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
18
1.3, 1.5, 2.0, 3.0, 4.0, 5.0
Yes
Yes
Yes (2 speed)
Yes
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
W
H
Battery BL1815
Battery BL1815N
Battery BL1820
Battery BL1830
Battery BL1840
Battery BL1850
L
*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
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
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
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
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-
AS
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.

Trouble shooting
P 11/ 12
Whenever you find any trouble in your machine, first, refer to this list to check the machine for solution.
(1) Use the full charged battery which has the star mark. (Fig. T-1 )
(2) When Housing is disassembled, check the conditions of the electrical parts
(Connectors, Lead wires, Switches, etc.), Armature, Stator, Gear section, etc.
(3) Do the running test in Low speed mode (when the trigger is being pulled just a little)
to check the following functions by repeating 10 times;
• F/R change lever • Operation mode change ring • High/Low speed change lever
• Variable speed control trigger
Note in Repairing
Check List for Trouble Shooting
Motor runs when the machine
is switched on.
In case of running inconstantly,
go to “No”.
LED indicator lamps
are on.
LED job light are on.
The machine does not
have any trouble.
Symptom Cause Corrective action
Rotation speed can
be changed.
Controller is broken. Replace Controller.
Connect it firmly.
Check Lead wires,
or replace it.
LED indicator lamps
are on.
Switch is broken.
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Controller is broken.
Rotor is broken.
Stator is broken.
Replace Controller.
No
Controller is broken.
Connectors are in incomplete
connection.
Lead wires are broken.
Replace Controller.
Check the items from top of the following list. (Description of the item is referred to Circuit diagram in Fig. D-1.)
Change Controller if your problem cannot be solved although its corrective action has been carried out.
Check Terminal,
or replace it.
Replace Switch.
Replace Rotor.
Replace Stator.
Switch is broken. Replace Switch.
Connect it firmly.
Check Lead wires,
or replace it.
LED circuit is broken.
Connectors are in incomplete
connection.
Lead wires are broken.
Replace LED circuit.
Switch is broken. Replace Switch.
LED job light are on.
Rotor is rubbed to
Stator.
Yes
Yes
No
Connect it firmly.
Check Lead wires,
or replace it.
Connectors are in incomplete
connection.
Lead wires are broken.
Switch is broken. Replace Switch.
Terminal is broken.
Star mark
Fig. T-1

P 12/ 12
Fig. T-2 Fig. T-3
1. Attach Tester bar (black) to the terminal of
Lead wire (white) which is connected to Switch.
(1) Set Digital tester (1R402) to the diode mode.
(2) Attach the tester bars as drawn in Figs. T-2 and T-3.
(3) There is no fault on Controller if Digital tester (1R402) indicates within 0.39V - 0.41V in the both tests.
If not, Controller is broken. Replace it with a new one.
1. Attach Tester bar (red) to (-) Pole of Terminal
to which Lead wire (black) is connected.
2. Attach Tester bar (red) to any of UVW
terminals of Stator unit (orange, white or
blue lead wires).
2. Attach Tester bar (red) to any of UVW terminals
of Stator unit (orange, white or blue lead wires).
Controller
Stator
B2 B1 B1
T+
T-
AS
Switch Switch
Digital tester Digital tester
Terminal
Controller
Stator
B2
T+
T-
AS Terminal
0.41
0.41
Trouble shooting
Test for recognizing the trouble on Controller
Tester bar (black) Lead wire (white)
Tester bar (red)
Terminal
UVW terminals Tester bar (red)
UVW terminals
Tester bar (red)