Makita DSL801 Repair Manual
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Makita DSL801 Repair Manual

Makita DSL801 Repair Manual

Cordless drywall sander
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OFFICIAL USE
For ASC
CORDLESS DRYWALL SANDER
DSL801
REPAIR MANUAL
June 2021
Ver.1

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  • Page 1 OFFICIAL USE For ASC CORDLESS DRYWALL SANDER DSL801 REPAIR MANUAL June 2021 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 TIGHTENING TORQUE SPECIFICATIONS ..........................5 REPAIR ......................................6 Battery, pad ..................................6 6-1-1 Disassembling ................................6 Handle section ..................................6 6-2-1 Disassembling ................................6 6-2-2 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. ...

  • Page 4: Lubricant And Adhesive Application

    LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease FA. No.2 a little Fig. 1 4 / 36...

  • Page 5: Tightening Torque Specifications

    TIGHTENING TORQUE SPECIFICATIONS Tightening torque Parts to fasten Fastener Q'ty (N∙m) Brush stopper ↔ Gear housing Pan head screw M4x14 0.8 - 1.2 ↔ Spindle Hex socket head bolt M6x16 8.0 - 11.0 Strain relief ↔ Pipe A Set screw M4x8 0.6 - 1.2 Brush ↔...

  • Page 6: Repair

    REPAIR Battery, pad Disassembling 6-1-1 Remove the battery. Fig. 2 Hold Pad [1] firmly by hand so that it does not turn, then remove Hex socket head bolt M6x16 [2] with Hex wrench 5, and then remove Pad [1]. Handle section Disassembling 6-2-1 Fig.
  • Page 7 Fig. 5 Remove the following parts from Handle section [1]:  Terminal [2]  Lock off button [3]  Switch lever [4]  Compression springs 4 [5] (2 pcs)  Lock on button [6]  Switch [7]  Dial circuit [8] ...

  • Page 8: Assembling

    Assembling 6-2-2 Fig. 8 Assemble Power supply cord unit [2] to Handle L [1], then assemble Cord cover [3] with Tapping screws 4x18 [4] (2 pcs). Note Align the triangle mark on the inside of Handle L [1] with the yellow tape of Power supply cord unit [2]. Refer to Circuit diagram and Wiring diagram for details.
  • Page 9 Fig. 12 Assemble the following parts into Handle L [1]:  Lock off button [2]  Switch lever [3]  Compression springs 4 [4] (2 pcs)  Lock on button [5] Note  Be careful not to forget to assemble Compression spring 4 [4] to Lock on button [5].

  • Page 10: Brush Section

    Fig. 14 Assemble Lock sleeve [2] to Pipe housing [1], then tighten Tapping screws 4x18 [3] (4 pcs) and Tapping screws 4x30 [4] (3 pcs). Tighten Lock ring [5]. Tips It is easy to work when assembled them on a plastic hammer.

  • Page 11: Assembling

    Assembling 6-3-2 Fig. 17 Assemble Leaf springs [2] (4 pcs) to Brush [1], then tighten Tapping screws 3x16 [3] (4 pcs). Fig. 18 Assemble Cover [1] from the flats of Gear housing [2]. Insert Earth plate A [3] into Gear housing [2], then tighten Tapping screw 4x18 [4].

  • Page 12: Head Cover Section

    Head cover section Disassembling 6-4-1 Fig. 19 Remove Hose 28-0.25 [3] from Hose connector on Arm section [1] and Head cover section [2]. Remove Sleeves 6 [4] (2 pcs) and Pan head screws M6x20 [5] (2 pcs) from Arm section [1], then widen Arm [1] to remove Frame section [6].

  • Page 13: Assembling

    Assembling 6-4-2 Fig. 21 Assemble Frame [2] to Head cover [1], then tighten Hex bolt M8x22 [3] and Hex bolt M8x17 [4]. Note Be careful with a mix-up between Hex bolt M8x22 [3] and Hex bolt M8x17 [4]. Fig. 22 Assemble Head cover [2] to Gear housing [1], then assemble Rubber caps [3] (2 pcs).
  • Page 14 Fig. 24 Assemble Leaf springs [2] (2 pcs) to Frame [1] with Pan head screws M4x10 [3] (2 pcs). First, screw one end of Hose 28-0.25 [6] into Head cover [4], then screw the other end into Hose connector [5]. 14 / 36...

  • Page 15: Motor Section

    Motor section Disassembling 6-5-1 Fig. 25 Remove Tapping screws 4x18 [2] (4 pcs) from Motor housing section [1], then remove Gear housing [3]. Fig. 26 Remove Tapping screws 3x16 [2] (6 pcs) and O ring 48 [3] from Motor housing section [1]. Note Motor housing [1] cannot be opened without removing O ring 48 [3].
  • Page 16 Fig. 28 Remove Tapping screws PT 2x6 [2] (3 pcs) from Stator [1] with a No.1 Phillips screwdriver, then remove Printed circuit board [3]. Remove Flat head screws M3x6 [4] (3 pcs) from Stator [1] with a No.1 Phillips screwdriver, then remove Receptacle [5].

  • Page 17: Assembling

    Fig. 31 Put 1R031 over Rotor [1]. Push out Ball bearing 627DDW [2] and Spur gear 19 [3] from Rotor [1] with 1R022, 1R281 and Arbor press. 1R022 Tips 1R022 Because Rotor [1] is attracted to various parts of 1R281 Arbor press and workability is poor, put 1R031 over 1R031 Rotor [1] to disable magnetic force.
  • Page 18 Fig. 34 Assemble Printed circuit board [2] to Stator [1] by tightening Tapping screws bind PT 2x6 [3] (3 pcs) with a No.1 Phillips screwdriver. Note Be careful not to strip the head of Tapping screw PT2x6 [3]. Fig. 35 Insert Connector [1] into Printed circuit board, then assemble Rotor [4] to Stator [3], and then assemble them to Motor housing [2].
  • Page 19 Fig. 36 Assemble Motor housing section [1] to Gear housing [2] with Tapping screws 4x18 [3] (4 pcs). Tips When the gear is hard to fit, rotate Spindle [4] with an adjustable wrench. 19 / 36...

  • Page 20: Gear Housing Section

    Gear housing section Disassembling 6-6-1 Fig. 37 Remove the following parts from Gear housing [1]:  Flat washer 23 [2]  Spur gears 14 [3] (3 pcs)  Needle cages 307 [4] (3 pcs)  Spur gear 17 [5]  Internal gear 47 [6] ...

  • Page 21: Assembling

    Assembling 6-6-2 Fig. 39 Press-fit Ball bearing 6001LLU [2] to Spindle [1] with 1R034. 1R034 Press-fit Flat washer 12 [3] and Ball bearing 6901ZZ [4] with 1R034. 1R034 Fig. 40 Assemble Retaining ring S-12 [2] to Spindle section [1] with 1R291. 1R291 Fig.

  • Page 22: Pipe Section

    Fig. 42 Assemble the following parts to Gear housing [1]:  Flat washer 18 [2]  Carrier complete [3]  Spur gears 13 [4] (5 pcs)  Internal gear 43 [5]  Spur gear 17 [6]  Internal gear 47 [7] ...
  • Page 23 Fig. 44 Remove Joint [2] from Pipe A [1]. Remove Hose connector [3] from Joint [2]. Fig. 45 Remove Lock sleeve [2] from Pipe A [1]. Fig. 46 Remove Set screw M4x8 [2] from Pipe A [1], then remove Cord holder [3] and Power supply cord unit [4].
  • Page 24 Fig. 48 Remove Clamp 24 [2] from Pipe B [1]. Remove Pipe B [1] from Pipe A [3] in direction of red arrow. Fig. 49 Remove Pipe stopper A [3] from Pipe A [2] with 1R306, 1R281, 1R033, Hex socket head bolt M6 [1] and Arbor press.

  • Page 25: Assembling

    Assembling 6-7-2 Fig. 50 Assemble Pipe B [2] to Pipe A [1] in direction of red arrow. Assemble Pipe stopper A [3] to Pipe A [1]. Assemble Clamp 24 [4] and Dust nozzle A [5] to Pipe B [2]. Push in the head of Rivet 7 [6], then assemble Dust nozzle A [5] to Pipe B [2].

  • Page 26: Pad

    Fig. 52 Assemble Lock sleeve [2] and Lock ring [3] to Pipe A [1]. Tips The direction of assembling the cut of Lock sleeve [2] may be either way. Fig. 53 Assemble Hose connector [2] to Joint [1]. Assemble Joint section [1] to Pipe A [3]. Fig.

  • Page 27: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 56 Color index of lead wires' sheath White Orange Blue Green Yellow Black AWG16 Line filter ø17-15mm (if used) AWG22 Controller B AWG24 UL1685 Capacitor AWG26 UL1685 Controller AWG28 Dial Connector Line filter ø17-30mm (if used) Bullet terminal Terminal Flag receptacle with lock (#250, t=0.8) Switch...

  • Page 28: Wiring Diagram

    WIRING DIAGRAM Motor housing section 8-1-1 Fig. 57 Power supply cord unit 3mm or more Tube Stator Sheath portion Rib B Strain relief Rib A Connector Place Tube in this space. Fix Power supply cord unit so that its sheath portion comes out 3mm or more from the edge of Strain relief. Place Connector in the position as shown.

  • Page 29: Arm Section

    Arm section 8-1-2 Fig. 58 Corrugated tube Set Corrugate tube on Arm set so that the convex portions should be overlapped to the concave portions three or more as shown. Cord cover section 8-1-3 Fig. 59 Triangle marking Tape A Power supply cord unit (Bullet terminal side) Dotted line B (The top of Triangle marking) Cord cover...

  • Page 30: Handle Section

    Handle section 8-1-4 Fig. 60 Connector for Wireless unit Connector (3-pin) Capacitor Boss A Switch Line filter on Lead wires with Terminal (if used) Rib A Flag receptacle Terminal Lead wire Fix Lead wires to Switch in this lead wire holder so that the red or white lead wire can be placed on the top. Be careful not to route Lead wires on this boss.

  • Page 31: Handle Section

    Handle section 9-1-1 Fig. 61 Connector (5-pin) Cord cover Line filter with Controller lead wires connect to Bullet Pipe A terminals (if used). Bullet terminal Power supply cord unit Controller Power supply cord unit Tape B SEC.A-A Triangle marking Dotted line B (The top of Triangle marking) Pipe B Dotted line Bullet terminals, Connector (5 pins) and Line filter on Lead wire with Bullet terminal of Controller must be stored in the space...

  • Page 32: 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 each part (Mechanical lock, Adherence of iron powder to Rotor and Stator, Disconnection of Connectors, Lead wires, Assembling of Stator, Connection of Terminal unit and Battery, etc.).

  • Page 33: 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 34: Wireless Activation

    10-4 Wireless activation  Be sure to prepare non-defective AWS-supported tool and vacuum cleaner for efficient defect inspection.  Check Step 1 (10-4-1) to Step 3 (10-4-3) in order and if some troubles happen, see 10-4-4.  During the inspection, do not use microwave oven nearby. AWS-supported tool AWS-supported vacuum cleaner Wireless activation lamp...

  • Page 35: Step 2: Tool Registration

    10-4-2 Step 2: Tool registration AWS-supported tool AWS-supported vacuum cleaner Press and hold down Wireless activation button, Press and hold down Wireless activation button, then make sure that Wireless activation lamp blinks then make sure that Wireless activation lamp blinks in green.

  • Page 36: Step 3: Checking Wireless Activation

    10-4-3 Step 3: Checking wireless activation The tool and cleaner should be about 5m apart from each other. AWS-supported tool AWS-supported vacuum cleaner Make sure that, when the tool is activated, Wireless Make sure that, when the tool is activated, Wireless activation lamp lights up in blue.

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