Makita DGA419 Repair Manual
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Makita DGA419 Repair Manual

Makita DGA419 Repair Manual

Cordless angle grinder
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OFFICIAL USE
For ASC
CORDLESS ANGLE GRINDER
DGA419 / DGA469 / DGA519 / DGA520
REPAIR MANUAL
February 2021
Ver.2

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Summary of Contents for Makita DGA419

  • Page 1 OFFICIAL USE For ASC CORDLESS ANGLE GRINDER DGA419 / DGA469 / DGA519 / DGA520 REPAIR MANUAL February 2021 Ver.2...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 REPAIR ......................................5 Grinding wheel/ Grip section ............................... 5 5-1-1 Disassembling ................................5 5-1-2 Assembling .................................. 6 Electric parts section ................................6 5-2-1 Disassembling ................................

  • 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: Lubricant And Adhesive Application

    LUBRICANT AND ADHESIVE APPLICATION Description Amount  Apply 9g in Gear housing ass’y. Makita grease R. No.00  Apply a little unless specified in the figure. Fig. 1 4 / 27...

  • Page 5: Repair

    REPAIR Grinding wheel/ Grip section 5-1-1 Disassembling Fig. 2 Push Lever [1] and pull it up to remove Wheel [2]. Fig. 3 Turn and remove Grip [1]. 5 / 27...

  • Page 6: Assembling

    5-1-2 Assembling Fig. 4 Set Wheel [1] in place, then turn and assemble Grip [2]. Electric parts section 5-2-1 Disassembling Fig. 5 Turn and remove Wheel cover [1] while pressing Lever. Fig. 6 Remove M4x30 Pan head screws [1] (2 pcs) and remove the following parts.
  • Page 7 Fig. 7 Remove 4x30 Tapping screws [1] (4 pcs) and Gear housing section [2]. Fig. 8 Make a gap between Gear housing cover assembly [1] and Motor housing set [2] with a slotted screwdriver and turn Gear housing cover assembly [1] about 45 degrees, then remove Rotor ass’y section [3] by tapping a corner of Motor housing set [2] with a plastic hammer.
  • Page 8 Fig. 9 Remove 4x18 Tapping screws [1] (5 pcs) and disassemble Motor housing set [2], Dust cover L [3] and Dust cover R [4]. Fig. 10 Remove the following parts from Motor housing set [1].  Switch lever complete [2] ...

  • Page 9: Assembling

    5-2-2 Assembling Fig. 12 Connect Connectors and Terminals to Stator complete [1] and assemble the following parts.  Switch TG73BDS-2 [2]  Switch unit [3]  Terminal [4] Note  If it is difficult to insert Lead wires, loosen the screw of Switch [2] with a slotted screwdriver, then spread the sheet metal of the insertion slot and insert Lead wires.
  • Page 10 Fig. 15 Assemble Gear housing cover section [2] to Motor housing set [1]. Insert Gear housing cover section [2] into Motor housing set [1] fully by tapping the tip of Gear housing cover section [2]. Note Be careful not to pinch your fingers between Motor housing set [1] and Gear housing cover assembly [2] because of the strong magnetic force.

  • Page 11: Rotor Section

    Fig. 18 Assemble and turn Wheel cover [2] while pressing Lever [1]. Rotor section 5-3-1 Disassembling Fig. 19 Hold Rotor in Vise with 1R038 (2 pcs), then turn and remove M6 Hex. nut [1] counterclockwise, then remove Spiral bevel gear 10 [2]. 1R038 Fig.
  • Page 12 Fig. 21 Push out Ball bearing 629LLB [2] from Gear housing cover assembly [1] with 1R401. 1R401 Fig. 22 Remove Ball bearing 607LLB [2] from Rotor ass’y [1] with 1R269. 1R269 12 / 27...

  • Page 13: Assembling

    5-3-2 Assembling Fig. 23 Assemble Ball bearing 629LLB [2] to Gear housing cover assembly [1]. Hold Gear housing cover assembly [1] with 1R032, and press-fit the following parts to Gear housing 1R033 cover assembly [1] with 1R033.  Rotor [3] ...

  • Page 14: Bearing Box Ass'y Section

    Bearing box ass'y section 5-4-1 Disassembling Fig. 25 Remove M4x20 P. H. screws with WR [2] (2 pcs) from Gear housing complete [1] and disassemble the following parts.  Bearing box ass’y [3]  Compression spring 4 [4]  Shaft [5] Note Be careful not to drop Shaft [5].
  • Page 15 Fig. 28 Hold Bearing box ass’y [1] with 1R258 and push out Spindle assembly [2] and Spiral bevel gear 37 [3] from Bearing box ass’y [1] with 1R029 and Arbor press. 1R029 1R258 Fig. 29 Remove Retaining ring R-42 [2] from Bearing box [1] with 1R005.
  • Page 16 Fig. 31 Remove O ring 45 [2] from Bearing box [1]. Fig. 32 Remove Ring 25 [2] from Spindle assembly [2]. Note Do not disassemble Spindle assembly [1] any further. Fig. 33 Remove the following parts from Gear housing complete [1]. ...

  • Page 17: Assembling

    5-4-2 Assembling Fig. 34 Assemble Torsion spring 5 [2] to Lever [1]. Assemble the following parts to Gear housing complete [3].  Lever [1]  Headed pin 4 [4]  Stop ring E-3 [5] Note Check that Lever [1] can be pulled smoothly and it returns with its spring force.
  • Page 18 Fig. 37 Press-fit Ball bearing 6905DDW [2] to Bearing box [1] with 1R165. 1R165 Fig. 38 Assemble Retaining ring (INT) R-42 [2] to Bearing box [1] with 1R005. 1R005 Fig. 39 Hold Spindle [1] with 1R415, then press-fit Bearing box ass’y [2] and Spiral bevel gear 37 [3] into Spindle [1] with a thin surface of 1R164.
  • Page 19 Fig. 40 Assemble Retaining ring S-24 [2] to Bearing box [1] with 1R291. 1R291 Fig. 41 Assemble Scrow wave spring 49 [2] to Bearing box [1]. Fig. 42 Assemble Shaft [2] to Bearing box [1]. Note Apply the specified grease to Shaft [2]. 19 / 27...
  • Page 20 Fig. 43 Assemble the following parts to Gear housing complete [1].  Compression spring 4 [2]  Bearing box ass’y [3]  M4x20 P. H. screws with WR [4] (2 pcs) 20 / 27...

  • Page 21: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 44 Color index of lead wires' sheath White Orange Blue Green Yellow Black AWG14 Terminal AWG16 Dial section AWG22 Noise suppressor AWG24 Controller AWG26 Stator AWG28 Sub controller Connector Only for AWS-supported tool Connector for Wireless unit Switch circuit diagram Flag receptacle with lock (#187, t=0.8) Switch unit circuit diagram...

  • Page 22: Wiring Diagram

    WIRING DIAGRAM Stator section Fig. 45 Switch Rib B Non-insulated terminal Rib C Good example Rib D Not good example Boss A Pin A Boss B Pin B Stator Rib A Assemble Non-insulated terminal to Switch in the direction shown in “Good sample”. Be careful not to put the thick lead wires of Stator on Pin A and Pin B.

  • Page 23: Controller Section

    Controller section Fig.46 Connector for Wireless unit Sub controller (if used) Rib E Controller Rib F Switch unit Rib G Noise suppressor Rib H Switch Terminal Dial section Fit Connectors (one or two) in the orientation shown in the figure. Do not place any Lead wires under Connectors. Be careful not to put any Lead wires on this Rib.

  • Page 24: Troubleshooting

    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 each part (Mechanical lock, Adherence of iron powder to Rotor and Stator, Disconnection of Connectors, Lead wires, Assembling of Stator, Connection of Terminal and Battery, etc.).
  • Page 25 1R402-B Tips By attaching 1R402-B to each probe of 1R402, you can make your hands free for easier check. Note Be careful not to reverse them. The reversed contacts could spoil the test. 1R402-B Wait until the figure on Tester gets stable. Controller is in order if Tester indicates 0.8±0.1V.

  • Page 26: Flowchart For Troubleshooting

    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 in Fig. 44.) After corrective action, return to the start of Troubleshooting and re-check again. Symptom Cause Corrective action...
  • Page 27 (Continued to previous page) The machine shows same symptom in spite Controller is broken. Check Stator complete or of the above corrective actions. replace it. 27 / 27...

This manual is also suitable for:

Dga469Dga519Dga520

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