Koki Holdings DS 18DD User manual

PRODUCT NAME
18 V Cordless Driver Drill
Models DS 18DD, DS 18DDX*
*: Designed for operating in USA and Canada only.
REPAIR GUIDE -----------------------------------------------------------------------------------------------------------------1
1. Precautions on disassembly and reassembly ------------------------------------------------------------1
• Disassembly----------------------------------------------------------------------------------------------------1
• Reassembly ----------------------------------------------------------------------------------------------------2
• Checking after reassembly ---------------------------------------------------------------------------------5
• Tightening torque----------------------------------------------------------------------------------------------5
• No-load current ------------------------------------------------------------------------------------------------5
• Wiring diagram-------------------------------------------------------------------------------------------------6
2. Precautions on disassembly and reassembly of the charger -----------------------------------------6
CONTENTS Page
D
Power Tools Service Manual
CONFIDENTIAL
Jul. 2020
Overseas Sales Management Dept.
DS 18DD

-1-
• Removal of the drill chuck
[2]
Clutch dial
WARNING: Always remove the battery from the main body before starting repair or maintenance
work. Because the tool is cordless, inadvertently activating the switch with the battery
left in the main body will start the motor rotating unexpectedly, and could cause serious
injury.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts lists and exploded
assembly diagrams for the Models DS 18DD and DS 18DDX.
1. Removal of the drill chuck
(1) For removal of the Drill Chuck [2] from the drill body, first use a vise to clamp the drill body, and then go
to steps (a) and (b) below. A cloth should be placed between the drill body and the vise to protect
Housing (A).(B) Set [11] against damage.
(a) Fully open the jaw of the Drill Chuck [2], and then use dedicated driver bit T25 (T-shaped
hexalobular screw) to turn the Left-Hand Hexalobular M5 [1] clockwise and remove it.
NOTE: The Left-Hand Hexalobular M5 [1] is a left-hand threaded screw. Use of a driver bit
other than T25 may strip the screw thread and thus prevent the removal of the Drill
Chuck [2]. To avoid this situation, be sure to only use dedicated driver bit T25.
(b) Insert an 8 mm hex. bar wrench into the top of the Drill Chuck [2], clamp it as shown below, and then
turn the wrench counterclockwise to detach the chuck. Use a pipe or other means of leverage in
case the chuck is difficult to loosen.
(2) Set the clutch dial to the clutch “1” position.
Disassembly
REPAIR GUIDE
Cloth
8 mm hex. bar wrench
Vise

-2-
[3]
[4]
[9]
[6]
[7]
[8]
[11]
[10]
2. Disassembly of housing (A).(B) set
(1) Remove the eight Tapping Screws (W/Flange) D3 x 16 [4] from the drill body, hold Housing (A).(B) Set
[11] at its battery mount portion, and then gently open Housing (A).(B) Set [11].
(2) Remove housing (B) and remove such built-in parts as modules and units. Lift up Gear Box (A) [3] to
remove the built-in parts together from housing (A). The built-in parts are Gear Box (A) [3], Wiring Ass’y
[6], Battery Terminal [10], Pushing Button [7], and Shift Knob [9].
• Disassembly of housing (A).(B) set

-3-
• Reassembly of the power supply unit and its vicinity
Generally, perform reassembly by reversing the disassembly procedure. However, special attention should
be given to the following items.
1. Reassembly of the power supply unit and its vicinity
Reassembly
[7]
Fit the protrusion of the direction
selector lever of the switch into the
hole of the Pushing Button [7].
Insert the brown internal wire into the
internal wire threading groove first, then
insert the orange internal wire, ribbon
cable, and purple internal wire into the
internal wire threading groove.
Insert the tip (connector) of the D wire
(blue) into the space in the housing.
NOTE: The D wire is intended for
exterior communication so
that the supplier can check
the controller status.
LED

-4-
2. Reassembly of housing (A).(B) set
(1) Mount the reassembled power supply unit and Gear Box (A) [3] in housing (A).
(2) Check that the protrusion of the direction selector lever of the DC-speed control switch is correctly put in
the hole of the Pushing Button [7].
(3) Mount the shift arm to the groove of the Shift Knob [9] positioning the "HIGH" marking on the Shift Knob
[9] at the rear.
(4) Mount housing (B) to housing (A) and fasten it with the eight Tapping Screws (W/Flange) D3 x 16 [4].
(5) After completing reassembly up to step (4), check that each marking on the clutch dial from “1” to drill
mark “ ” is aligned with the triangle mark on Housing (A).(B) Set [11], and the clutch dial rotates
regularly. If number “1” or the drill mark “ ” on the clutch dial is not properly aligned with the triangle
mark on Housing (A).(B) Set [11], the clutch dial may be improperly mounted. Mount the clutch dial
correctly. Check the operation of the Shift Knob [9]. Switch the Shift Knob [9] and make sure the speed
is correctly switched between HIGH and LOW. If the speed change is disabled or abnormal, the Shift
Knob [9] or other parts may not be properly mounted. Mount the Shift Knob [9] or other parts correctly.
3. Mounting the drill chuck
Mount the Drill Chuck [2] to the spindle and fasten it with the Left-Hand Hexalobular M5 [1].
NOTE: The tightening torque of the Drill Chuck [2] is 29.4±2 N•m {300±20 kgf•cm}. It is higher than
that of the conventional models. Securely tighten the Drill Chuck [2] at 29.4±2 N•m {300±20
kgf•cm}. If the Drill Chuck [2] is tightened at lower torque, the Drill Chuck [2] may be loose.

-5-
After reassembly, install the battery in the tool body and check for operation of each component as follows.
(1) Checking for lighting of the LED light
Make sure the LED light turns on while pulling the switch and automatically turns off in about ten
seconds when you release your finger from the switch.
(2) Checking for rotating direction of the drill chuck
Press the Pushing Button [7] and check the Drill Chuck [2] rotates as indicated on the button. When you
press the “R” side of the Pushing Button [7], the Drill Chuck [2] turns clockwise as viewed from the rear
of the tool body.
(3) Checking for runout of the drill chuck
Check that runout of the Drill Chuck [2] is 0.8 mm or less under the following conditions.
Condition 1: Set a 12-mm dia. test bar in the Drill Chuck [2] and measure runout of the Drill Chuck [2] at
a position 110 mm away from the tip of the Drill Chuck [2].
Condition 2: Set a 6-mm dia. test bar in the Drill Chuck [2] and measure runout of the Drill Chuck [2] at
a position 70 mm away from the tip of the Drill Chuck [2].
Item
No. Part name No. used
Tightening torque
N•m kgf•cm
[1] Left-Hand Hexalobular M5 1 3.4±0.5 35±5
[2] Drill Chuck 13TLRA-N 1 29.4±2 300±20
[4] Tapping Screw (W/Flange) D3 x 16 (Black) 8 1.3±0.3 13±3
Measure the no-load current by using a fully charged battery after no-load running for five minutes.
No-load current: 2.0±1.0 A (DC 19.8 V—equivalent to the voltage of a fully charged battery) in High mode
Checking after reassembly
Tightening torque
No-load current

-6-
• Wiring diagram
• Connecting diagram LED
M
DC-speed control switch
Battery terminal
+ (red) Controller
- (black)
LD (green)
2. Precautions on disassembly and reassembly of the charger
Refer to the Service Manual for precautions on disassembly and reassembly of the charger Models
UC 18YFSL and UC 18YKSL.
Wiring diagram
[9]
LED
Insert the internal wire into the
internal wire threading groove.
[10]
[8]
[3]

M O D E L
Rev.1 DS18DD
506
508
507
509
504
510
501 502 503
1
2
3
45
9
6
7
12
11
10
501
505
8

ITEM CODE NO.
NO. NO. USED
1 337426 LEFT-HAND HEXALOBULAR M5 1
2 376359 DRILL CHUCK 13TLRA-N 1
3 374383 GEAR BOX (A) 1
4 313687 TAPPING SCREW (W/FLANGE) D3 X 16 (BLACK) 8
5 NAME PLATE 1
6 376360 WIRING ASS'Y 1
7 374399 PUSHING BUTTON 1
8 376362 DC-SPEED CONTROL SWITCH 1
9 374382 SHIFT KNOB 1
10 376361 BATTERY TERMINAL 1
11 376357 HOUSING (A).(B) SET 1
*12 333352 BATTERY BSL 1815 (EUROPE) 2 INCLUD. 502
*12 334725 BATTERY BSL 1815 (CHN) 2 INCLUD. 502
*12 334726 BATTERY BSL 1815 (TPE) 2 INCLUD. 502
*12 339783 BATTERY BSL 1830C (EUROPE, AUS, NZL) 2 INCLUD. 502
*12 376029 BATTERY BSL 1850C (EUROPE, AUS, NZL) 2 INCLUD. 502
*501 CHARGER (MODEL UC18YKSL) 1 FOR CHN, SIN, MAL, AUS, NZL
*501 CHARGER (MODEL UC18YFSL) 1 FOR EUROPE
502 329897 BATTERY COVER 1
503 983006 + DRIVER BIT NO. 2 65L 1
504 336642 CASE 1
505 376358 HOOK SET 1
506 336471 CASE ASS'Y (STACKABLE 2) 1 INCLUD. 507-509
507 336472 LATCH 4
508 336473 HANDLE 1
509 336474 HINGE 2
510 376502 INNER TRAY 1
DESCRIPTION REMARKS
STANDARD ACCESSORIES