Makita BHP459 Manual

Models No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
P 1/ 11
BHP459
Cordless Hammer Driver Drill
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may vary by country.
+ – bit 2-45 ........ 1
Belt clip .............. 1
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 192 (7-9/16)
78 (3-1/16)
238 (9-3/8)*2
256 (10-1/8)*3
*2: with Battery BL1815
*3: with Battery BL1830
Li-ion Battery BL1830
Li-ion Battery BL1815
Drill bits for wood
Drill bits for steel
Phillips bits
Fast charger DC18RA
(for USA, Canada, Guam, Panama, Colombia, Mexico)
Fast charger DC18RC
(for all countries except the countries above)
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
[Drawn above is the image
with BL1830.]
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: min-1=rpm
Energy capacity: Wh
Voltage: V
Capacity: Ah
High
Weight according to
EPTA-Procedure 01/2003: kg (lbs)
Low
Max output: W
24 (27*4)/ 54
Charging time (approx.): min.
Cell Li-ion
15/ 22 with DC18RC (DC18RA*1)
18
1.3 (1.5*4)/ 3.0
Yes
Yes
Yes (2 speed)
Yes
Yes
1.5/ 1.7 (3.3/ 3.8)
13 (1/2)
38 (1-1/2)
16 stages + drill mode
Clutch torque setting: N.m (in.lbs) 1.0 - 5.0 (9 - 44)
45 (400)
25 (220)
45 (400)
0 - 1,500
0 - 400
1.5 (1/16) - 13 (1/2)
250
LED job light
TECHNICAL INFORMATION
Model BHP459 Cordless Hammer Driver Drill has been developed
specially for light to medium duty drilling and fastening applications.
This model is equipped with a basic BLDC motor (BrushLess DC motor) specially
designed to provide, above all, more work amount on a single full battery charge.
This product is powered by 18V-1.3(1.5*4)Ah/ 3.0Ah Li-ion batteries BL1815/ BL1830,
and available in the variations listed in the next page.
*4for some countries only
L
H
W
Impacts per minute:
minˉ¹=ipm
High
Low
0 - 22,500
0 - 6,000
Masonry 13 (1/2)
OFFICIAL USE
for ASC & Sales Shop

BHP459RFE
BHP459RF
Model No.
Type Quantity
Plastic
carrying
case
Battery
cover
Battery
No NoBHP459Z No
2 1
1 No
1 No
No
DC18RC
Charger
No
Yes
BL1830
BHP459RFE3
BHP459RH
BHP459RHE BL1815 Yes
Yes
2 1
DC18RC
BHP459SHE 2 1DC18SD BL1815
BHP459
Housing
color
BHP459RFEW 2 1
Makita blue
Makita blue
Makita blue
White
Note: All models also include the accessories listed in "Standard equipment" of page 1.
3 2
Makita blue
Variation list
P 2/ 11

Repair
It is not required to lubricate the gear section because the portion is replaced as a factory- lubricated gear unit.
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Drill Chuck
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R359 Drill chuck removing tool
[2] LUBRICATION
DISASSEMBLING
Hex wrench 10
(Use this tool if Drill chuck cannot be removed by the method of
described in “[3]-1 Drill chuck disassembling”.)
removing/ mounting Drill chuck
Fig. 1
M6x22 Flat head screw
(Left handed thread)
Note: It is required to remove Drill chuck when replacing Gear assembly, but you need not when replacing
the parts that are independent of Gear assembly.
(1) Remove M6x22 Flat head screw. (Fig. 1)
(2) Preset the machine. (Fig. 2)And set Hex wrench 10 to Vise. (Fig. 3)
(3) While holding Hex wrench 10 with Drill chuck firmly, remove Drill chuck from Gear assembly. (Fig. 4)
Fig. 2
Attach Battery.
F/R change lever
Set F/R Change lever
to Reverse (counter-
clockwise) rotation.
Set Speed change lever
to Low speed mode
designated with 1.
Speed change lever
Set Change ring
to Drill mode.
Change ring
Open Drill chuck fully and remove M6x22
Flat head screw by turning it clockwise.
CORRECT WRONG
Fig. 3
Fig. 4
Setting of Hex wrench10
Vise
Grip flat surfaces
of Hex wrench 10.
Hex wrench 10
Hex wrench 10,
viewed from side [A]
Vise
Hold the long end.
[A]
Do not hold edges
of Hex wrench 10.
Do not hold
the short end.
Hex wrench 10,
viewed from side [A]
Note: Use Impact driver to unscrew
M6x22 Flat head screw if it
could not be removed
manually.
[A]
Clockwise
Counterclockwise
Hex wrench 10
Vise
Clockwise*1recoil force
of Machine
Note: The rotational direction is viewed from operator.
1. Hold Hex wrench 10 with Drill chuck and grip Machine.
Important:
Grip Machine tightly with both hands to provide
the sufficient counterclockwise*2force against
clockwise*1recoil force of Machine.
2. Pull Switch trigger slowly.
3. Spindle rotates counterclockwise*2and consequently
Drill chuck is removed from spindle.
Counterclockwise*2force to be applied by operator
P 3/11

P 4/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Drill Chuck (cont.)
ASSEMBLING
Fig. 5
End of the threaded
portion of Spindle
Drill chuck
Fig. 6
Attach Battery.
F/R change lever
Set F/R Change lever
to Forward (clockwise)
rotation.
Set Speed change lever to Low speed
mode designated with 1.
Speed change lever
Set Change ring to Drill mode.
Change ring
Counterclockwise
Hex wrench 10
Fig. 7
Clockwise
4. Open Drill chuck fully, and tighten Drill chuck
with M6x22 Flat head screw by turning it
counterclockwise with Impact driver.
(1) Seat Drill chuck on Spindle. (Fig. 5)
(2) Set the machine to Drill mode, Low gear mode and Forward rotation mode. (Fig. 6)
(3) Set Hex wrench 10 to vise. (Refer to Fig. 3)
(4) Tighten Drill chuck. (Fig. 7)
M6x22 Flat head screw
(Left handed thread)
Turn Drill chuck clockwise by hand until
it is seated on the end of the threaded
portion of Spindle.
Note: Apply adhesive (ThreeBond 1342 or Loctite 242)
to threaded portion when re-using the removed
M6x22 Flat head screw.
Counterclockwise*2recoil
force of Machine
Note: The rotational direction is viewed from operator.
1. Hold Hex wrench 10 with Drill chuck and grip Machine.
Important: Grip Machine hard with both hands to provide
sufficient clockwise*1force against
counterclockwise*2recoil force of Machine.
2. Pull Switch trigger slowly to turn Spindle clockwise*1.
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.
Clockwise*1force
to be applied
by operator

P 5/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Assembly, Rotor Section
DISASSEMBLING
(1) Disassemble Rotor section and Gear assembly. (Figs. 8 and 9)
(2) Separate Rotor from Stator. (Fig. 9)
Fig. 8
Fig. 9
1. By unscrewing nine 3x16 tapping screws,
remove Housing R from Housing L.
2. Remove Gear assembly
together with Rotor section
and Speed change lever.
3. Remove Speed change lever
and Rotor section from
Gear assembly.
3x16 Tapping screw
(9 pcs.)
Housing R
Rotor section
Housing L
Gear assembly
Rotor section
Gear assembly
Speed change
lever
rear
Compression
spring 4
Drill chuck sideRotor side Drill chuck side
Rotor side
4. Push Speed change lever assembly toward Rotor side
until it stops to have space between the pin on the lever
of Gear assembly and rear Compression spring 4.
5. While lifting up Rotor side of Speed change
lever assembly, pull it toward the direction
designated with black arrow.
Pin on the lever of
Gear assembly
front Compression spring 4 compressed
by the lever of Gear assembly
Space between rear Compression spring 4
and the pin on the lever of Gear assembly.
Put Rotor section on a workbench so that
the drive end of Rotor touches the workbench.
Press Stator down to separate it from Rotor.
Rotor
Stator
Stator
Rotor
Caution for Handling of Rotor
Fig. 10A Fig. 10B
* Magnetic loss of Rotors
* Damage on the magnet portion of Rotors
When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 10A
because Rotor has 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 Rotors. (Fig. 10B)

P 6/ 11
Repair
ASSEMBLING
Fig. 11
Spur gears
Rotor’s gear
3 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.
(1) Assemble Gear assembly and Rotor section in the reverse order of disassembly. (Refer to Figs. 9 and 8)
Note: Be careful not to pinch your fingers between Stator and Rotor’s fan when assembling Rotor. (Fig. 11)
1. While holding Stator on workbench, insert Rotor into Stator
slowly until the drive end of Rotor reaches the workbench.
2. When the drive end of Rotor reaches
the workbench, lift up Stator slowly.
Rotor
Stator
Gear assemblyRotor section
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Assembly, Rotor Section (cont.)
Fig. 12
(2) Assemble Speed change lever assembly. (Fig. 12)
rear Compression
spring 4
The front Compression spring 4
compressed by the lever of
Gear assembly.
Drill chuck
side
Rotor side
Pin on the lever
of Gear assembly
Drill chuck
side
Rotor side
Drill chuck
side
Rotor side
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.
Space between the rear Compression
spring 4 and the pin on the lever of
Gear assembly.
Pin on the lever of Gear assembly fit to
the coil of the rear Compression spring 4
4. Slide Speed change lever
assembly to the either position
2 (High speed mode) or
1 (Low speed mode).

[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear Assembly, Rotor Section (cont.)
[3]-3. F/R change lever
P 7/ 11
Repair
ASSEMBLING
Fig. 13
Housing L
Projection of
Gear assembly
Groove of Housing L
Leaf spring
2. Mount Gear assembly and Rotor section
to Housing L with the projection
on the groove.
1. Make sure to put Leaf spring
in place as drawn below.
Assemble Gear assembly and Rotor section to Housing L. (Fig. 13)
Fig. 14
F/R Change lever can be assembled to Switch. (Fig. 14)
Stator
Rib
Rib
Before assembling Switch to Housing L,
fit the prong of F/R change lever to
the projection of Switch.
Housing L
3. Make sure that the ribs of Housing L are
fitted tightly in the notches of Stator.
projection
prong portion
Notch of Stator
Notch of Stator
F/R change
lever

P 8/ 11
Circuit diagram
Fig. D-1
Color index of lead wires' sheath
Black
White
Red
Orange
Blue
LED Light
Yellow
Controller
Stator
Printed
wiring
board
Switch
Terminal
Terminal
Connector B1B2
Connector

Housing L
Switch
Lead wires
Wiring diagram
Wiring of LED Lead wire
Wiring to Switch
Flag connectors of Lead wires must be connected to
Switch so that their wires come to Housing L side.
Flag connectors
LED Lead wires must be tightened between LED
bushing and Lead wire holder when routing these
wires between the following Ribs and Boss:
* the space between Ribs A and C
* the space between Ribs A and B
* the space between Ribs A and D
* the space between Rib A and Boss
LED bushing
Rib A
Rib C
Pin
Rib D
Boss
Lead wire
holders
Rib B
Fig. D-2
Fig. D-3
LED Lead wires must be routed around Pin.
Fix LED lead wires with either of
two Lead wire holders.
P 9/ 11

Stator
Terminal
Controller
Switch
Be careful not to put
Lead wires on this place.
Wiring diagram
Wiring in Housing L
Fig. D-4
Be careful not to put
Lead wires on these Ribs.
Be careful not to put
Connecting terminals
under or on Capacitor.
Printed wiring
board
Boss
Capacitor
Rib A
Rib D
Rib B
Projection
of Controller
Be careful not to put Lead wires
on Ribs A, B and D.
Connecting terminals
Be careful not to put
Lead wires on this Boss.
Put the slack portion of Lead wires
of Stator and those of Printed wiring
board in this place.
Put one or more Lead wires
of Stator into both Lead wire
holders.
Route Lead wires of Circuit
board and those of Stator
between Rib A and Boss.
Fix Lead wires of Stator and
those of Circuit board in the
bottom of either Lead wire
holders.
Housing L
Controller
Terminal
projection
of Controller
While routing Lead wires connecting to Terminal
over the projection of Controller, assemble Controller
and Terminal to Housing L.
P 10/ 11

Wiring diagram
Wiring and Mounting of
Printed Wiring Board to Stator
Fig. D-5
Insulator
Lead wires of Printed wiring board must be faced
to the opposite side of Lead wires of Stator.
Stator
Printed wiring board
Printed wiring board
By fastening four screws, assemble Printed wiring
board to Insulator without wobbling.
Note: The screws must be tightened to 0.3N·m of
torque.
Lead wires
of Stator
Lead wires of
Printed wiring board
Four Screws
Four Screws
P 11/ 11