Makita DVC860L Manual

CONCEPT AND MAIN APPLICATIONS
Model DVC860L is a corded and cordless vacuum cleaner powered by AC and
two 18V Li-ion batteries in series.
Its main features are as follows:
• Clothltertype;forbothWet&Dryvacuumcleaning
• Largeon-offswitch;alsoequippedwithmainpowerswitch
• Variable suction power control by dial
• Dualbatteryfuelgauge
• Removablestoragebox
• Removable power supply cord for better maneuverability
Note: Not compatible with 1.3Ah Li-ion battery BL1815.
Specication
Model
Specication DVC860L
Power unit AC/DC
Battery
Voltage:V 36(18x2)
Capacity: Ah 1.5,2.0,3.0,4.0,5.0
Energycapacity:Wh 27x2,36x2,54x2,72x2,90x2
Cell Li-ion
Chargingtime(approx):min 15,24,22,36,45withDC18RD
15x2,24x2,22x2,36x2,45x2withDC18RC
Wet/Drytype Wet&Dry
Variable suction power control Yes(bydial)
Continuousruntime(approx.)onasinglefull
batterycharge:minute 30-65withtwobatteriesBL1850;BL1850B
Suctionpower:W on DC power 70-25
on AC power 320
Maxsealedsuction:kPa on DC power 9
on AC power 24
Maxairow:m3/ minute on DC power 2.1
on AC power 3.6
Tankcapacity:L Wet 6
Dry 8
Noise: dB on DC power 64
on AC power 75
Protectionfromelectricshock Double insulation
Powersupplycord:m(ft)*1NorthAmericancountries:6.0(19.7),
Othercountries:5.0(16.4)
Weightaccordingto
EPTA-Procedure01/2003*2:kg(lbs) 8.6(19.0)*3,9.2(20.3)*4
Dimensions:mm(")
Length(L) 366(14-3/8)
Width(W) 334(13-1/8)
Height(H) 368(14-1/2)
*1 As for the shord cord, connection cord is included.
*2 WithPlasticdustbag650x650
*3 WithtwobatteriesBL1815N;BL1820
*4 WithtwobatteriesBL1830;BL1840,BL1840B;BL1850,BL1850B
Voltage(V) Current(A) Cycle(Hz) ContinuousRating(W) Max.Output(W)
Input Output
110 10 50/60 1,050 --- ---
120 9.2 50/60 --- --- ---
220 5 50/60 1,050 --- ---
230 4.8 50/60 1,050 --- ---
240 4.6 50/60 1,050 --- ---
OFFICIAL USE
forASC&SalesShop
TECHNICAL INFORMATION
Model No.
Description Corded and Cordless Vacuum Cleaner
DVC860L
L
W
H
PRODUCT
P1/29
October2015

P2/29
Nozzle assembly
Hosecomplete38-2.5
Plasticdustbag650x650
Plasticdustbagset(10pcs)
Straightpipe
Bendingpipe
Corner nozzle
Toolbox
Connection cord*1
Battery*2
Battery cover*3
Charger*2
*1 Depends on destinations.
*2BatteryandChargerarenotsuppliedwith“Z”model.
*3SuppliedwiththesamequantityofextraBattery.
Note:Thestandardequipmentmayvarybycountryormodelvariation.
Hosecomplete28-1.5/28-3.5/28-5.0/38-1.5/38-2.5/38-5.0
Frontcuffs22/24/38
Holder 10-33
Plasticdustbagset
Powderlter
Damper
Pre-lter
Filterforwetvacuumcleaning
Paperdustbag7L/10L
Straightpipe
Bendingpipe
Nozzle assembly
Corner nozzle
Anchor nozzle
Round brush
Cleaningset
18VLi-ionbatteryBL1815N;BL1820,BL1820B;BL1830;BL1840,BL1840B;BL1850,BL1850B
FastchargerDC18RC
ChargerDC24SC
ChargerDC18SD
AutomotivechargerDC18SE
FourportmultichargerDC18SF
TwoportmultifastchargerDC18RD
Standard equipment
Optional accessories

P 3/ 29
Repair
Caution: 1. Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
2. Wait at least 5 minutes after removing battery or unplugging from power source, and then start
repairing because you may get electric shock by the electricity remaining in Controller.
3. Use 1R276 Acrylic Dust Box to prevent dust from spreading when repairing device for dust collecting.
[1] NECESSARY REPAIRING TOOLS
Code No. Description Use for
1R263
1R274
1R276
1R291
DIGITAL TESTER
1R402 checking energizing condition of Motor assembly
[2] LUBRICATION
Fig. 1
Item No. Description Amount
a little
a little
Portion to lubricate
BEARING EXTRACTOR removing Caster
TYPE 72 FIELD INSERT JIG press fitting Caster
ACRYLIC DUST BOX prevention against dust scattering
RETAINING RING S AND R
PLIERS removing Switch
Apply Makita grease FA No.2 to the portions designated with the black triangle to protect parts and product
from unusual abrasion.
Switch
19
21
19
21
O ring 14
O ring 9
Circumference
Circumference
Switch dial
Switch lever
Switch base complete
Stop ring E12
Index
[1] NECESSARY REPAIRING TOOLS . . . . . . . . . . . . . P 2
[2] LUBRICATION
[3] -1. Motor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3
[3] -2. Carbon brush set . . . . . . . . . . . . . . . . . . . . . . . . . P 10
[3] -3. Switch base section . . . . . . . . . . . . . . . . . . . . . . P 13
[3] -4. Straight pipe and Stopper
[3] -5. Float section . . . . . . . . . . . . . . . . . . . . . . . . . . P 14
[3] -6. Caster . . . . . . . . . . . . . . . . . . . . . . . . . P 16
[3] -7. Bumper
[3] -8. Inlet section . . . . . . . . . . . . . . . . . . . . . . . . . P 17
[3] -9. Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . P 18
Legend Symbol . . . . . . . . . . . . . . . . . . . . . . . . . P 19
Parts list for Circuit diagram
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . P 20
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . P 21
[4] TROUBLE SHOOT . . . . . . . . . . . . . . . . . . . . . . . . . P 27

P 4/ 29
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Motor section
DISASSEMBLING
Fig. 2
(60)
1. Separate Motor section from Tank (64) by
releasing Hooks (60).
Note: Hold Motor section tightly when you
activate without Tank (64) because Motor
section swings around.
2. <How to remove Battery cover complete>
Opening Battery cover complete (1),
remove it by pushing its hinge portion toward
the direction designated with arrow with Slotted
head screwdriver.
2a. <How to remove Grip (3)>
Keeping Grip (3) in foldered position as per the
Photograph to left, remove Grip (3) by pushing
its hinge portion toward the direction designated
with black arrow with Slotted head screwdriver.
< Note >
No need to remove Grip (3), unless Grip (3) itself
or Cowling (7) is replaced.
Slotted head screwdriver
3. Remove Switch button (4) by levering
up with Slotted head screwdriver,
inserted into the space at the center of
Switch button (4).
4. Remove 2 pcs. of Compression
spring 20 (5).
5. Switch D2VW-01-3HS (29) is held to
Cowling complete (7) with its tall rib.
Opening the tall rib with Needle-nose
pliers, shift the Switch (29) from the
place where it was, gripping with external
nails of 1R291.
(1)
(64)
(3)
(7)
Motor
section
(4)
(5)
6. Push the Switch (29) into the space
under Cowling complete (7).
7. Unscrew six 4x65
Tapping screws (6).
8. Separate Cowling complete (7) from
Separator (34).
1R291
Needle-nose pliers
(29)
(29)
(7)
(34)
(6)
(1) Separate Cowling complete from Separator. Fig.2

P 5/ 29
Repair
[3] -1. Motor section
DISASSEMBLING
Fig. 3
3. Lift up Separator (34) while pressing down
Tank cover complete (43).
4. Remove Motor assembly (39) from Tank
cover complete (43).
(27)
Lead wire
holder
Lead wire
of (39)
2. Lifting up Controller B (27), remove Lead wires of
Motor assembly from Lead wire holder.
1. Tracing Lead wires connected to Motor assembly (39),
disconnect the Connector that is connected to
Controller C (65).
(2) Take out Motor assembly. Fig.3
(65)
Connector
(39)
(34)
(43) (39) (39)
(38)
(40)
Small slotted head
screwdriver or pricker
Lock device
< Note >
While pressing Lock device of Terminal with small
slotted head screwdriver or pricker, pull out Lead wire
from Motor assembly (39).
(39)
(43)
5. Remove Rubber
ring 60 (38) and
Rubber ring 120 (40)
from Motor
assembly (39).
[3] DISASSEMBLY/ASSEMBLY

P 6/ 29
Repair
[3] -1. Motor section
ASSEMBLING
Fig. 4
2. Assemble Rubber ring 60 (38) to Motor assembly (39)
while fitting its protrusion to the hole of Motor case
section of (39).
(1) Assemble Motor assembly. Fig.4
a. Fit the groove of Rubber ring 120 (40)
to the circumference rib.
c. Put lead wires of Motor assembly
to the notch of Brush holder.
1. Assemble Rubber ring 120 (40) to Motor
assembly (39) while paying attention to
a, b and c.
b. Fit four protrusions of Rubber
ring 120 (40) to four notches
of Motor assembly (39).
Four Positioning Ribs
(40)
Circumference
rib of (39)
[3] DISASSEMBLY/ASSEMBLY
(38)

P 7/ 29
Repair
[3] -1. Motor section
ASSEMBLING
(2) Mount Motor assembly to the upset Separator by inserting from Tank cover complete side. Fig. 5
1. Assemble Motor assembly (39) to the upset
Separator (34) while fitting the groove of Rubber
ring 120 (40) to the rib of Separator (34).
(34)
3. Assemble Rear block filter (42) carefully not to
push it deeper than the height of
rib of Separator (34).
4. Make sure that Rubber ring 120 (40) fits to the rib
of Separator (34) at its groove portion.
(39)
Rib
(42)
(40)
2. Pass the lead wires of Motor assembly (39)
through the square hole for Lead wire passing.
Groove
(42)
(40)
5. Assemble Front dumper (45) aligning its V
shaped portion to the triangle portion of Tank
cover complete (43).
7. Attach Front dumper (45) and Band dumper (44)
to the ribs of Tank cover complete (43) while
making sure that they are flat.
7. Assemble Tank cover complete (43)
together with Float cage (48) to
Separator (34).
Fig. 5
Square hole for
Lead wire passing
(45)
(44)
(43)
(43)
(48)
(34)
6. Mount Band dumper (44).
(34)
[3] DISASSEMBLY/ASSEMBLY

P 8/ 29
Repair
[3] -1. Motor section
ASSEMBLING
1. Set the machine, Separator (34) top,
Float cage (48) down.
Fig. 6
(34)
(65)
(48)
(39)
(9)
2. Put the Lead wires of Motor assembly (39)
on this route.
3. Connect the lead wires of motor assembly (39）
with those of Controller C (65).
4. Set Top damper (9) to the reverse side
of Cowling complete (7),
* aligning its notch to the center of
Cowling complete (7)
* aligning its shape to that of Cowling
complete.
(9)
(7)
(3) Connect Motor assembly’s lead wires with Controller C and stick Top damper to the reverse side of Cowling complete.
Fig. 6.

P 9/ 29
Repair
[3] -1. Motor section
ASSEMBLING
Fig. 7
(36)
(36)
(4) Set Lead wires and electrical parts to Separator before mounting cowling complete. Fig. 7
(65)
Heat sink
Do not put any lead wires
on Heat sink.
Put lead wires in this place
so that they do not come
out to the outside of
Spacer (34).
Screw boss
Put lead wires of Power
supply cord (36) so deep
that they are not put on
Screw boss.
Be careful not to put lead wires on Screw boss,
Terminal and Ribs for Terminal setting.
Screw boss
Terminal Terminal
Controller C (65) has to be put
exactly to the place where it is.
(34) (34)
(18)
(18)
Fix Lead wires (red) with two lead wire holders
of Switch base complete (18). Otherwise, they
can be damaged by the rib of Cowling complete.

P 10/ 29
Repair
[3] -1. Motor section
ASSEMBLING
Fig. 8
(5) Mount Cowling complete and Switch button. Fig. 8
2. Tank cover complete (43) and Cowling
complete (7) are about 10mm away because
of Top damper mounted to the reverse side
of Cowling complete (7).
However, there is no problem if the Cowling
complete (7) closely touches Tank cover
complete (43) when it is pushed.
3. Tighten Cowling complete (7) with six 4x65 Tapping
screws (6).
4. Mount 2pcs.of Compression spring 20 (5).
1. While pulling out Switch D2VW-01-3HS (29)
through the hole of Cowling complete (7), mount
Cowling complete (7).
Gap
No Gap
(7)
(43) (7)
(43)
5. Opening the tall rib with Needle-nose pliers,
set Switch (29) to the place where it is,
gripping with external nails of 1R291.
6. Mount Switch button (4).
(5)
(5)
(6)
(29)
1R291
Needle-nose pliers
(29)
(4)
(29)
(7)

P 11/ 29
Repair
[3] -1. Motor section
ASSEMBLING
Fig. 9
(5) Mount Battery cover. Fig. 9
Fig. 10
(1)
(7)
2. Assemble the other hinge to Cowling complete (7).
1. Inserting Battery cover complete (1) at an angle,
assemble one of its hinge to Cowling complete (7).
[3] -2. Carbon brush set
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
(1) Disassemble Motor assembly. Fig. 2, Fig. 3
Disassemble Brush holder. Fig. 10
1. Inserting slotted head screwdriver to the illustrated portions alternately, lift up Brush holder (69).
Slit
(69)
(67)
2. Remove Brush spring (67) from
Carbon brush.
3. Pull out Carbon brush (68)
while lifting up it.
4. Remove Brush spring (67).
(68)
< Note >
Pay attention to the slit portion of Brush holder (69). The Brush holder (69) may get broken from the slit
if Brush holder (69) is expanded frequently too wide.
(67)

P 12/ 29
Repair
ASSEMBLING
Fig. 11
(1) Mount Brush spring and Carbon brush. Fig. 11
1. Set Brush spring (67) to the place
shown on the left.
2. Pull Brush spring (67) toward the direction
designated with arrow while gripping the
long arm of Brush spring with Needle-nose
pliers.
[3] -2. Carbon brush set
[3] DISASSEMBLY/ASSEMBLY
Needle-nose pliers
Groove for Brush
spring fitting
Long arm of Brush spring,
exactly fitting to Groove
3. Set long arm of Brush spring to the groove of Carbon brush.
Long arm of Brush spring,
slipping off from the groove
Conducting terminal
Conducting terminal
4. Conducting terminal
disconnected from
Carbon brush (68)
causes poor energizing.
5. Correct the form of Conducting
terminal using long nose pliers
to contact exactly with Carbon
brush (68), if the condition of
Conducting terminal is as per
the photo on left.
(68)
6. Make sure by pushing
carbon brush (68) up
and down whether the
Conducting terminal
has elasticity to keep
contact with Carbon brush (68).
(67)
(67)
(68)
Right Wrong

P 13/ 29
Repair
ASSEMBLING
DISASSEMBLING
Fig. 12
Fig. 13
(2) Check the energizing condition. Fig. 12
(1) Disassemble Cowling complete. Fig. 2
(2) Disassemble Switch base section. Fig. 13
2. Unscrew two 4x18
Tapping screws (10)
with which Switch
holder (11) is fixed to
Switch base (18).
1. Remove Switch lever (20),
O ring 14 (19),
Switch dial (22)
and O ring 9 (21).
4. Remove Sub controller (16)
opening claws with your
finger.
LED Circuit (15) can be
removed in the same way
as Sub controller (16).
5. Remove Stop ring E-7 (17)
and E-14 (14).
3. Remove Switch holder (11)
together with Switch (13)
from Switch base (18).
[3] -2. Carbon brush set
[3] -3. Switch base section
[3] DISASSEMBLY/ASSEMBLY
Contacting 1R402 as shown in the photo on left, check the
energizing condition while rotating Fan of Motor assembly (39)
by hand.
If the energizing is discontinued even a moment, check the following
matters again.
* whether Brush spring fits exactly to the groove of
Carbon brush. Fig. 11.
* whether the conducting Terminal contacts constantly
with Carbon brush. Fig. 11.
1R402
Fan of (39)
(39)
(16)
(19) (20)
(22)
(21)
(10)
(11)
(10)
(13)
(18)
claw
claw
(16)
(14)
(17)
(14)
(17)
(15)

P 14/ 29
Repair
DISASSEMBLING
Fig. 14
Fig. 15
(3) Component parts of Switch base section are as shown in Fig. 14.
Assemble Stopper to Straight pipe at the illustrated position. Fig. 15
[3] -3. Switch base section
ASSEMBLING
[3] -4. Straight pipe and Stopper
[3] DISASSEMBLY/ASSEMBLY
10
10
(10) 4x18 Tapping screw 2 pcs.
(11) Switch holder
(13) Switch
(14) Stop ring E-12
(15) LED Circuit
(16) Sub controller
(17) Stop ring E-7
(18) Switch base complete
(19) O ring 14
(20) Switch lever
(21) O ring 9
(22) Switch dial
11
13
14
15
16 17
18
19
20
21
Straight pipe
Stopper
125~135mm
Note: Put on Makita grease FA No.2 a little on the circumference
of O ring 14 (19) and O ring 9 (22) when assembling.
22

P 15/ 29
Repair
DISASSEMBLING
Fig. 16
Disassemble Float section. Fig. 16
[3] -5. Float section
[3] DISASSEMBLY/ASSEMBLY
(48)
(43)
(64)
1. Separate Motor section together with Tank cover
complete (43) and Float cage (48) from Tank (64)
by releasing Hook (60).
2. Unscrew three
4x18 Tapping
screws (49).
3. Separate Float
cage (48) together
with Float
complete (46).
4. Separate Float complete (46)
from Float cage (48).
5. Separate Sponge
seal 70 (48) from
Float complete (46).
(60)
(60)
(49)
(48)
(48)
(46)
(47)

P 16/ 29
Repair
ASSEMBLING
Fig. 17
Fig. 18
Paying attention to the matters in Fig. 17, assemble Float section, taking reverse step of Fig. 16.
[3] -5. Float section
DISASSEMBLING
[3] -6. Caster
[3] DISASSEMBLY/ASSEMBLY
(46) (47)
2. Facing Rubber seal 70 (47) to Tank cover complete (43) side,
mount Float complete (46) to Tank cover complete (43).
1. Mount Rubber seal 70 (47) to Float complete (46).
Inlet
(62) (61)
1. Make a gap for 1R263 by applying
Slotted head screwdriver to the
joint of Caster 50 (62) and Tank (64).
2. Remove Caster 50 (62) by levering it
up with 1R263, inserted to the gap,
made by slotted head screwdriver.
3. Slide Slotted head screwdriver in the
groove of Tank (64) until it touches the
leg of Caster 50 (61) and then slightly
lift up Caster 50 (61).
4. Remove Caster 50 (61) by levering it
up with 1R263.
(43)
(46)
(47)
(62)
Slotted head screwdriver
Disassemble Casters from Tank. Fig. 18
Slotted head screwdriver
1R263
(61)
1R263
Groove of (64)
(64)

P 17/ 29
Repair
ASSEMBLING
Fig. 20
Front and rear casters can be assembled. Fig. 19
[3] -6. Caster
ASSEMBLING
[3] -7. Bumper
[3] DISASSEMBLY/ASSEMBLY
Plastic hammer
1R274
(61), (62)
Strike 1R274 applied to Casters (61), (62).
So, Casters are assembled to Tank.
Triangle mark
as a Notch
2. Assemble Bumper (51) tightly to Tank (64).
Opposite side of Inlet
(Rear side)
Inlet side
(Front side)
(62)
Fig. 19
Assemble Bumper to Tank. Fig. 20
1. Set Bumper (51) while aligning Triangle mark
to the center.
(51)
Opposite side of Inlet
(Rear side)
(64)

P 18/ 29
Repair
ASSEMBLING
Front and rear casters can be assembled. Fig. 21
[3]-8. Inlet section
[3] DISASSEMBLY/ASSEMBLY
1. Mount Holder (55) to Holder plate (54).
2. Mount Holder (55) together with Holder
plate (54) to Tank (64).
4. Fasten Inlet (59) to Holder plate (54)
through Holder (55) and Tank (64)
with three 4x28 Tapping screws (53).
3. Mount O ring 56 (58) to Holder (54).
And assemble Inlet (59).
Fig. 21
(55)
(54)
(64)
(53) (54)
(53)
(64)
(53)
(58)
(59)
(55)

P 19/ 29
Repair
ASSEMBLING
Tighten the parts with fastening torque listed below. Fig. 22
[3] -9. Tightening torque
[3] DISASSEMBLY/ASSEMBLY
Fig. 22
(31)
(31) 4x25 Tapping screw
(32) Strain relief
(34) Separator
(A)
(A) M4x20 Pan head screw
(32)
(53)
(53) 4x28 Tapping screw
(54)
(54) Holder plate
(64) Tank
(59) Inlet
(34)
Parts, tightened
with screws to right
Tightening
torque (N.m)
1.5 ~ 1.8
3 pcs.
2 pcs.
1 pc.
1.3 ~ 1.8
0.5 ~ 0.7
Screws used
Qty
Stopper
Stopper, Straight pipe
Straight pipe
(59)
(64)
(6)
(7)
(34)
(43)
(48)
(49)
(10)
(11)
(18)
(57)
(60)
(60) Hook
(64) Tank
(10) 4x18 Tapping screw
(57) 4x18 Tapping screw
(11) Switch holder
(18) Switch base
(49) 4x25 Tapping screw
(6) 4x65 Tapping screw
(7) Cowling comp.
(34) Separator
(43) Tank cover comp.
Parts, tightened
with screws to right
Tightening
torque (N.m)
6 pcs.
2 pcs.
2 pcs.
3 pcs.
1.0 ~ 1.3
Screws used
Qty
(48) Float cage
(43) Tank cover comp.
(64)

P 20/ 29
(25A)
(25B)
Flag receptacle 187 with lock
Flag receptacle 250 with lock
Symbol Description
Description Used Q’ty
Place to be mounted
Legend Symbol
Parts list for Circuit diagram
Flag receptacle 250 with lock
covered with insulated sleeve
Straight type receptacle 250 with lock Terminal A (25A) and Terminal B (25B)
Straight type receptacle 187 with lock
Straight type receptacle 187 with lock
Switch
Flag receptacle 187 with lock,
covered with insulated sleeve Switch D2VW-01-3HS (29) and Motor assembly (39)
(K) Closed end connector
(18) Switch base complete
Sub controller
Terminal A
Terminal B
Circuit diagram
(29) Switch D2VW-01-3HS
(36) Power supply cord
(28)
(39) Motor assembly
(27) Controller B
Controller A
(65) Controller C
Connector
(33) Terminal block
(32) Strain relief
(35) Line filter 2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
4
(13)
(16)
(15) LED Circuit
(CN)
Item No.
Terminal A (25A) and Terminal B (25B)
Switch (13)
Switch D2VW-01-3HS (29)
Motor assembly (39)
Terminal A (25A) and Terminal B (25B)