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DGA405

Makita DGA405 Datasheet

  • Hello! I've analyzed the provided datasheet for the Makita DGA405, DGA455, and DGA505 cordless angle grinders. These models have features like a brushless DC motor and automatic speed control, and safety features like Kick-Back Detection. I'm ready to answer any questions you might have about them.
  • What type of battery is compatible with these angle grinders?
    What does the Kick-Back Detection (KBD) feature do?
    What is the no-load speed of these angle grinders?
The subject models are cordless angle grinders powered by 18V Li-ion battery,
and equipped with highly enhanced Brushless DC motor compared to the current
models DGA402/ DGA452.
A built-in controller changes the cutting speed automatically according to
load condition, enabling the user to obtain high speed rotation on light duty
application/ high torque on heavy duty application.
KBD: Kick-Back Detection shuts down the tool to protect the user,
if the rotation speed suddenly slows down (e.g., kickback).
Paddle switch type
Model No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
P 1/ 11
Dimensions: mm (")
DGA405
Width (W) DGA455
117 (4-5/8)
130 (5-1/8)
DGA505
DGA405
Height (H)
140 (5-1/2)
140 (5-1/2)
DGA455,
DGA505 145 (5-3/4)
Note: The standard equipment may vary by country or model variation.
DGA405, DGA455, DGA505
18V Cordless Angle Grinders L
H
W
Specification Model DGA405
18
Weight according to
EPTA-Procedure 01/2003: kg(lbs)*22.5 (5.6) 2.6 (5.7)2.4 (5.4)
Battery
1.5, 2.0, 3.0, 4.0, 5.0Capacity: Ah
Voltage: V
Li-ionCell
Energy capacity: Wh 27, 36, 54, 72, 90
Charging time (approx.): min. 15, 24, 22, 36, 45 with DC18RC
Wheel size: mm (") Hole diameter
6 (1/4)Max. thickness
Diameter 100 (4)
16 (5/8) 22.23 (7/8)
8,500
No
Yes
Yes
Yes
Yes
Yes
Paddle
Switch type
Electronic
control
Overload warning lamp
Electronic current limiter
Soft start
Anti-restart function
Battery fuel gauge
Soft grip
*2 With BL1830/ BL1840/ BL1850
*1 With BL1830/ BL1840/ BL1850
*2 With BL1815N/ BL1820
Note: BL1815 is not compatible.
DGA505 DGA455
115 (4-1/2) 125 (5)
Lock nut wrench
Side grip
Depressed center wheel (100mm for DGA405, 115mm for DGA455, 125mm for DGA505)
Battery cover (except “Z” model)
Plastic carrying case (except “Z” model)
Fast charger DC18RC (except “Z” model)
Li-ion battery BL1830 or BL1840 (except “Z” model)
Wheel covers
Vibration proof grip
Wire cup brush
Dust extractor attachment
Super flange
Dust collecting wheelcover
Lock nut
Dust collect cover
Sanding lock nut
Rubber pads
Abrasive discs
Fast charger DC18RC
Fast charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Four port multi charger DC18SF
Dust collecting wheel guards
Li-ion battery BL1815N
Li-ion battery BL1820
Li-ion battery BL1830
Li-ion battery BL1840
Li-ion battery BL1850
Length (L)*1All 362 (14-1/4)
Length (L)*2All 348 (13-3/4)
OFFICIAL USE
for ASC & Sales Shop
No load speed: min.-ı= rpm
P 2/ 11
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R004
1R027
1R029
1R036
1R045
1R258
1R268
1R269
1R280
1R286
1R291
Retaining ring pliers ST-2
Bearing setting pipe 18-10.2
Bearing setting pipe 23-15.2
Bearing setting plate 17.2
Gear extractor (large)
V block
Spring pin extractor M3
Bearing extractor
Round bar for Arbor 6-50
Round bar for Arbor 12-50
Retaining ring S and R pliers
removing/assembling Ring spring 11 from/to Spindle
assembling Rotor to Ball bearing 629LLB in Gear housing cover.
removing Ball bearing 6201DDW from Bearing box
assembling Spiral bevel gear 37 to Spindle
supporting Spindle when assembling Spiral bevel gear 37 to Spindle
disassembling Rotor from Gear housing cover
supporting Bearing box when removing Spindle from Spiral bevel gear 37
disassembling Pin 4 from Pin cap
removing Ball bearing 607LLB and 696ZZ
disassembling Spindle from Bearing box
disassembling Ball bearing 629LLB from Gear housing cover
disassembling/assembling Retaining ring R-32 from/to Bearing box
[2] LUBRICATION
Apply Makita grease R No.00 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion.
Fig. 1
Item No. Description
5
14
AmountPortion to lubricate
Gear housing
O ring 26
Gear room for Spiral bevel gear 37 and Spiral bevel gear 10
Spiral bevel gear 10
Spiral bevel gear 37
9 g
Inner periphery that appears from Gear housing cover a little5
14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Rotor, Ball bearing 629LLB, 607LLB, Spiral bevelgear 10
DISASSEMBLING
2. Insert Slotted screwdriver into
the notch of Gear housing cover,
then pry off Gear housing cover
from Motor housing.
1. Remove four 4x30 Tapping screws, and then separate the assembled part of Gear housing and Bearing box
from Gear housing cover.
(1) Remove Rotor, Ball bearing 629LLB, 607LLB and Spiral bevel gear 10 as drawn in Fig. 2.
Bearing box
Motor housing
Slotted screwdriver
3. While holding Rotor ass’y by a gloved hand,
turn M6 Hex nut counterclockwise with Wrench 10.
Then remove Spiral bevel gear 10.
4. Hook the jaws of 1R045 with Gear housing cover,
then push out Rotor ass’y.
In this step, Ball bearing 629LLB still remains in
Gear housing cover.
Spiral bevel gear 10
Gear housing cover
M6 Hex nut
1R286
Rotor ass’y
Gear housing cover Ball bearing 629LLB
Ball bearing 629LLB
5. Press down Ball bearing 629LLB with 1R286.
Small hole
Gear housing cover
Note: Face the small hole toward upward.
Do not face the large hole toward
upward. (Refer to Fig. 4 of Page 4.)
Ball bearing
607LLB
1R269
6. Remove Ball bearing 607LLB with 1R269.
1R045
Notch of Gear housing cover
Fig. 2
Gear housing
P 3/ 11
4x30 Tapping screw
(4 pcs.)
Rotor ass’y
Repair
NotchSwitch lever complete
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Rotor, Ball bearing 629LLB, 607LLB, Spiral bevel gear 10 (cont.)
Fig. 3R Fig. 3F
Caution for Handling of Rotor
When handling or storing multiple Rotors,
be sure to keep a proper distance between
Rotors as shown in Fig. 3R
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. 3F)
* Magnetic loss of Rotors
* Damage on the magnet
portion of Rotor
Ball bearing
607LLB
Rotor
1. Assemble Ball bearing
607LLB to Rotor.
(1) Assemble Rotor ass’y to Gear housing cover as drawn in Fig. 4.
(2) Assemble Gear housing cover and Gear housing section as drawn in Fig. 5.
4. Assemble Spiral bevel gear 10 to Rotor ass’y,
and secure the gear by turning M6 Hex nut
clockwise with Wrench 10.
Keep enough distance between Rotors so that
they are out of their magnetic forces each other.
ASSEMBLING
Spiral bevel gear 10
M6 Hex nut
Fig. 4
Fig. 5
Gear housing
Spindle
Gear housing cover
2. Assemble Gear housing to Gear housing cover.
Face Spindle toward Switch lever complete.
1. Assemble Gear housing cover to Motor housing. Face the notch
of Gear housing cover toward Switch lever complete.
P 4/ 11
2. Assemble O ring 26 to the inner groove of Gear housing cover, and apply Makita grease
R No. 00 to the inner periphery of O ring 26, and then, insert Ball bearing 629LLB from
the large hole side of Gear housing cover.
3. Receive the inner race of Ball bearing 629LLB
in Gear housing cover with 1R027, and pressfit
the shaft of Rotor ass’y into the hole of Ball
bearing 629LLB.
Large hole of
Gear housing
cover
O ring 26
with Grease R No. 00
on the inner periphery
Ball bearing 629LLB
1R027
Hole of Ball bearing 629LLB
Inner race of Ball
bearing 629LLB
Repair
Ball
bearing
696ZZ
1. Remove four M4x14 Pan head screws,
and then separate Bearing box from
Gear housing.
(1) Remove Ball bearing 696ZZ and Ring spring 11 from Spindle as drawn in Fig. 6.
(2) Remove Spindle, Spiral bevel gear 37, Ball bearing 6201DDW etc. as drawn in Fig. 7.
2. Remove Ball bearing
696ZZ with 1R269.
3. While opening the gap of Ring spring 11
with 1R004 or 1R291, lever up the opposite
carefully with Slotted screwdriver.
Ring spring 11 is removed from Spindle.
DISASSEMBLING
Fig. 6
Fig. 7
1R269
Ring spring 11 1R004 or 1R291
1. Receive Bearing box on 1R258.
Provide an impact to Spindle carefully with
Arbor press so that Arbor press does not touch
Spiral bevel gear 37 and Spindle sinks slightly.
2. Press down Spindle with
1R280.
1R258 1R258
Note: Be careful not to put the following
portions onto 1R258.
* Protruded portion of Bearing box
* Labyrinth ring of Spindle
3. Spindle and Spiral bevel gear 37
are removed.
4. Remove Retaining ring R-32 with
1R291 from the groove in Bearing box.
5. Turn Bearing box upside down, and
press down Ball bearing 6201DDW
from Bearing box with 1R027.
6. Flat washer 12 is removed
from Bearing box.
Spindle
Spindle
Labyrinth
ring
Flat washer 12
Spiral bevel gear 37
Bearing box
Ball bearing
6201DDW
Ball bearing
6201DDW
(in Bearing box)
P 5/ 11
Slotted screwdriver
Retaining
ring R-32
Groove of
Bearing box
1R027
Small hole of Bearing box
1R280
7. Be careful about each position and the direction of Labyrinth ring
Note: When Spindle is removed from Spiral bevel gear 37, Ball bearing 6201DDW has a damage during the removal
process. Therefore, replace Ball bearing 6201DDW with a new one.
Spindle Labyrinth ring
M4x14 Pan head
screw (4 pcs.)
Bearing box Ball bearing
6201DDW
O ring 45 Ball bearing 696ZZFlat washer 12
Ring spring 11
Spiral bevel gear 37Retaining ring
R-32
Gear housing
Bearing box
M4x14 Pan head
screw (4 pcs.)
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Spiral bevel gear 37, Ball bearing 696ZZ / 6201DDW
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Spiral bevel gear 37, Ball bearing 696ZZ / 6201DDW (cont.)
[3]-3. Shaft lock mechanism
(1) Assemble Flat washer 12 and Ball bearing 6201DDW to Bearing box. (Refer to Fig. 7 of page 5.)
(2) Secure Ball bearing 6201DDW with Retaining ring R-32. (Refer to Fig. 7 of page 5.)
(3) Assemble Spiral bevel gear 37 to Spindle as drawn in Fig. 8.
(4) Reverse the disassembly procedure of Figs. 7 and 6 of page 5 to set Bearing box section in place.
Remove Shaft lock mechanism (Shoulder pin 4, Compression spring 8 and Pin cap) as drawn in Fig. 9.
2. Put 1R029 on the area around the center
hole of Spiral bevel gear 37 and then
press it down.
3. Snap Ring spring 11 into the groove
of Spindle to secure Spiral bevel
gear 37, and then assemble Ball
bearing 696ZZ to Spindle.
1. Insert the thread of Spindle into
the hole on 1R036 to receive
the stepped portion of Spindle
as drawn below.
ASSEMBLING
DISASSEMBLING
Fig. 8
Fig. 9
1R0361R036
Bearing box
Thread of Spindle
Stepped
portion of
Spindle
Spiral bevel
gear 37
Bearing box
1R029
1R036
Ball bearing
696ZZ
Ring spring 11
3. Apply 1R268 to Shoulder pin 4 through
the small hole on Pin cap and tap 1R268
with Metal hammer.
Shoulder pin 4 is removed from Gear
housing.
4. Release 1R268 from Pin cap
carefully so that Pin cap is not
slung by Compression spring 8.
Shoulder pin 4
Pin cap
Note: Do not reuse Pin cap. It is because removal of
Shoulder pin 4 damages the inside surface.
(1) Clean up the plastic dust from Gear housing, Compression spring 8 and Shoulder pin 4. (Fig. 11)
(2) Assemble the components as drawn in Fig. 12.
1. Separate Gear section (Gear housing, Bearing
box) by unscrewing four 4x30 Tapping screws.
2. Separate Bearing box section from Gear housing
by unscrewing four M4x14 Pan head screws.
Small hole
of Pin cap
Compression
spring 8
1R350
Gear housing
Gear housing
Bearing box
Bearing box
4x30 Tapping
screws (4 pcs.)
M4x14 Pan head
screws (4 pcs.)
P 6/ 11
ASSEMBLING
Fig. 11 Fig. 12
Be sure to clean up
plastic dust here.
O ring 5 Shoulder pin 4
with O ring 5
Top of Shoulder pin 4
1. Insert Shoulder pin 4 through
the hole of Gear housing complete.
Pin cap
Compression Spring 8
2. Assemble Compression spring 8
and new Pin cap to Shoulder pin 4.
Repair
Fig. 13
1. Fit four projections on Housing set into four
mating cavities in Stator complete.
2. Be sure to align the center line of Bearing room
with the terminal of Stator complete.
Assemble Stator complete as drawn in Fig. 13.
[3] DISASSEMBLY/ASSEMBLY
[3]-4. Stator complete
ASSEMBLING
Mating cavity on
the left side and
the right side
(tow each)
Terminal of
Stator complete
(Center line)
Projections in
Housing set
on the left side
and the right side
(two each)
P 7/ 11
Repair
Bearing room
(to fit Ball bearing
607LLB of Rotor
ass’y) on Housing
set
[4] TROUBLE SHOOTING
Symptom Cause Corrective action
The Tester designates between
0.79 and 0.81V by the steps
shown in Fig. T-3 of page 9.
In case the tester is not ready,
go to “Yes”
Yes Yes
Lamp (a) is ON.
See “Lamps on
Housing set”.
Yes
Yes
No
No
Lamps on Housing set
The function does
not have trouble.
Scratch on the core of
Rotor or mechanical
trouble is recognized.
In spite of the above corrective actions,
the machine shows same symptom.
Yes
Yes
No
No
No
No
All of Lamps (b), (c),
(d) are ON.
See “Lamps on
Housing set”.
Replace Controller.Controller is broken.
Replace Stator complete*.Controller is broken.
Replace Stator complete*.Controller is broken.
Replace Stator complete.
Replace Stator complete*.
Replace Stator complete*.
Replace Rotor ass’y.
Controller is broken.
Replace Stator complete*.
Controller is broken.
Check the engagement of
Gears and Rotor ass’y or
condition of mechanical
parts.
Mechanical trouble
occurs.
Check Connectors,
or replace them.
Check Connectors or
replace them.
Lead wires are
disconnected.
Check Lead wires, or
replace the broken wire(s).
Lead wires are broken. Check Lead wires, or
replace the broken wire(s).
Rotor ass’y is broken.
Stator complete is
broken.
Switch is broken. Replace Switch.
Terminal is broken.
(a): Mode lamp (green)
If Green lamp is ON, the machine is
automatically set in High Torque mode.
(b),(c), (d): Battery power remaining lamp
All 3 stages of Battery power
remaining lamp are on.
See “Lamps on Housing set”.
Controller is broken.
P 8/ 11
Repair
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 complete, Gear section, etc.
Note
Check List for Trouble Shooting
Motor runs when the machine
is switched on (in forward and
reverse mode;10 times each)
In case of running inconstantly,
go to “No”.
Check the items from the top in Fig. T-2. (Description of the item is referred to Circuit
diagram in Fig. D-1 of page 10.)
Repeat the check of the corrective action ten times.
Check Terminal,
or replace it.
Connectors are
disconnected.
Connectors are
disconnected.
Star mark
Fig. T-1
Fig. T-2
*It includes Controller.
2. Lock Switch lever complete
with an insulating tape or a like.
[4] TROUBLE SHOOTING (cont.)
Test for recognizing the short-circuit of FET* on controller
Fig. T-3
Remove Battery, and then do as shown in Fig. T-3.
3. Attach the black bar to (+) Terminal,
and the red bar to (-) Terminal.
Note: Be careful not to reverse them.
The reverse attachment could spoil the test.
Wait until the display shows the value without
fluctuation.
(+) Terminal
(-) Terminal
Insulating tape
Switch lever complete
black bar
red bar
P 9/ 11
1. Set Digital tester (1R402) in the diode mode ( mark).
*FET: Field effect transistor
Repair
**It includes Controller.
4. There is no fault of FET on Controller if the display
indicates between 0.79V and 0.81V.
If the display indicates 0V or 0.4V approximately,
FET built in Controller has any trouble,
and Stator complete** has to be replaced.
Fig. D-1
White
Orange
Blue
Yellow
Green
Color index of lead wires' sheath
Black
Red
Switch
Non-insulated terminal (to insert the plate end into Switch terminal No.3
and fasten the plate with the M3.5 screw of Switch)
Switch unit
Tape
Terminal
Connector
AWG24
AWG24
AWG28
AWG14
AWG28
AWG22
AWG14
AWG14
AWG14
Controller
Line filter
(if used)
Stator
P 10/ 11
Circuit diagram
Polyolefin tube
Polyolefin tube
AWG28
Flag terminal with lock
(#250, t=0.8mm)
Flag terminal with lock
(#187, t=0.8mm)
AWG22
White lead wire is used
for some countries.
Fig. D-2
Wiring of Controller to Stator complete
Wiring after setting Switch and Switch unit
Pin A Pin B
Boss for fitting
Switch unit Boss A
Rib B
Rib A
Rib D
Boss B
Rib F
Rib E Connectors
Stator
Rib G
Controller
Terminal
Line filter (if used)
Rib H
Housing set R side Housing set R side
Note: Insert the plate end of Non-insulated terminal into Switch terminal No. 3
as drawn in Figs. R and D-1 of page 10.
Switch unit
Fig. R Fig. F
Housing
set L
Housing
set L
Switch
Switch Switch
Route lead wires (red, yellow, black) of Terminal
between Rib E and Rib F.
Put Line filter between Rib G and Rib H.
P 11/ 11
Wiring diagram
Bend thick lead wires (orange, white, blue) of Controller
here so as not to pinched between mating portions of
Housing L and R.
Fix Lead wires in these Lead wire holders one by one.
Route three thick lead wires (orange, white, blue)
of Controller between Pin A and Pin B.
Route Polyolefin tube of Controller between;
• Rib A and Boss A
• Rib B and Boss for Switch unit fitting
• Rib B and Rib D
• Pin A and Boss B
Put Connectors (of Lead wires
for Switch unit and Controller)
in this space.
Fix Lead wires from Switch unit
in these Lead wire holders.
/