Makita DHP480 Manual

CONCEPT AND MAIN APPLICATIONS

Specification

Standard equipment

Optional accessories

Note: The standard equipment may vary by country or model variation.

Fast charger DC18RC

Charger DC18SD

Charger DC24SC

Automotive charger DC18SE

*3: Battery, charger and Plastic carrying case are not supplied with “Z” model

*4: Supplied with the same quantity of extra Battery

Drill bits for wood

Drill bits for steel

Drill bits for masonry

Driver bits

Bit holder

Battery*3

Charger*3

Battery cover*4

Plastic carrying case*3

Belt clip

+ – bit 2-45

Model DHP480 is a superior class cordless hammer driver drill model, featuring:

• Compact tool size with an overall length of 199mm (7-7/8")

• High power and maintenance-free achieved with new BLDC(BrushLess DC) motor

• Enhanced dust and drip-proof design to ensure reliable operation even under

bad weather.

• Battery fuel gauge shows the remaining capacity by pulling switch trigger.

Dimensions: mm (")

Width (W)

Height (H)

Length (L) 199 (7-7/8)

79 (3-1/8)

243 (9-9/16)*1

260 (10-1/4)*2

Battery

Capacity of drill chuck: mm (")

Capacity: mm (")

Max lock torque: N.m (in.lbs)

Electric brake

Variable speed control

Mechanical speed control

Reversing switch

Max fastening

torque: N.m (in.lbs)

Torque setting

Steel

Wood

Soft joint

Hard joint

No load speed:

minˉ¹=rpm

Energy capacity: Wh

Voltage: V

Capacity: Ah

High

Weight according to

EPTA-Procedure 01/2003: kg (lbs)

Low

24, 27, 36, 54, 72, 90

Cell Li-ion

Charging time (approx.): min. 15, 15, 24, 22, 36, 45 with DC18RC

1.3, 1.5, 2.0, 3.0, 4.0, 5.0

Yes

Yes (2 speed)

Yes

13 (1/2)

38 (1-1/2)

Masonry 13 (1/2)

16 stage + drill mode

Clutch torque setting: N.m (in.lbs) 1.0 - 5.0 (9 - 44)

60 (530)

36 (320)

54 (480)

0 - 1,550

0 - 400

Impacts per minute:

minˉ¹ = ipm

High

Low

0 - 23,000

0 - 6,000

1.5 (1/16) - 13 (1/2)

Max output: W 370

LED job light

Battery BL1815

Battery BL1815N

Battery BL1820

Battery BL1830

Battery BL1840

Battery BL1850

*1: with BL1815, BL1815N or BL1820

*2: with BL1830, BL1840 or BL1850

1.5 (3.2)*1

1.7 (3.8)*2

Models No.

Description

PRODUCT

TECHNICAL INFORMATION

DHP480

18V Cordless Hammer driver drill

OFFICIAL USE

for ASC & Sales Shop

P 1/ 12

P 2/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Drill chuck

DISASSEMBLING

Fig. 1

Fig. 2

4. Set 1R298 to Keyless

drill chuck.

1. Fit Anvil of TW450D to the socket of 1R298.

2. Firmly holding the machine at its grip portion,

remove Keyless drill chuck by driving BTW450

in reverse mode.

Note: Use 1R359 to remove Keyless drill chuck

if it cannot be removed in this step.

See Figs. 6 and 7.

1. Open Drill chuck fully and remove M6x22

Flat head screw by turning it clockwise with

Slotted screwdriver.

Note: Use Impact driver to unscrew M6x22

(-) Flat head screw if it cannot be

removed manually.

M6x22 (-) Flat head screw

(Left handed thread)

(2) For removing Keyless drill chuck, it is necessary to use Impact wrench with strong fastening torque such as

Model BTW450 (440 N.m in max fastening torque).

Remove Drill chuck as drawn in Fig. 2.

(1) Remove M6x22 (-) Flat head screw. Then, preset the machine as drawn in Figs. 1-2 and 1-3. And then, set 1R298 to

the machine. (Fig. 2)

BTW450

Firmly hold the grip portion during the work.

2. Set Speed change lever to

Low speed mode designated

with 1.

1R298

Anvil

1R298

It is not required to lubricate, because this product has gear mechanism of factory assembled.

Code No. Description Use for

1R298 Hex bar 10 with square socket removing Drill chuck

1R359

---

Chuck removing tool removing Drill chuck

(If it is impossible to remove as per the illustration in Figs. 1 and 2.)

Hex wrench 10 removing Drill chuck

[2] LUBRICATION

[1] NECESSARY REPAIRING TOOLS

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

3. Set Change ring to Drill mode.

P 3/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Drill chuck (cont.)

Fig. 3

ASSEMBLING

(1) Set Hex wrench 10 to Vise as drawn in Fig. 3.

(2) Mount Drill chuck to Spindle as drawn in Fig. 4.

Fig. 4

End of the threaded

portion of Spindle

1. Turn Drill chuck clockwise until

it sits on the end of the threaded

portion of spindle.

Drill chuck

Hex wrench 10

F/R change lever

Set F/R change lever to

Forward (clockwise) rotation.

Set Speed change lever

to Low speed mode

designated with 1.

Set Change ring

to Drill mode.

Speed change lever

Change Ring

Correct Wrong

Vise

[A]

Clamp the long end. Do not clamp edges

of Hex wrench 10.

Hex wrench 10,

viewed from side [A]

Clamp flat surfaces

of Hex wrench 10

[A]

Hex wrench 10,

viewed from side [A]

Hex wrench 10 Hex wrench 10

Vise

2. Setting the machine as illustrated below, pull Switch trigger slowly to turn Spindle to Forward

(clockwise) rotation.

Note: Pull the trigger so that Spindle’s rotating reaches full speed in one second.

3. Drill chuck is tightened and consequently Spindle is locked.

Fig. 5

(3) Secure Drill chuck as drawn in Fig. 5.

M6x22 (-) Flat head screw

(Left handed thread)

Open Drill chuck fully, and tighten Drill chuck with M6x22 (-) Flat head

screw by turning it counterclockwise with Slotted screwdriver.

Note: Apply adhesive (ThreeBond 1342 or Loctite 242) to threaded

portion when re-using the removed (-) M6x22 Flat head screw.

Do not clamp

the short end.

P 4/ 12

DISASSEMBLING

ASSEMBLING

Referring to Fig. 7, assemble Gear assembly.

If it is difficult to remove Drill chuck as drawn in Figs. 1 and 2, use 1R359. (Fig. 6)

Steel ball 5 (12 pcs.)

Gear case B

Pin 3.5 (2 pcs.)

Spur gear 11

(5 pcs.)

Spur gear 16C complete

(5 pcs.)

Spur gear 13B complete

(5 pcs.)

Flat fillister head pin 1.2 (2pcs.)

Spur gear 19C complete

(4 pcs.)

Spur gear 14-41C

Motor bracket

Tapping screw

BT3x16

(4pcs.)

Washer 12

Internal gear 39C

Internal gear 51C

Internal gear 41

Speed change lever

Speed change cam

Lock ring

Lock cam

Carrier C complete

How to Use 1R359

1) Disassemble Gear assembly until Spindle can be seen.

(Fig. 6A)

2) Assemble Lock cam to Carrier C complete, then attach

them to 1R359. (Fig. 6B)

3) Fix 1R359 securely in vise.

4) Insert the spline portion of Spindle into Lock cam.

(right in Fig. 6C)

5) Remove *Chuck screw by turning it clockwise using

Cordless impact driver.

* M6x22 (-) Flat head screw (left-handed, threadlocker

coated)

6) Fix one leg of a Hex wrench 10 in the jaws of Drill chuck.

(left in Fig. 6C)

7) Attach an appropriate steel pipe to the other leg of the wrench.

Drill chuck can now be removed by turning the pipe counterclockwise. (left in Fig. 6C)

Lock cam

Carrier C

complete

1R359

Spindle

Vise

Steel pipe

Fig. 6A Fig. 6B

Fig. 6C

Fig. 6

Fig. 7

Hex wrench 10

Lock cam

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Drill chuck (cont.)

Spindle

Lock cam

P 5/ 12

Fig. 8

DISASSEMBLING

(1) Remove Drill chuck as drawn in Figs. 1 an 2.

(2) Disassemble Gear assembly as drawn in Fig. 8.

1. By unscrewing nine 3x16 tapping screws,

remove Housing R from Housing L.

2. Remove Gear assembly section (Gear assembly,

Change ring, Speed change lever) and Motor

section (Rotor and Stator) from Housing L.

Housing R 3x16 Tapping screw

(9 pcs.)

Change ring

Stator

Rotor

Gear assembly

Speed

change lever

Housing L

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Rotor, Gear assembly

3. Remove Speed change lever from Gear assembly.

Note: Be careful not to lose Compression spring 4.

4. Separate Gear assembly from Motor section.

Gear

assembly

Motor section

Speed

change lever

5. Put Rotor section on a workbench so that

the drive end of Rotor touches the workbench.

Press Stator down to separate it from Rotor.

Stator Stator

Rotor

P 6/ 12

When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 9A

because Rotor is a strong magnet, failure to follow this instruction could result in:

•Finger injury caused by pinching between Rotors pulling each other

•Magnetic loss of Rotors or damage on the magnet portion of Rotor. (Fig. 9B)

Fig. 9A Fig. 9B

* Magnetic loss of Rotors

* Damage on the magnet portion of Rotor

1. Put Leaf spring in place as drawn below.

(1) Pass Rotor into Stator complete as drawn in Fig. 10.

(2) Mount Leaf spring to Housing L, and join Gear assembly with Motor section. (Fig. 11)

Caution for Handling of Rotor

ASSEMBLING

Leaf spring

Fig. 10

Fig. 11

1. Holding Stator complete on a workbench, slowly insert Rotor

in Stator complete until Rotor’s drive end reaches the workbench.

2. When the drive end of Rotor

reaches the workbench, lift up

Stator complete slowly.

Rotor

Stator complete

Gear

assembly

2. Before pushing Rotor section (Rotor and Stator) fully

in Gear assembly, make sure that Rotor’s gear engages

with the super gears of Gear assembly to rotate them

smoothly.

Motor section

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Rotor, Gear assembly (cont.)

P 7/ 12

ASSEMBLING

Fig. 12

(3) Assemble Speed change lever assembly as drawn in Fig. 12.

Drill chuck

side

Stator Gear assembly

Drill chuck

side

Drill chuck

side

Pin on the lever

of Gear assembly

front Compression spring 4

1. Apply the front Compression

spring 4 of Speed change lever

assembly to the flat side

(without pin) of Gear assembly

for Speed change.

2. Push Speed change lever assembly

toward Rotor side until it stops to

have space between the pin of

Gear assembly and the rear

Compression spring 4.

3. Fit the pin of Gear assembly to

Spring’s coil with slowly

returning Speed change lever

assembly toward Drill chuck side.

4. Slide Speed change lever

assembly to the either position

2 (High speed mode) or

1 (Low speed mode).

Pin on the lever of Gear assembly fit to

the coil of the rear Compression spring 4

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Rotor, Gear assembly (cont.)

Space between the rear Compression

spring 4 and the pin on the lever of

Gear assembly.

The front Compression spring 4

compressed by the lever of

Gear assembly.

P 8/ 12

Gear assembly

F/R change lever

Stator

(4) Assemble Gear assembly and Rotor section to Housing L as drawn in Fig. 13.

Fig. 13

1. Make sure that the ribs of Housing L are

fitted tightly in the notches of Stator.

F/R Change lever

2. Before assembling Switch to Housing L,

fit the prong of F/R change lever to

the projection of Switch.

prong portion

projection

ASSEMBLING

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Rotor, Gear assembly (cont.)

Rib

Notch of Stator

Rib

Notch of Stator

Circuit diagram

Wiring diagram

P 9/ 12

Color index of lead wires' sheath

Black

Fig. D-1

Fig. D-2

White

Red

Orange

Yellow

LED

Connector

Controller

Terminal

Stator

Printed

wiring

board

Blue

B2 B1

T+

T-

Switch

Terminal

Connector

Housing L

Wiring to Switch

Housing L

Flag

terminal

Flag connectors of Lead wires must be connected to

Switch so that their wires come to Housing L side.

Controller

Wiring diagram

P 10/ 12

Printed wiring board

Rib of

Controller

Rib of Controller

Controller

Put Lead wires connecting

Terminal and Controller

between (Controller’s) Rib

and Housing L.

Wiring of Lead wires connecting Terminal and Controller

Terminal

Housing L

Rib E

Rib F Rib G

Rib H

Stator

Rib A

Switch

Terminal

Controller

Be careful not to put Connecting

terminals under or on Capacitor.

Insulated connector (3 pcs.)

Do not put any Lead wires

onto these Ribs.

Wiring in Housing L

Wiring in upper space of Switch

Fig. D-3

Rib B Rib C

Rib D

LED light

circuit

Put connector

to this space.

Put the slack portion of Lead wires

of Printed wiring board to the space

keeping the distance from the tip

of Rib A toward LED side.

Put the slack portion of Lead wires

of Stator and those of Controller

for connecting to LED light circuit

in this space while paying attention

not to put any lead wires onto the ribs.

Be careful not to put Lead wires

onto Ribs E, F, G and H when

guiding them in the space

between Switch and Stator.

Put the following Lead wires

under the other Lead wires.

* Lead wire (red) of

Terminal

* Lead wire (white) of

Controller

Put the following Lead wires

into this groove.

* Stator’s lead wires (3 pcs.)

* Lead wires of Printed

wiring board

* Lead wires for connecting

to LED

Capacitor

(integral part of Controller)

When checking Controller,

do the test according to

“Test for recognizing

the trouble on Controller”

at last page.

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