Makita DGA411 Repair Manual
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Makita DGA411 Repair Manual

Makita DGA411 Repair Manual

Cordless rear handle saw
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CORDLESS REAR HANDLE SAW
DGA411/ DGA412/ DGA413/ DGA414/
DGA461/ DGA462/ DGA463/DGA464/
DGA511/ DGA512/ DGA513/ DGA514
REPAIR MANUAL
January 2018
Ver.1

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Summary of Contents for Makita DGA411

  • Page 1 CORDLESS REAR HANDLE SAW DGA411/ DGA412/ DGA413/ DGA414/ DGA461/ DGA462/ DGA463/DGA464/ DGA511/ DGA512/ DGA513/ DGA514 REPAIR MANUAL January 2018 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 TIGHTENING TORQUE SPECIFICATIONS ..........................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 REPAIR ......................................5 Caution: Battery have to be removed, before repairing for your safety ..................5 Rotor , Ball bearings 629LLB / 607LLB, Spiral bevel gear 10 .................... 5 6-1-1 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 Item of Lubricant Amount of Grease MAKITA Grease R No.00 9g to Gear room a little amount to O ring 26 Fig. 1 4 / 23...

  • Page 5: Repair

    REPAIR Caution: Battery have to be removed, before repairing for your safety. Rotor , Ball bearings 629LLB / 607LLB, Spiral bevel gear 10 6-1-1 Disassembling Fig. 2 Removing 4x30 Tapping screw [1] (4 pcs.), separate Gear housing [2] from Gear housing cover. Fig.
  • Page 6 Fig. 5 Applying 1R045 to Gear housing cover [1] and 1R045 shaft of Rotor [2], turn the handle. Now, Rotor [2] is separated from Gear housing cover[1]. Fig. 6 Ball bearing 629LLB [2] can be removed from Gear housing cover [1], by pushing it with finger. Fig.

  • Page 7: Assembling

    6-1-2 Assembling Fig. 8 Do not put Rotors [1] contacting each other.as shown in photograph to left. Otherwise, fall of quality arises on Rotor [1], because of the following reasons. Caution ・Decreasing of magnet force each other from the contact portion. ・Rotors are violently dragged each other by incredible strong magnetic force.
  • Page 8 Fig. 10 Put Gear housing cover on 1R033, aligning the Ball bearing 629LLB in Fig. 9 to center hole of 1R033. 1R032 And stand Rotor [1] on Gear housing cover inserting into the Ball bearing 629LLB. And then setting Ball bearing 607LLB to shaft of Rotor [1], put 1R032 on the Ball bearing 607LLB, and press with Arbor press, until it stops.
  • Page 9 Fig. 11 Fixing Rotor with 1R038 and vise, set Spiral bevel 1R254 1R220 gear 10 [2] to Rotor, passing shaft of Rotor [1] through Spiral bevel gear 10 [2]. 1R222 Pre-setting fastening torque of 1R254 to 4.9~5.9N.m, attach 1R220, 1R222, Bit adapter assembly and Socket bit 10 to 1R254.

  • Page 10: Spiral Bevel Gear 37, Bearing Box Section

    Spiral bevel gear 37, Bearing box section 6-2-1 Disassembling ※ No need to disassemble Motor section to repair Spiral bevel gear 37, Bearing box section Fig. 13 Unscrewing four M4 x 14 Pan head screws[1] (4 pcs) , separate Bearing box from Gear housing. Fig.
  • Page 11 Model No. used parts in Bearing box and Spindle Model No. used parts in Bearing box and Spindle DGA413 DGA411 Lead flange to Spindle Labyrinth ring to Spindle DGA414 DGA412 DGA463 DGA461...
  • Page 12 6-2-1-1 With electric brake Fig. 19 6. Remove Ball bearing 6201DDW [20], pushing it toward Spiral bevel gear side Re-use using 1R026. 1R026 [20] <Note> < Tips > Ball bearing 6201DDW has been broken in the step of Fig.16. [20] Fig.
  • Page 13 6-2-1-2 Without electric brake Available for DGA411, DGA412, DGA461, DGA462 DGA511, DGA512 Fig. 22 1. Put Bearing box section on 1R031, aligning Labyrinth ring [25] to the edge of 1R031. [25] 1R032 2. Put 1R032 on Spiral bevel gear 37 [18].

  • Page 14: Assembling

    6-2-2 Assembling 6-2-2-1 With electric brake Available for DGA413, DGA414, DGA463, DGA464, DGA513, DGA514 Fig. 26 1. Insert Spindle [26] into Lead flange [47] [25] and fix the Spindle to Lead flange [47] [26] with Retaining ring R-26 [25]. 1R291 [26] [25] [47]...
  • Page 15 Now, Spiral bevel gear 37 [18] has been assembled to Spindle [26]. 1R028 1R029 6-2-2-2 Without electric brake Available for DGA411, DGA412, DGA461, DGA462, DGA511, DGA512 Fig. 31 1. Pass Spindle [6] through Labyrinth ring [25]. 2. Put Bearing box section on 1R031, aligning the [26] Labyrinth ring [25] to the edge of 1R031.
  • Page 16 6-2-2-2 Without electric brake 6. Put Bearing box section on 1R028, aligning the Fig. 34 Ball bearing 6201DDW to the edge of 1R028. And assemble Spindle [26] by pressing with Arbor press. [26] 7. Putting Spiral bevel gear 37 [18] on 1R029, press Spindle [26] with Arbor press.

  • Page 17: Switch Knob, Switch Lever

    6-3 Switch knob, Switch lever The following steps are available for all of this series models. Fig. 41 1. Assemble Torsion spring 2 [37] to Lever [36]. [38] 2. Assemble Pin 2 [38], by passing it through Lever [36]. [36] [37] Fig.

  • Page 18: Circuit Diagram

    7. CIRCUIT DIAGRAM Symbol of Item No. electrical parts Descriptions. Color index of lead wires' sheath Connector Black Blue Connector for connection to Green Auto start wireless system Orange Flag connector with Lock # 250 t = 0.8 White Flag connector with Lock # 187 t = 0.8 Yellow Insulated terminal (M3.5 Screw) Straight connector with Lock # 187 t = 0.8...

  • Page 19: Wiring Diagram

    8. WIRING DIAGRAM Wiring of Lead wires Wiring to Switch connected to Dial section Tab of inside Lead wires, connected to Dial Straight connector with section, are put to the place Controller's lead wire between Rib F and Rib E. (white) has to be connected And Sub controller is set on that to Tab of inside.

  • Page 20: Troubleshooting

    9. TROUBLESHOOTING Test for short-circuit in FET (Field Effect Transistor) of Controller Trouble on Controller can be checked with Tester as follows. (1) Set Tester to Diode mode. (2) Removing Battery from the machine, lock Switch trigger to ON position. (3) Contact black probe with (+) Terminal.

  • Page 21: Flowchart Of Troubleshooting

    Fig. T-1 9-2 Flowchart of Troubleshooting Star mark (1) Use the full charged battery which has the star mark. (Fig. T-1) (2) Check conditions of the mechanical section, Rotor to Stator rub, Connectors, Lead wires, etc. , when Motor housing set are disassembled. (3) Do the running test by repeating 10 times while operating speed control dial in order to reproduce symptoms easily.

  • Page 22: Wireless Activation

    Wireless activation (ForDGA412/ DGA462/ DGA512/ DGA414/ DGA464/ DGA514) When checking the wireless activation, be sure to prepare an our wireless supported tool (Circular saw, etc.). Check Step 1 (9-3-1) to Step 3 (9-3-3) in order and if some troubles happen, refer to 9-3-4 Tool side Vacuum cleaner side...

  • Page 23: Step3 : Checking Wireless Activation

    9-3-3 Step3 : Checking wireless activation The tool and cleaner should be separated about 5m each other. Vacuum cleaner Supported tool When the tool is activated, the wireless activation lamps When the tool is activated, the wireless activation lamps lights up in blue. lights up in blue.

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