Makita DTR180 Repair Manual
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Makita DTR180 Repair Manual

Makita DTR180 Repair Manual

Cordless rebar tying tool
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OFFICIAL USE
For ASC
CORDLESS REBAR TYING TOOL
DTR180, DTR181
REPAIR MANUAL
June 2022
Ver.1

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Summary of Contents for Makita DTR180

  • Page 1 OFFICIAL USE For ASC CORDLESS REBAR TYING TOOL DTR180, DTR181 REPAIR MANUAL June 2022 Ver.1...

  • Page 2: Table Of Contents

    Housing section .................................. 17 6-6-1 Disassembling ................................17 6-6-2 Assembling ................................18 Guide arm section ................................20 6-7-1 Disassembling (DTR180) ............................20 6-7-2 Disassembling (DTR181) ............................21 6-7-3 Assembling (DTR180) .............................. 23 6-7-4 Assembling (DTR181) .............................. 25 Gear section..................................27 6-8-1 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 Makita grease FA No.2 a little ThreeBond 1342 or Loctite 243 a little Fig. 1 [DTR180] 4 / 44...
  • Page 5 Description Amount Makita grease FA No.2 a little Loctite 273 a little Fig. 2 [DTR181] 5 / 44...

  • Page 6: Tightening Torque Specifications

    TIGHTENING TORQUE SPECIFICATIONS Tightening torque Parts to fasten Fastener (N∙m) Housing L ↔ Side plate L Housing R ↔ Side plate R H.S.button head screw M3x6 Guide plate B ↔ Guide arm A 0.4-0.8 Housing R ↔ Stopper +Pan head screw M3x8 Contact plate ↔...

  • Page 7: Repair

    REPAIR Battery Removing 6-1-1 Remove Battery from the machine, then remove Cable tie wires and Hook. Wire guide section Disassembling 6-2-1 Remove Battery from the machine. Fig. 3 Open Reel cover [1], then remove the equipped Hex wrench 2.5 [2] and Cable tie wires [3]. Tips Wind up Cable tie [3] so that it does not slacken, then pass Wire end through the side hole [4] of Bobbin.

  • Page 8: Assembling

    Assembling 6-2-2 Fig. 5 Put Guide plate A [1] on Guide arm [2]. Fit the protrusion of Cutter A [3] into Guide plate A [1]. Fig. 6 Assemble Link arm A [2] to the pin of Link arm B [1]. Note Apply the specified grease to their sliding portions.

  • Page 9: Reel Cover Section

    Fig. 9 Push up Contact plate [1], then insert Contact plate cover [2]. Tighten Hex socket head bolt M3x20 [3] to the tightening torque 1.3 - 1.8 N·m. Reel cover section Disassembling 6-3-1 Disassemble Wire guide section. (6-2-1) Fig. 10 Open Reel cover [1], then remove Tapping screws bind PT 3x16 [2] (2 pcs).

  • Page 10: Assembling

    Assembling 6-3-2 Assemble Housing cover side. (6-4-2) Fig. 12 Assemble the following parts, then tighten Tapping screws bind PT 3x16 [1] (2 pcs).  Reel bearing cam [2]  Reel cover [3]  Reel base [4]  Reel bearing [5] ...

  • Page 11: Housing Cover Side

    Housing cover side Disassembling 6-4-1 Disassemble Reel cover. (6-3-1) Fig. 14 Remove Tapping screws PT 3x16 [1] (4 pcs), then remove Housing cover [2]. Fig. 15 Disconnect Connectors, then cut Closed end splices [1] as close as possible to the crimped end. Tips [10] Cut Closed end splices [1] as close as possible to the...

  • Page 12: Assembling

    Fig. 17 Lift up Wire guide pipe section [1] obliquely to remove it. Tips Wire guide pipe section [1] cannot be pulled out without pushing Contact plate [2] upward. Remove Sponge sheet B [4] and Stop ring E-4 [5] from Wire guide pipe [3]. Assembling 6-4-2 Assemble Motor section.
  • Page 13 Fig. 20 Assemble Lock lever [1] and Compression spring 3 [2], then place them in Housing R [3]. Fig. 21 Insert Compression spring 3 [1] into Housing R [2]. Assemble Compression spring 3 [1] while pressing it with Release lever [3]. Tighten Tapping screw bind PT 3x16 [4], then assemble Flat washer 4 [5] and Release lever [3].
  • Page 14 Fig. 22 Fix Sensor circuit lead wires in the groove of Motor base. (6-5-2) Attach Closed end splices [1] (2 pcs) to the same color lead wires (2 pcs each), then crimp them with 1R377. Connect Connector [2]. Assemble Motor section [3] in place, then fix Lead wires in Housing 1R377 R [4] with 1R411.

  • Page 15: Motor Section

    Motor section Disassembling 6-5-1 Disassemble Housing cover side. (6-4-1) Fig. 24 Remove Tapping screw bind PT 3x10 [1], then remove Sensor circuit [3] from Motor base [2]. Fig. 25 Remove Tapping screw PT 3x16 [1], then remove Wire guide A [2]. Fig.

  • Page 16: Assembling

    Assembling 6-5-2 Assemble Housing section. (6-6-2) Fig. 28 Align the protrusion of Motor base [1] with the hole of DC motor [2]. Assemble Motor base [1] with Pan head screws M3x8 [3] (2 pcs). Fig. 29 Assemble Sponge sheet A [2] to Motor base [1]. Assemble Spur gear 30A [4] so that DC motor [3] and Spur gear 30A [4] engage.

  • Page 17: Housing Section

    Housing section Disassembling 6-6-1 Disassemble Motor section. (6-5-1) Fig. 33 Remove H.S.H.button head screws M3x6 [3] (2 pcs each) from Housing L/R [2] with Hex wrench 2.0 [1], then remove Side plates L/R [4]. Fig. 34 Remove Magnet arm [2] and Compression spring 3 [3] from Housing R [1].

  • Page 18: Assembling

    Curl guide [1] and Pin 5 [3].  Push down Curl guide [1] to check the operation. [3] [2] Fig. 38 (DTR180) Move Contact plate [1] and Push plate [2], then place Guide arm section [3] in Housing R [4]. Fix Trigger section [5].
  • Page 19 Fig. 39 (DTR181) Place Guide arm section [1] in Housing R [2]. Note Be careful with the position between Push plate [3] and the hook portion of Main sleeve [4]. Fig. 40 Assemble Housing L [2] by tightening Tapping screws bind PT 3x16 [1] (11 pcs). Fig.

  • Page 20: Guide Arm Section

    Guide arm section Disassembling (DTR180) 6-7-1 Disassemble Housing section. (6-6-1) Fig. 43 Push out Pin 5 [1] with a slotted screwdriver, then remove the following parts:  Contact plate [2]  Flat washer 3 [3]  Compression spring 4 [4] Fig.

  • Page 21: Disassembling (Dtr181)

    Fig. 47 Remove Stop ring E-3 [1] from the other side, then remove Shoulder pin 4 [2], and then remove the following parts:  Torsion spring 7 [3]  Push plate [4]  Pull plate [5] Fig. 48 Remove H.S.button head screws M3x6 [1] (2 pcs) with Hex wrench 2.0, then remove Guide plate B [3] from Guide arm A [2].
  • Page 22 Fig. 51 Remove Hex socket head bolt M3x8 [1] with Hex wrench 2.5, then remove Wire guide B [2]. Fig. 52 Remove the following parts from Guide arm section:  Top plate [1]  Cutter B [2]  Cutter A [3] ...

  • Page 23: Assembling (Dtr180)

    [3] from Guide arm A [2]. Fig. 57 Remove Pan head screw M3x8 [2] from Contact plate [1], then remove Magnet base B [3]. Assembling (DTR180) 6-7-3 Assemble Gear section. (6-8-2) Fig. 58 Assemble Guide arm A [2] and Guide plate B [3] by tightening H.S.button head screws M3x6 [1] (2...
  • Page 24 Fig. 59 Insert Pin 3 [2] into Lead holder [1]. Fig. 60 Assemble Magnet base B [3] to Contact plate [2] by tightening Pan head screw M3x8 [1]. Fig. 61 Insert Shoulder pin 4 [1] into the following parts, then assemble Stop ring E-3 [2]. ...

  • Page 25: Assembling (Dtr181)

    Fig. 63 Assemble Lead holder [1] to Guide arm section [2]. Tips Align the grooves, then assemble them while rotating them. Fig. 64 Hook the longer leg of Torsion spring 7 [1] on the hook of Lead holder [2]. Fig. 65 Set Compression spring 4 [1], Flat washer 3 [2] and Contact plate [3], then insert Pin 5 [4].
  • Page 26 Fig. 67 Assemble Magnet base B [2] to Contact plate [1] with Pan head screw M3x8 [3]. Fig. 68 Assemble the following parts to Guide arm section [1]:  Link arm B [2]  Pull plate [3]  Push plate [4] ...

  • Page 27: Gear Section

    Fig. 72 Assemble Wire guide B [1] to Guide arm section, then tighten Hex socket head bolt M3x8 [2] with Hex wrench 2.5. Fig. 73 Assemble Compression spring 4 [1] and Flat washer 3 [2] to Guide arm section. Assemble Contact plate [3] to Guide arm section, then insert Pin 5 [4] into them.

  • Page 28: Assembling

    Fig. 76 Remove the following parts from Housing R [1]:  Main controller [2]  Switch unit [3]  Switch circuit [4]  Terminal [5]  Switch plate [6] Assembling 6-8-2 Assemble BL motor section. (6-9-2) Fig. 77 Assemble Main sleeve section [1] to Housing R [2]. Hold Main sleeve section [1], then turn Rotor [3] to check the operation of Main sleeve section [1].

  • Page 29: Bl Motor Section

    Fig. 79 Assemble the electrical parts in accordance with Circuit diagram and Wiring diagram. Assemble the following parts in Housing R [1], then fix Lead wires and Connectors with 1R411.  Main controller [2]  Switch unit [3]  Switch circuit [4] ...

  • Page 30: Assembling

    Fig. 82 Pull out Rotor [1]. Remove Tapping screw bind PT 3x10 [2], then remove Sensor circuit [3]. Fig. 83 Remove Pan head screw M3x12 [1], then slide and remove Bearing retainer [2]. Fig. 84 Remove Main sleeve [1] and Gear assembly [2]. Assembling 6-9-2 Assemble Magnet wheel and Stopper.

  • Page 31: 6-10 Magnet Wheel And Stopper

    Fig. 87 Assemble Sensor circuit [2] by tightening Tapping screw bind PT 3x10 [1]. Assemble Rotor [3]. Fig. 88 Assemble the electrical parts in accordance with Circuit diagram and Wiring diagram. Connect Terminal unit into Stator [1], then tighten Flat head screws M3x6 [2] (3 pcs) with a No.1 Phillips screwdriver.

  • Page 32: 6-10-2 Assembling

    Fig. 91 Pull out Ball bearing 6801LLB [1] from Magnet wheel [2] with 1R263 (2 pcs). 1R263 1R263 6-10-2 Assembling Fig. 92 Push Ball bearing 6801LLB [2] into Magnet wheel [1]. Fig. 93 Assemble the following parts by tightening Tapping screw bind PT 3x16 [1]: ...

  • Page 33: 6-11 Checking The Operation

    6-11 Checking the operation Fig. 95 While pressing Release lever [1] and holding Cable tie wire [2] so that it does not come loose, place it in Housing [3]. Fig. 96 Set Battery. Check that Cutter A/B [1] works when the main switch is turned on.

  • Page 34: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 99 Stator Sensor board (for detection of Contact plate position) Sensor circuit (Sensor board/ for detection of Cable tie wire loading Sensor board amount) Switch board Fuse Sensor circuit (Sensor board/ for detection of Twist arm AWG22 position) Sensor board (for detection of Reel position) Controller...

  • Page 35: Wiring Diagram

    WIRING DIAGRAM Assembling of Sensor circuit (Sensor board/ for detection of Twist arm position) Fig.100 Lead wire Sensor circuit (Sensor board/ for detection of Twist arm position) Sensor board base Assemble Sensor circuit (Sensor board/ for detection of Twist arm position) to Sensor board base so that the lead wires come out as shown.

  • Page 36: Section 1

    Section 1 Fig.102 Groove C Groove A Housing R Controller Opening A Notch portion Sensor board (for detection of Twist arm position) View of Controller from Mold face Groove B Fix Sensor circuit (Sensor board/ for detection of Twist arm position) lead wires in Groove C of Motor base so as not to come loose between Sensor board and Groove C.

  • Page 37: Section 3

    Section 2 Fig.103 Opening B Switch board Groove G Housing R Groove F Groove D Groove E Controller Fix the following Controller lead wires in Groove D, Groove E and Groove F:  Sensor boards (for detection of Contact plate position/ Curl guide position) lead wires ...
  • Page 38 Section 3 Fig.104 Controller Terminal Connector A cross section of A-A Switch unit Switch unit side Connector B Controller side Switch circuit Put Lead wires for Switch unit under the lead wires for Terminal and Switch circuit. Fix Lead wires for Terminal in this groove. Place Fuse in this space.

  • Page 39: Section 4

    Section 4 Fig.105 Sensor board (for detection of Reel position) Groove A Solenoid Connector A Fix Lead wires for Sensor board (for detection of Reel position) in Groove A so as not to come loose between Sensor board and Groove A. Place Solenoid so that the Lead wires come out as shown.

  • Page 40: Section 5

    Section 5 Fig.106 DC motor Rib B Groove B Lead wire holder B Connector B Groove C Rib A Sensor board (for detection of Curl guide position) Sensor board (for detection of Contact plate position) Closed end splice Lead wires holder A Protrusion portion Fix Lead wires (Red, Black) for DC motor in Groove C and Groove B so as not to come loose between grooves.

  • Page 41: 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 the electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc.

  • Page 42: Chart For Troubleshooting

    Chart for Troubleshooting When Main power is turned on (before pulling Trigger) 9-3-1 Symptom Cause Corrective action Main power is not turned on. Main controller is broken. Replace Main controller. Curl guide is not closed completely. Remove foreign matter from Curl guide. Iron powder is attached on Magnet arm Remove iron powder from Magnet arm complete.

  • Page 43: After Main Power Is Turned On (After The Operation To Pull Trigger)

    After Main power is turned on (after pulling Trigger) 9-3-2 Symptom Cause Corrective action Tie wire comes untied from the plastic reel and Replace Cable tie wire. Tie wire interferes with Housing. Tie wire cannot be pulled out of the reel by hand. Replace Cable tie wire.

  • Page 44: Although There Is No Indication Of "Error", Tying Cannot Be Performed

    Although there is no indication of “Error”, Tying cannot be performed. 9-3-3 Symptom Cause Corrective action When rotating Rotor by hand, Gear Replace Gear assembly. assembly does not operate smoothly. Link arm A complete and Link arm B Replace Link arm A complete or Link arm complete are broken.

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