2] (DMP180/001G etc.) 1R511 Tips Commercial manual air inflators can be substituted for Cordless air inflator [2].
  • Page 21 OFFICIAL USE For ASC Fig. 36 When repairing the mechanical section. Remove 1R511, then tighten Valve cap [2] (with O ring 8 [3]) to Top cap [1]. Tips When tightening Valve cap [2], sometimes the threads of Valve cap [2] do not engage with the threaded hole of Top cap [1] because O ring 8 [3] rise, so push it slightly to insert O ring 8 [3] fully, then tighten Valve cap [2].

  • Page 22: Mechanical Section

    OFFICIAL USE For ASC Fig. 38 Assemble Housing R [2] to Housing L [1], then tighten Tapping screws 4x18 [3] (12 pcs). Note  Assemble Housing R [2] straight. Be careful not to bend Leaf springs (2 pcs). Especially for Leaf spring [5] near Trigger [4], visually check that the rib end of Housing R [2] is inserted into the bottom side of Leaf spring [5].
  • Page 23 OFFICIAL USE For ASC Fig. 41 Remove Seal ring [2] from Chamber [1] with 1R495. 1R495 Fig. 42 Push out Driver [1] from the top side, and when it moves, pull it out from the opposite side. Tips Use the grip of a hammer [2] or a piece of wood to push out Driver [1] to prevent its top from wearing out.
  • Page 24 OFFICIAL USE For ASC Fig. 44 Remove Cylinder [2] (with O rings 55 [3] (2 pcs) from Nose [1] by turning it counterclockwise. Tips If it is hard to turn, hold Nose section [1] in Vise or grip the flats of Cylinder [2] with an adjustable wrench to turn and remove Cylinder [2].
  • Page 25 OFFICIAL USE For ASC Fig. 48 When Lifter and Lifter cap are removed together. Hold Lifter cap [1] and push Lifter shaft [2] in the center with your hand to remove Lifter [3]. Tips If Lifter [3] cannot be removed by hand, use Arbor press to remove it.
  • Page 26 OFFICIAL USE For ASC Fig. 52 When removing Bearing 6002DDW from Lifter shaft Remove Bearing 6002DDW [2] from Lifter shaft [1] with 1R269. Tips 1R269 Because there is no gap between Lifter shaft [1] and Ball bearing 6002DDW [2], set 1R269 and turn it while holding its jaws firmly with the water pump pliers [3] so that its jaws enter into the gap and can pull out Ball bearing 6002DDW [2].
  • Page 27 OFFICIAL USE For ASC Fig. 55 If Ball bearing 6806DDW cannot be removed even by prying up Carrier. 1R479 Warm Nose [2] with a heat gun [1], then remove Carrier [3] and Ball bearing 6806DDW [4] by tapping Nose [2] with 1R479. Tips If Nose [2] is warmed from the outside where Ball bearing 6806DDW [4] is assembled with a heat gun...
  • Page 28 OFFICIAL USE For ASC Fig. 57 Remove H.S.H.bolts M5x12 [1] (3 pcs), then remove Driver guide [2]. Remove Adjuster section [3] and Compression spring 12 [4]. Note Remove the last one of H.S.H.bolt M5x12 [1] while holding Adjuster shaft [5] to prevent the parts from popping out due to the tension of Compression spring 12 [4].

  • Page 29: Assembling

    OFFICIAL USE For ASC Assembling 6-4-2 Fig. 60 Align the screw holes (2 positions) of Nose [1] and its protrusion with the holes (3 positions) of Sensor circuit [2], then assemble Sensor circuit [2] with Pan head screws M3x8 [3] (2 pcs). Fig.
  • Page 30 OFFICIAL USE For ASC Fig. 63 Assemble Contact arm [1] with its bent side facing upward. Assemble Adjuster sleeve [2] with its flat side facing Contact arm [1] side, then tighten Hex.lock nut M6-10 [4] with Socket bit 10 [3] and an impact driver.
  • Page 31 OFFICIAL USE For ASC Fig. 67 Align the position of Compression spring 12 [2] with the U-shape of Nose [1], then lift up Driver guide [3] to assemble it with the orientation of the protrusion of Driver guide [3] fits into the groove of Contact arm [4].
  • Page 32 OFFICIAL USE For ASC Fig. 70 Support Nose [2] with an appropriate Pipe jig [1], then press-fit Ball bearing 6806DDW [5] with Arbor press [3] and an appropriate Pipe jig [4]. Fig. 71 Assemble Carrier [2] to the inner surface of Ball bearing 6806DDW [1].
  • Page 33 OFFICIAL USE For ASC Fig. 74 Engage Spur gear 13 [1] with the center gear of Gear assembly [2], then assemble them by aligning the screw hole of Nose [3] with the screw hole of Gear assembly [2]. Note Assemble in a position where the concave shape of positioning of Nose [3] aligns with the convex shape of Gear assembly [2].
  • Page 34 OFFICIAL USE For ASC Fig. 77 Align the flats of Lifter shaft [1] with the flats of the center hole of Pin cover [2], then assemble Pin cover [2]. Face the grooved side of Holder [3] toward Pin cover [2], then assemble Holder [3] to Lifter shaft [1] by aligning the concave shape of Lifter shaft [1] with the convex shape of Holder [3].
  • Page 35 OFFICIAL USE For ASC Fig. 80 Align the screw holes of Lifter cap [1] with those of 1R219 Nose to assemble it. Tips Bearing 6002DDW is a little tightly assembled, so press down Lifter cap [1] firmly to assemble it. Tighten H.S.H.bolts M5x20 [2] (2 pcs), then finally tighten them firmly to the specified torque with 1R219.
  • Page 36 OFFICIAL USE For ASC Fig. 82 Insert Driver [2] from Front cushion side [1] to assemble it. Note  Check that Pin 5 [3] is not visible by looking inside from Front cushion [1] side.  If Pin 5 [3] is visible, adjust Spur gear 13 [4] by turning it with 1R495 to prevent the teeth of Driver [2] from touching Pin 5 [3] even if Driver [2] is inserted.
  • Page 37 OFFICIAL USE For ASC Fig. 84 Insert Cylinder [2] into Nose [1], then tighten Cylinder [2] firmly by turning it clockwise. Adjust the position of Chamber [3] by turning it clockwise until the concave portion of Nose [1] aligns with the triangle mark of Chamber [3]. [4] [5] Tips Cylinder [2] may be difficult to insert because of X-...
  • Page 38 OFFICIAL USE For ASC Fig. 87 Align the notch of Chamber [1] with the notch of Top cap [2], then tighten Hex.socket head bolts M6x25 [3] (4 pcs), and then finally tighten them to the specified torque with 1R219. Note Injecting compressed air into Chamber [1] should be done just before assembling Housing L to Housing R.

  • Page 39: Circuit Diagram

    OFFICIAL USE For ASC CIRCUIT DIAGRAM Section 1 Fig. 88 AWG14 LED circuit AWG22 Sensor circuit Specification of mode selectable between “Single nailing” and Controller “Continuous nailing” Flag receptacle with lock (#250, t=0.8) Switch circuit Switch Specification of “Single nailing” only Straight receptacle with lock (#250, t=0.8) Switch unit A (for Contact arm) Line filter (if used)

  • Page 40: Section 2

    OFFICIAL USE For ASC Section 2 Fig. 89 Specification of mode selectable between “Single nailing” and AWG14 “Continuous nailing” Controller Connector Line filter (if used) Switch unit B (for Trigger) Stator Circuit diagram of Switch for Trigger Terminal unit Black Sensor board Blue 40 / 47...

  • Page 41: Wiring Diagram

    OFFICIAL USE For ASC WIRING DIAGRAM Section 1 Fig.90 Battery holder L Stator Terminal Switch Motor housing L Fix Controller lead wires for Terminal in this groove. Fix Stator lead wires in this groove. Connect Flag receptacle to Switch so that the lead wire comes out as shown. 41 / 47...

  • Page 42: Section 2

    OFFICIAL USE For ASC Section 2 Fig.91 Switch unit A (for Contact arm) LED circuit Switch circuit Switch unit B (for Trigger) Boss A Fix LED circuit lead wires and Switch unit A lead wires in these grooves. Assemble Switch unit A as shown. Assemble LED circuit so that their lead wires come out to the opposite side of Boss A.

  • Page 43: Section 4

    OFFICIAL USE For ASC Section 3 Fig.92 Switch circuit Switch End of Tape Capacitor Housing L Line filter B (if used) LED circuit Rear side of machine 10mm End of Sponge Switch unit A (for Contact arm) Sponge Rib C Rib A End of Black tube Rib B...
  • Page 44 OFFICIAL USE For ASC Section 4 Fig.93 Sensor circuit Place Connector for Sensor circuit in this space. Be careful not to put Sensor circuit lead wires in this groove. 44 / 47...

  • Page 45: Troubleshooting

    OFFICIAL USE For ASC TROUBLESHOOTING Whenever you find any trouble in your machine, first, see this list to check the machine for solution. 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 46: 10 Flowchart For Troubleshooting

    OFFICIAL USE For ASC 10 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...
  • Page 47 OFFICIAL USE For ASC (Continued from the previous page) Motor runs by pressing Contact Connectors are poorly Connect Connectors firmly. arm and Trigger switch. connected. (Be careful with the order of pressing in Single nailing mode.) Lead wires are broken. Check Lead wires or replace them.

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