Makita DTD155 Operating instructions

DTD155
REPAIR MANUAL
CORDLESS IMPACT DRIVER
OFFICIAL USE
For ASC

2 / 26
1CONTENTS
1CONTENTS......................................................................................................................................................................2
2CAUTION.........................................................................................................................................................................3
3NECESSARY REPAIRING TOOLS................................................................................................................................3
4LUBRICANTANDADHESIVEAPPLICATION...........................................................................................................3
5TIGHTENING TORQUE SPECIFICATIONS ................................................................................................................4
6DISASSEMBLING/ASSEMBLING...............................................................................................................................5
6-1 Advance preparation.................................................................................................................................................5
6-2 Bit sleeve...................................................................................................................................................................5
6-2-1 Disassembling...................................................................................................................................................5
6-2-2 Assembling.......................................................................................................................................................6
6-3 Hammer case ............................................................................................................................................................6
6-3-1 Disassembling...................................................................................................................................................6
6-4 Hammer ....................................................................................................................................................................9
6-4-1 Disassembling...................................................................................................................................................9
6-4-2 Assembling.....................................................................................................................................................10
6-5 Hammer case ..........................................................................................................................................................12
6-5-1 Assembling.....................................................................................................................................................12
6-6 Rotor and other electric parts ..................................................................................................................................13
6-6-1 Disassembling.................................................................................................................................................13
6-6-2 Assembling.....................................................................................................................................................16
7CIRCUIT DIAGRAM ....................................................................................................................................................20
8WIRING DIAGRAM .....................................................................................................................................................21
9TROUBLE SHOOTING ................................................................................................................................................23
9-1 Note in Repairing....................................................................................................................................................23
9-2 Flowchart of Troubleshooting.................................................................................................................................24
9-3 Short-circuit test on FET (Field Effect Transistor) of controller.............................................................................26

3 / 26
2CAUTION
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.
Handle the disassembled parts carefully. Clean and wash them properly.
3NECESSARY REPAIRING TOOLS
Code No.
Description
Use for
1R003
Retaining ring pliers ST-2N
removing / installing Ring spring 10
1R041
Vise plate
removing/ installing Hammer case complete
1R045
Gear extractor (large)
disassembling Hammer section
1R212-A
Tip for Retaining ring pliers
use with 1R003
1R212-B
Plate set (with screws)
use with 1R003
1R223
Torque wrench shaft 20-90 N
･
m
installing Hammer case complete
1R224
Ratchet head 12.7 ( for 1R223)
use with 1R223
1R288
Screwdriver magnetizer
removing Steel balls
1R402-A
Digital tester
diagnosing Controller
1R402-B
Alligator clip set for tester
use with 1R402 -A
1R411
Lead wire insert
fixing Lead wires
1R412
Diagnostic jig for LED
diagnosing LED circuit
1R413
Diagnostic jig for switch
diagnosing Switch
-
Hex socket 27-50
removing / installing Hammer case complete
-
Extension bar (Square drive 12.7mm)
removing Hammer case complete
4LUBRICANTAND ADHESIVEAPPLICATION
Apply the following lubricants and adhesives.
Lubricant
Amount
Makita grease FA No.2
Gear portion
1g
Except Gear portion
a little
Fig. 1
Anvil shaft
Apply into the groove on
Anvil surface.
Impact portion of
Hammer
Cam groove on Spindle
Gear portion: 1g
Whole surface of
Steel ball 3

4 / 26
5TIGHTENINGTORQUE SPECIFICATIONS
Parts to fasten Parts description
Tightening Torque
(N
･
m)
Housing R complete Housing L
complete
3x16 Tapping screw 1.1-1.3
Sensor board

Stator
PT 2x6 Tapping screw
0.2-0.3
Hammer case

Bearing box
Bearing box
40.0-45.0

5 / 26
6DISASSEMBLING/ASSEMBLING
6-1 Advance preparation
Fig. 2
1
Remove Battery [1].
6-2 Bit sleeve
6-2-1 Disassembling
Fig. 3
1
Using 1R003 with 1R212-Aand 1R212-B attached to it,
remove Ring spring 10 [1] by widening the end gap of
Ring spring 10 [1].
Note
Press the top of Bit sleeve with your thumb and index finger
so that Ring spring [1] and Flat washer 11[2] do not pop out.
Fig. 4
2
Remove Flat washer 11 [1], Compression spring 13 [2], Bit
sleeve [3] and two Steel balls 3 [4].
Tip
Remove two Steel balls 3 [4] with a slotted screwdriver
magnetized by 1R288.
1R212-A
1R212-B
[1]
[2]
[1]
[2]
[3]
[4]
[1]

6 / 26
6-2-2 Assembling
Fig. 5
1
Insert two Steel balls 3 [1], one each, into the two holes of
Anvil M [2] and then install Bit sleeve [3], Compression
spring 13 [4] and Flat washer 11 [5] in place.
Tip
Apply Makita grease FA No 2 to the two holes ofAnvil M [2]
to prevent Steel ball 3 [1] from falling off.
Fig. 6
2
Using 1R003 with 1R212-Aand 1R212-B attached to it,
install Ring spring 10 [1] by widening the end gap of Ring
spring 10 [1].
Note
Press the top of Bit sleeve with your thumb and index
finger so that Ring spring [1] and Flat washer 11[2] do
not pop out.
Replace with new Ring spring 10 [1] if the end gap of
Ring spring 10 [1] is deformed (and widened).
6-3 Hammer case
6-3-1 Disassembling
Fig. 7
1
Remove Belt clip if it is attached on left or right side.
Note
Take a note of which side it was on, because it needs to be put
back in place.
2
Disassemble Bit sleeve as shown in Fig. 3.
3
Remove nine 3x16 Tapping screws [1] to remove Housing
R [2] and Switch plate [3].
[1]
[5]
[3]
[4]
[2]
1R212-A
1R212-B
[1]
[2]
[3]
[2]
[1]
[1]

7 / 26
Fig. 8
4
Remove Hammer case [1] and Motor section [2] together
from Housing L [3], and then pull out Motor section [2]
from Hammer case [1].
Fig. 9
5
Insert a slotted driver between Bumper [1] and Hammer
case cover [2] to pry off Bumper [1].
Fig. 10
6
Hold the flats of Hammer case complete [1] in a vise.
Note
Hold the flats of Hammer case complete [1] in a vise with
1R041.
Fig. 11
7
Remove Bearing box with a commercial Extension bar, to
which Socket 27 [2] is attached.
Tip
Turn Bearing box [1] clockwise to remove.
[1]
[2]
[3]
[2]
[1]
[1]
1R041
[1]
[2]

8 / 26
Fig. 12
8
Remove Internal gear 43 [1] and Hammer section [2] from
Hammer case.
Fig. 13
9
Push out Anvil M [1] from Hammer case [2].
Fig. 14
10
Remove Nylon washer 19 [1] with a slotted screwdriver.
[1]
[2]
[1]
[1]
[2]

9 / 26
6-4 Hammer
6-4-1 Disassembling
Fig. 15
1
Turn the handle of 1R045 clockwise to push Spindle [1]
and compress Compression spring 21[2].
Tip
Set 1R045 on Hammer [3] so that the protrusions of
Hammer [3] and the claws of 1R045 cross at a right
angle.
Align the opening for Steel ball insertion with the top
of Cam groove on Spindle [1] by turning 1R045.
Note
1R045 should be held securely by hand so that the claws of
1R045 do not slip off.
Fig. 16
2
Remove two Steel balls 4.8 [1] by inserting a slotted
screwdriver magnetized by 1R288.
Fig. 17
3
Turn 1R045 counterclockwise to loosen Hammer [2] and
then take out Spindle and related parts [1] from Hammer
[2] and remove Compression spring 21 [3] and Washer 21
[4].
Tip
When removing Spindle [1] from Hammer [2], place them
with Hammer [2] side down so that Steel balls 3 (24 pcs) do
not fall down.
Fig. 18
4
Spindle section can be disassembled into Flat washer 12
[1], two Pins 3.5 [2], two Spur gears 17 [3] and Spindle [4].
[2]
[4]
[3]
[1]
[2]
[1]
[3]
[1]
[3]
1R045
[4]
[1]
[3]
[2]
[1]

10 / 26
Fig. 19
5
Remove Flat washer 20 [1] from Hammer [2] with a slotted
screwdriver magnetized by1R288
6-4-2 Assembling
Fig. 20
1
Apply Makita grease FA No.2 inside after putting Steel
balls 3 [2] in the groove of Hammer [1].
Note
Twenty-four Steel balls 3 [2] are put in the groove of Hammer
[1] as shown left. There is a gap equivalent to the size of one
Steel ball 3 [2].
Fig. 21
2
Install Flat washer 20, Compression spring 21 [2], Washer
21 [3] and Spindle [4] on Hammer [1].
Tip
Apply Makita grease FA No.2 to Cam grooves on Spindle [4]
where Steel balls 4.8 are put.
Fig. 22
3
Turn the handle of 1R045 clockwise to push Spindle [1]
and compress Compression spring 21.
Tip
Set 1R045 on Hammer [2] so that the protrusions of
Hammer [2] and the claws of 1R045 cross at a right
angle.
Align the opening for Steel ball insertion with the top of
Cam groove on Spindle [1] by turning 1R045.
Note
1R045 should be held securely by hand so that the claws of
1R045 do not slip off.
[1]
[2]
[2]
[1]
1R045
[1]
[2]
[4]
[3]
[2]
[1]

11 / 26
Fig. 23
4
Insert two Steel balls 4.8 [1], one each, into each of the two
Cam groove of Spindle [2].
Note
Don’t insert two Steel balls into one of the two grooves.
Fig. 24
5
After removing 1R045, install two Spur gears 17 [1] and
two Pins 3.5 [2] on Spindle [3].
Fig. 25
6
Install Flat washer 12 [1] on Spindle [2].
Tip
Apply Makita grease FANo 2 to Flat washer 12 [1] to prevent
it from falling off.
[1]
[1]
[3]
[2]
[2]
[1]
[1]
[2]
[1]
Opening for
Steel ball
insertion
Opening for
Steel ball
insertion

12 / 26
6-5 Hammer case
6-5-1 Assembling
Fig. 26
1
Assemble Nylon washer 19 [1] andAnvil M [2] to
Hammer case [3].
Tip
Apply Makita grease FA No.2 to the groove on the surface of
Anvil M [2].
Fig. 27
2
Install Internal gear 43 [1] on Bearing box [2], and then
install Hammer section [3] on Internal gear 43 [1].
Tip
Apply Makita grease FA No.2 to the following portions:
Surface of two Spur gears 17 [4]
Top hole of Spindle [5]

Surface of Hammer [3] surrounding Spindle [5]
Note
Check that O ring 33 [6] is inserted in Bearing box [2].
Check that Hammer section [3] rotates without
wobbling.
Fig. 28
3
Holding Anvil M [2], install Hammer case [1] on Hammer
section [3]. And then assemble them to Bearing box [4].
Tip
Engage concave portions of Hammer case [1] and
convex portion of Internal gear 43 [5].
If the projections of Hammer [3] interfere with the
T-shaped anvil portion of Anvil M [2], turnAnvil M
together with Hammer case a little to engage Hammer
case section and Internal gear section completely.
[1]
[6]
[5]
[1]
[2]
[4]
[5]
[3]
[2]
[3]
[5]
[4]
[1]
[2]
[3]
[1]
Groove

13 / 26
Fig. 29
4
Clamp the flats of Hammer case [1] in a vise.Attach Hex
socket 27-50 to 1R224.And then fasten Bearing box [2] to
Hammer case [1] with 1R223 to a tightening torque of
40.0- 45.0 N･m.
Tip
Turn Bearing box [2] counterclockwise.
Note
Insert 1R041 between Hammer case and the vise.
Fig. 30
5
Install Bumper [1] on Hammer case [2].
Note
Check that there is no gap between Bumper [1] and Hammer
case [2].
6-6 Rotor and other electric parts
6-6-1 Disassembling
Fig. 31
1
From Housing L [7], remove the assembly of the following
parts: Motor section [1], LED circuit [2], Switch [3],
Controller [4], Terminal [5] and F/R change lever [6].
[1]
[2]
[1]
[2]
1R041
1R223
1R224
[1]
[7]
[5]
[4]
[2]
[6]
[3]

14 / 26
Fig. 32
2
Remove Rotor [1] from Stator [2].
Tip
Push Rotor [1] against workbench.
Push down Stator [2] to remove Rotor [1] from Stator [2].
Fig. 33
Note
When handling or storing multiple Rotors, be sure to keep a
proper distance between Rotors. Because Rotor has strong
magnet force, 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. 34
3
Remove Switch [3] from Controller by disconnecting two
Flag receptacles [1] and Connector [2].
Tip

Remove Flag receptacles [1] while releasing lock with a
slotted screwdriver or the like.
Diagnose Switch with 1R413.
Fig. 35
4
To remove Stator [3] from Controller, first disconnect three
Straight terminals, and then remove Sensor board [2] from
Stator [3] by removing three PT 2x6 Tapping screws [1]
with a No.1 Phillips screwdriver.
Tip
Straight terminals can be easily removed with a help of
Pliers or the like.
[1]
[2]
[3]
[2]
[1]
[2]
[3]
[1]

15 / 26
Fig. 36
5
Remove LED circuit [2] from Controller by
disconnecting Connector [1].
Tip
If LED does not light up, check it with 1R412.
Fig. 37
6
Remove Terminal [1] from Controller by disconnecting
three Flag receptacles [2].
Tip
Remove Flag receptacles [2] while releasing lock with a
slotted screwdriver or the like.
[1]
[2]
[2]
[1]

16 / 26
6-6-2 Assembling
1
Assemble by reversing the disassembly
procedure.
Fig. 38
2
Fix Sensor board [1] of Controller with three PT 2x6
Tapping screws.
.
Tip

The orientation of Sensor board [1] matters. The black
sensor element side should face towards Stator [2].
Holes of Sensor board [1] and two projections of Stator
[2] should be engaged.
Fig. 39
3
Insert Rotor [1] into Stator [2].
Tip
Push the drive-end of Rotor [1] against workbench.
Insert Rotor [1] into Stator [2] by lifting up Stator [2] slowly.
Note
Before assembling, blow off iron powder from Rotor [1]
with an air duster to prevent abnormal rotation.
Don’t insert Rotor [1] forcefully into Stator [2] because
Sensor board [3] may get broken.
Fig. 40
4
Connect three Straight terminals to Terminal [1] as follows:
+ (left)………Red
AS (center) …Yellow
- (right) ……..Black
[2]
[1]
Projection of Statorl
Projection of Statorl
[1]
[2]
[3]
[1]

17 / 26
Fig. 41
5
Connect three Straight terminals between Controller and
Stator correctly. Connect wires of similar colors
.
Note
Insert three Straight terminals firmly because loose
connection leads to abnormal rotation.
Fig. 42
6
Flip the cover of Switch [3], then insert Connector into
Connector socket [1] and then connect two Flag terminals
[2] to Switch; connect Red terminal to B1 and White
terminal to B2.
Note
Be careful not to twist Lead wires.
Fig. 43
7
Connect Connector [1] of LED circuit [2] to Controller.
Fig. 44
8
Install Hammer case [1] on Motor section and then
assemble them to Housing L[2].
Note

Check Hammer case [1] rotates without wobbling.
Engage the groove of Stator [3] and the projection of
Housing L[2]. Engage the hole of Hammer case [1] and
that of Housing L [2].
Tip
Route LED Lead wire [4] under all other Lead wires.
[1]
[2]
[3]
[2]
[1]
[3]
[2]
[1]
[4]

18 / 26
Fig. 45
9
Install Controller [1], Terminal [2], Switch plate [3] on
Housing L [4].
Tip
Put each Lead wire into the grooves of Housing and Lead
wire holders with 1R411.
Fig. 46
10
Install Switch [1] with F/R change lever [2] on Housing L
[3].
Tip
Be careful with the orientation of F/R change lever [2].
Fig. 47
11
Put LED Lead wire and Straight terminal into Housing L
[1] with 1R411.
Tip

In order to prevent thin Lead wires from coming off,
first route thin Lead wires of LED circuit [2] and Sensor
board in the grooves of Housing L [1], and then route
thick Lead wires on the thin Lead wires..
It will make wiring easier to put the three Lead wires of
Straight terminals in the following order: Blue, White,
Orange.
[3]
[1]
[4]
[2]
[1]
[2]
[3]
[1]
[2]

19 / 26
Fig. 48
12
Fatsten Housing R [2] to Housing L by tightening nine
3x16 Tapping screws [1].
Note
Check the following points before fastening Housing R:
Lead wires are not pinched between Housings Land R.
F/R change lever [3] moves normally.
Switch plate [4] is set in place.
13
Fasten Belt clip [6] back to its original position (left or right
side of Housing [7]) with M4x12 Truss head screw [5].
[4]
[2]
[1]
[1]
[1]
[3]
[5]
[6]
[7]

20 / 26
7CIRCUIT DIAGRAM
Fig. 49
Switch
B1
B2
Red/AWG18
White/
AWG18
Black/AWG18
Yellow/AWG22
Red/AWG22
Terminal
T+
AS
T-
Flag receptacle
(with lock #187 t=0.8mm)
Controller
Flag receptacle
(with lock #187 t=0.8mm)
Flag receptacle
(with lock #250 t=0.8mm)
AWG=American wire gauge
Sensor
board
LED circuit
Stator
Orange/AWG18
White/AWG18
Blue/AWG18
Orange/AWG16
White/AWG16
Blue/AWG16
Straight
terminal
Fuse
Red/AWG18