Makita DPB181 Manual

Model No.
Description
CONCEPT AND MAIN APPLICATIONS
Dimensions*1: mm (")
Width (W)
Height (H)
Length (L) 468 (18-1/2)
197 (7-3/4)
233 (9-1/8)
*1With Battery BL1830, BL1840
or BL1850
OFFICIAL USE
for ASC & Sales Shop
DPB181
Cordless Portable Band Saw
Model DPB181 is lightweight and compact cordless portable band saw.
The design is specialized in excellent maneuverability in horizontal and
overhead applications.
The following features are the same as BPB180/ DPB180.
• Adjustable stopper plate
• Easy blade replacement
• powered by 18V Makita Li-ion battery
Battery protection circuit is equipped with DPB181. The function works when
the battery with a star mark is set on DPB181.
Note: BL1815 is not compatible.
Battery*4
Charger*4
Battery cover*5
Band saw blade 13-835 (18 teeth per inch)
Hex wrench 4
Wheel cover set (for some countries)
Tool bag (for some countries)
Fast charger DC18RC
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Battery BL1815N
Battery BL1820
Battery BL1830
Battery BL1840
Battery BL1850
Battery
Variable speed control dial
Blade speed: m/s (ft/min.)
Type
Voltage: V
Capacity: Ah
Li-ion
18
1.5, 2.0, 3.0, 4.0, 5.0
No
Weight according to
EPTA-Procedure 01/2003*2: kg (lbs)
3.2 (7.1)*3
3.5 (7.7)*1
Overload protector No
LED job light Yes
3.2 (630)
Max output (W) 350
Square pipe [width x height]
Length
Width
Height
Cutting capacity:
mm (")
Blade size:
mm (")
Round pipe [diameter]
64 x 64 (2-1/2 x 2-1/2)
13 (1/2)
0.5 (0.02)
835 (32-7/8)
64 (2-1/2)
Note: The standard equipment may vary by country or model variation.
PRODUCT
P 1/ 18
*2With Band saw blade 13-835 and Battery *3With Battery BL1815N or BL1820
*4 Battery and Charger are not supplied with “Z” model.
*5 Supplied with the same quantity of extra Battery
Specification
Standard equipment
Optional accessories
Band saw blade 13-835
(14, 18, 24 teeth per inch)
Wheel cover set
Hook set
Cutting wax
TECHNICAL INFORMATION
Energy capacity: Wh 27, 36, 54, 72, 90
Charging time (approx.): min. 15, 24, 22, 36, 45 with DC18RC
L
W
H

P 2/ 18
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R029 Bearing setting pipe 23-15.2
1R031 Bearing setting pipe 28-20.2 assembling Ball bearings
1R036 Bearing setting plate 17.2
1R045 Gear extractor (large) removing Spindle
1R232 Pipe 30 supporting Gear housing when removing/assembling Ball bearing
1R242 Round bar for Arbor 13-100 assembling Ring spring
1R248 Round bar for Arbor 22-100 removing/assembling Ball bearings
1R269 Bearing extractor removing Ball bearings
1R283 Round bar for Arbor 9-50 removing/assembling Ball bearings
1R291 Retaining ring S and R pliers removing/assembling Retaining ring S-15
1R311 Retaining ring pliers with long bent nails removing/assembling LED
[2] LUBRICATION
Apply Makita grease N. No.1 to the following portions designated with the black triangle to protect parts and product
from unusual abrasion.
Fig. 1
Item No. Description AmountPortion to lubricate
Spur gear 14
Spur gear 7 complete
Internal gear 36 2 g
a little
a little
a little
Gear housing
Gear housing cover
a little
Spindle complete
Lever shaft
Pin portion for accepting Spur gear 14
Pin portion for accepting Spur gear 14
Whole of teeth portion where 6 pcs. of Spur gear 14 engage
Drum portion where Plane bearing 30 contacts
Drum portion which push Compression spring 9
Plane bearing 30
Frame
Lever 54
DC Motor
11
12
14
44
a
b
a
b
Compression spring 9

P 3/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Switch section
Fig. 2
Fig. 3
DISASSEMBLING
ASSEMBLING
(1) Assemble Leaf spring and Lock off button to Handle L as drawn in Fig. 3.
(2) Assemble Switch section to Handle L by reversing the disassembly procedure. (Fig. 2)
1. Fit Leaf spring to Lock off button.
Disassemble Switch section as drawn in Fig. 2.
Handle R
4x18 Tapping screw
(7 pcs.)
1. Separate Handle R from Handle L by unscrewing
seven 4x18 Tapping screws.
2. Remove Switch and Switch lever from Handle L.
3. Remove Lock off button and Leaf spring from Handle L.
Note: Be careful not to lose Leaf spring.
Handle L
Switch
Switch lever
2. Mount Lock off button together with Leaf spring to Handle L.
Note: Be sure that Leaf spring is mounted exactly into
Handle L before mounting Handle R.
Lock off button
Leaf spring
Lock off button
Leaf spring

P 4/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. DC Motor
Fig. 4
DISASSEMBLING
Motor housing
4. Unscrew three 4x18 Tapping screws
fastening Gear housing to Frame.
(1) Disassemble Motor section as drawn in Fig. 4.
1. Push out the tap of Cap from the groove of Wheel A
with a slotted screwdriver and then remove Cap as
drawn below.
2. Remove M6x17 Hex socket head bolt with Impact
driver while holding the wheel by hand.
3. Remove Wheel A and Flat washer 6 from the machine.
M6x17 Hex socket head bolt
Flat washer 6
Wheel A
4x18 Tapping screw
(3 pcs.)
Gear housing Frame
Cap
Groove
Tab
Wheel A (Motor side)
Motor housing

P 5/ 18
Repair
Fig. 5
2. Remove seven 4x18 Tapping screws.
And then separate Handle R from Handle L.
3. Separate Motor housing L by unscrewing
four 4x18 Tapping screws.
4. Separate DC Motor together with Gear housing
section from Motor housing R by disconnecting
Receptacles from DC Motor.
5. Pull out DC Motor from Gear housing section. Note in disassembling:
If Ball bearing of DC Motor remains
in the Gear housing cover, remove
the ball bearing as drawn in Fig. 6 in
the next page.
Handle R
Handle L
Note in disassembling:
Do not pull out Motor housing from Handle L forcibly
because they are connected by Lead wires.
(2) Disassemble the DC Motor as drawn in Fig. 5.
Receptacles
Ball bearing
Motor housing
DC Motor
[3] DISASSEMBLY/ASSEMBLY
[3] -2. DC Motor (cont.)
DISASSEMBLING
1. Remove the following 4x18 Tapping screws.
A 6 pcs. of the screws fastening
Handle section to Frame
B 4 pcs. of the screws fastening
Motor housing to Frame
A
B
DC Motor
Gear housing
Gear housing cover

P 6/ 18
Repair
Fig. 6
Fig. 7
1. Remove Gear housing cover
from Gear housing.
2. Put Gear housing cover on 1R232. Remove Ball bearing
with 1R283 by pressing it with Arbor press.
(3) Remove the Ball bearing of DC motor from Gear housing cover as drawn in Fig. 6.
(1) Assemble DC Motor to Gear housing cover as drawn in Fig. 7.
(2) Before assembling Handle R, set Lock off button and Switch to Handle L as drawn in Figs. 3 and 2.
Then,assemble Motor section to the machine by reversing the disassembly procedure. (Refer to Figs. 5 and 4)
Gear housing
Motor housing R
Motor housing L
4x18 Tapping screw
(4 pcs.)
Gear housing cover
Ball bearing
1R232
1R283
Gear housing
cover
Gear housing
cover
Gear housing
ASSEMBLING
Gear housing
cover
1. Assemble Gear housing
cover to Gear housing.
2. Assemble DC Motor to Gear housing cover.
Note: Do not use removed Ball bearing.
3. Align the seam of DC Motor to
the notch of Gear housing cover.
4. Facing the seam and the notch side to Motor housing L side, set DC Motor and Gear housing section
to Motor housing R.
Then, assemble Motor housing L to Motor housing R with four 4x18 Tapping screws.
Gear housing
Ball bearing
notch
seam
notch
seam
[3] DISASSEMBLY/ASSEMBLY
[3] -2. DC Motor (cont.)
DISASSEMBLING
Ball bearing

P 7/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Gear housing
Fig. 8
DISASSEMBLING
Lock washer
Spur gear 14
(3 pcs.)
Gear housing
cover
1. Remove Gear housing
cover from Gear housing
by unscrewing three 4x18
Tapping screws.
2. Remove Lock washer, Spur gear 14
(6 pcs.), Spur gear 7 complete and
Internal gear 36 from Gear housing.
3. Remove Retaining ring S-15
from Spindle of Gear housing
with 1R291.
4. Disassemble Spindle
with 1R045.
Gear
housing
(1) Disassemble Motor section as drawn in Fig. 4.
(2) Disassemble DC Motor as drawn in Fig. 5.
(3) Disassemble Gear housing as drawn in Fig. 8.
Spur gear 7 complete
Internal gear 36
Spindle
Spur gear 14
(3 pcs.)
Retaining ring S-15
5. Remove Ring 15. Then, set M6x17 Hex socket head bolt to Spindle as a jig.
And then, disassemble Ball bearing 6902ZZ from Spindle with 1R269.
Ring 15
6. Put Gear housing on 1R232. Then, applying 1R248 to
Ball bearing 6902ZZ from Lock washer assembling side,
press it down with Arbor press to remove Ball bearing
6902ZZ from Gear housing.
Spindle
Spindle
1R045 M6x17 Hex socket
head bolt
Ball bearing
6902ZZ
Spindle
1R269
Gear housing
1R232
Ball bearing
6902ZZ
1R248

P 8/ 18
Repair
Fig. 9
ASSEMBLING
1. Put Ball bearing 6902ZZ onto 1R036 and
set Spindle to the bearing. Then, applying
1R031 to Spindle, press it with Arbor press
to assemble the bearing to Spindle.
(1) Assemble Gear housing as drawn in Fig. 9.
1R036
1R031
6. Assemble 3 pcs. of Spur gear 14
to Spindle in first, and assemble
Internal gear 36, Spur gear 7
complete, another 3 pcs. of
Spur gear 14 and Lock washer.
3. Put Gear housing onto 1R031 as follow.
Then, pass Ring 15 through Spindle.
And then, set Ball bearing 6902ZZ
to Spindle.
4. Put 1R029 onto the bearing,
and press it with Arbor press.
5. Assemble Retaining
ring S-15 to Spindle
with 1R291.
1R031
Spindle
Gear housing
Gear housing
2. Put Gear housing onto 1R036 and insert the assembled
Spindle section into Gear housing. Then, applying
1R031 to Spindle section, press it with Arbor press.
Ball bearing
6902ZZ
Ball bearing
6902ZZ
Ball bearing
6902ZZ
Ring 15
Assembled
Spindle section 1R031
1R031
1R029
1R036
Retaining ring S-15
Lock washer
Spur gear 14
(3 pcs.)
Spur gear 7 complete
Internal gear 36
Spindle
Spur gear 14
(3 pcs.)
Ball bearing
6902ZZ
Gear housing
Gear housing
cover
7. Secure Gear housing cover
with three 4x18 Tapping screws.
Gear housing
(2) Assemble DC Motor to Gear housing as drawn to the upper right illustration in Fig. 7.
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Gear housing (cont.)

P 9/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Lever Shaft
Fig. 10
Fig. 11
DISASSEMBLING
ASSEMBLING
1. Pull off Ring spring 12 from the machine,
and set Lever 54 to the release position.
2. Pull off Lever 54.
4. Pull off Lever shaft. 5. Remove Plane bearing 30 and
Compression spring 30.
3. Remove Lever holder by unscrewing
four 4x18 Tapping screws.
(1) Disassemble Lever shaft as drawn in Fig. 10.
Lever
holder
Lever shaft Plane bearing 30
Compression sprig 9
4x18 Tapping
screws
( 4 pcs. )
(1) Set Compression spring 9 and Plane bearing 30 as drawn to the right illustration in Fig. 10.
(2) Mount Lever shaft to Frame as drawn in Fig. 11.
Ring spring 12Lever 54 Lever 54
Compression spring 9
Lever shaft
Pin portion
Face the pin portion to the opposite side of
Compression spring 9, and mount Lever shaft.

P 10/ 18
Repair
ASSEMBLING
(3) Mount Ring spring 12 to Lever 54 as drawn in Fig. 12.
Using 1R242 as a guiding jig, set Ring spring 12 from the opposite side of Grip portion.
Note: Refer to the following drawings for the proper direction of Ring spring 12.
Ring spring 12
Fig. 12
Fig. 13
Grip portion of Lever 54
Face the grip portion of Lever 54 to the release mark side, and mount
the lever to Lever shaft while aligning the lever to the guide line.
“Release mark”
“Tension mark”
(4) Assemble Lever holder to Frame with four 4x18 Tapping screws. (Refer to the upper right drawing in Fig. 10)
(5) Mount Lever 54 over Lever shaft as drawn in Fig. 13.
Lever shaft
Lever holder
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Lever Shaft (cont.)
Grip portion
1R242
Ring spring 12
Guide line for Lever setting
to release position

P 11/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Slide Plate
ASSEMBLING
Assemble Slide plate as drawn in Fig. 14.
Fig. 14
tab portion of
Slide plate
Protection plate
4. Push Slide plate toward the Tab side until it stops.
And turn M5x12 Hex socket set screw until it seats.
5. Check that Slide plate can slide smoothly
without wobbling. If not, adjust the set screw
to turn it back less than 180° to slide the plate
smoothly.
3. Secure Slide plate in place with
four 4x18 Tapping screws and
Flat washers 4.
Sleeve 5
(4 pcs.)
M5x12 Hex socket
set screw
tab portion
M5x12 Hex socket
set screw
Slide plate
1. Set Lever 54 to the release position
to make the fitting space for the tab
portion of Slide plate.
2. Set Protection plate to Flame.
Then, put 4 pcs. of Sleeve 5
to the illustrated position of
Frame. And then, set Slide
plate onto them.

P 12/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Upper Holder 42, Lower Holder 42
DISASSEMBLING
(1) Remove Upper holder 42 and Lower holder 42 as drawn in Fig. 15.
(2) Disassemble Upper/Lower holder section as drawn in Fig. 16.
Remove Lower holder 42 and
Upper holder 42 by unscrewing
4x18 Tapping screws (2 pcs. each).
Fig. 15
Fig. 16
4x18
Tapping screw
4x18
Tapping screw
Lower holder 42
Upper holder 42
Pin 6
Ball bearing 696ZZ
Ball bearing
696ZZ (4 pcs.)
Flat
washer 6
Flat washer 6
1. Using Screwdriver No. 3, disassemble four Ball bearings 696ZZ
and two Flat washers 6 by unscrewing two M5 +Pan head screws.
2. Remove another Ball bearing 696ZZ together with Pin 6.
And pull off Pin 6 from the bearing.
Upper/Lower holder section
Screwdriver No. 3
M5 +Pan head
screw (2 pcs.)

P 13/ 18
Repair
ASSEMBLING
(1) Assemble Upper/Lower holder section as drawn in Fig. 17.
Fig. 17
Pin 6
Ball bearing 696ZZ
1. Pass Pin 6 through Ball bearing 696ZZ and mount them to the holder.
Ball bearing
696ZZ
Ball bearing 696ZZ
Flat washer 6
2. Pass M5 +Pan head screw through Ball bearing 696ZZ, Flat washer 6 and another Ball bearing 696ZZ,
and tighten the screw to the holder with Screwdriver No. 3.
Flat washer 6
Flat washer 6
(2) Assemble Lower holder 42 and Upper holder 42 to Frame as follows. (Refer to Fig. 15)
* Lower holder 42: Motor housing side
* Upper holder 42: Lever 54 side
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Upper Holder 42, Lower Holder 42 (cont.)

P 14/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Rubber Tire of Wheel Complete
DISASSEMBLING
(1) Disassemble Wheel complete as follows.
* Wheel A (Motor side): Remove as drawn in Fig. 4.
* Wheel B (Lever 54 side): 1. Set Lever 54 to release position. See the upper left illustration in Fig. 10.
2. Remove Cap and Wheel B like as Wheel A. (See Fig. 4)
(2) Remove Rubber tire from Wheel as drawn in Fig. 18.
Fig. 18
Fig. 19
Fig. 20
1. Fit Rubber tire to the notch portions of
Wheel as drawn below.
2. Fit the rest portion of Rubber tire to Wheel by pressing it
by hand.
Note: Make sure that Rubber tire fits to Wheel closely.
Insert small slotted screwdriver into the notch of Wheel, then
remove Rubber tire by prying it off with the screwdriver.
Notch
Notch
Slotted
screwdriver
Rubber tire
ASSEMBLING
(2) Assemble Wheel and Flat washer 6 to Spindle with M6x17 Hex socket head bolt. And then, mount Cap to the wheel.
(Refer to Fig. 4.)
Note: Do not forget to mount Flat washer 15 before assembling Wheel B (Lever 54 side) as drawn in Fig. 20.
(1) Assemble Rubber tire to Wheel as drawn in Fig. 19.
Flat washer 15 Wheel B
Flat washer 6
Cap
M6x17 Hex socket head bolt

P 15/ 18
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -8. LED Light Circuit
DISASSEMBLING
ASSEMBLING
Fig. 21
(1) Separate Frame section from Motor housing section. And then, remove Handle R.
(See the upper illustrations in Fig. 5)
(2) Remove LED light circuit as drawn in Fig. 21.
(1) Set LED Light circuit to Handle L.
Note: Be careful that the circuit is not damaged when assembling.
(2) Insert Rubber pin 4 to the place as drawn in Fig. 21.
(3) Assemble Handle section and join them to Frame. (Refer to the upper illustrations in Fig. 5)
1. Pull off Rubber pin 4
with 1R311.
2. Remove LED light circuit with 1R311.
Rubber pin 4
LED light
1R311

Circuit diagram
P 16/ 18
Fig. D-1
White
Red
Blue Yellow
Color index of lead wires' sheath
Black Orange
to Switch
to DC Motor
to Terminal Line filter
(if used)
to Switch
LED
Line filter (if used)
Fuse (if used)
Controller unit
Controller
DC Motor, Switch, Terminal are connected to Controller unit as follows.
LED
Controller
Line filter
(if used)
Line filter (if used)

Wiring diagram
P 17/ 18
Wiring to DC Motor
Wiring in Motor Housing R
Setting of Controller to Handle L
Motor housing R
DC Motor
Lead wire
holder A
Rib B
DC Motor
Handle L
Controller
Lead wires
Facing the wire connected side to Handle L side,
set Controller to Handle L.
And push Controller until it stops.
And then, make sure that any of its Lead wires
do not cross over the joint line of Handle L’ s edge.
Joint line
Lead wires (red, blue) have to be put
into Lead wire holders A and B.
Pass the Lead wires through Line filters.
Line filter
Put one Line filter between Rib A
and Lead wire holder A.
And put another one between Rib B
and Lead wire holder A.
Red marking
Fig. D-2
Fig. D-3
Fig. D-4
Lead wire (blue) of Controller unit has to be put
under Flag receptacle of Lead wire (red).
Lead wire
holder B
Rib A
Red marking
When DC motor is mounted to Housing L,
check the following.
•Route the Lead wires to Housing L side.
•Red marking is located as drawn to the right.

Fuse (if used)
Wiring diagram
P 18/ 18
Wiring in Handle
Controller
Line filter
Terminal
Rib A Rib B
Fig. D-5
Rib C
Rib J
Inner wall of Housing
Rib D
Do not put any lead wires onto
Ribs C, D, E and F.
Fix Lead wires connected to LED
light circuit with Lead wire holders.
Rib E Rib F
Rib I Connector
Controller unit’s lead wires (blue, red) with Connector
Inner wall
Rib H
Put the above Lead wires to the place
between Inner wall and Ribs I, H and G.
Rib G
Switch
LED light circuit
Fuse
Put Fuse to the place
as drawn below.
Switch
Do not put Fuse
onto this Rib.
Fix the above lead wires
with this lead wire holder.
Pass Lead wires (black, orange)
connected to DC Motor through
Line filter and put Line filter to
the room surrounded by ribs.
Except for the Lead wires (balck,
orange), any lead wires must not
be put in the room.
Pass Lead wires connected to LED
light circuit between Rib J and
the inner wall of Housing.
Put the following lead wires between Rib A and Rib B.
* Lead wires (blue, red) from DC motor
* Lead wires (black, orange, yellow) connected to Terminal
Set LED light circuit to Handle L while facing
the wire connected portion to Front side.
Wire connected portion
Front side
(Lever 54 side)