Makita DGA405 Datasheet

Brand: Makita

Model: DGA405

Type: Datasheet

Makita DGA405 is a cordless angle grinder powered by an 18V Li-ion battery, equipped with a brushless DC motor. It features a built-in controller that adjusts cutting speed to load conditions, providing high speed for light-duty applications and high torque for heavy-duty tasks. The KBD (Kick-Back Detection) system shuts down the tool if rotation speed suddenly drops, protecting the user from kickback. It has a paddle switch, overload warning lamp, electronic current limiter, soft start, anti-restart function, and battery fuel gauge.

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)

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

Specification Model DGA405

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

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

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

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

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

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

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

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.

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

AWG28

AWG14

AWG28

AWG22

AWG14

Controller

Line filter

(if used)

Stator

P 10/ 11

Circuit diagram

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.

Makita DGA405 Datasheet

Makita DGA405 Datasheet

Related papers

Other documents