Transcript
OFFICIAL USE for ASC & Sales Shop
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ECHNICAL INFORMATION
Model No.
DHP459
Description
Cordless Hammer Driver Drill
PRODUCT P 1/ 11 L
CONCEPT AND MAIN APPLICATIONS
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Model DHP459 Cordless Hammer Driver Drill has been developed specially for light to medium duty drilling, hammer drilling and fastening applications. This model is equipped with a basic BLDC motor (BrushLess DC motor) specially designed to provide, above all, more work amount on a single full battery charge. This product is powered by BL1815 (1.3Ah), BL1815N (1.5Ah), BL1820 (2.0Ah), BL1830 (3.0Ah), BL1840 (4.0Ah) or BL1850 (5.0Ah).
Specification Voltage: V Capacity: Ah Battery Energy capacity: W Cell Charging time (approx.): min. Max output: W High No load speed: min-1=rpm Low Impact per minute: High min-1=rpm Low Capacity of drill chuck: mm (") Steel Capacity: mm (") Wood Masonry Torque setting Clutch torque setting: N.m (in.lbs) Max lock torque: N.m (in.lbs) Max. fastening Soft joint torque: N.m (in.lbs) Hard joint Electric brake Mechanical speed control Variable speed control Reversing switch LED job light Weight according to EPTA-Procedure 01/2003: kg (lbs)
18 1.3, 1.5, 2.0, 3.0, 4.0, 5.0 24, 27, 36, 54, 72, 90 Li-ion 15, 15, 24, 22, 36, 45 with DC18RC 250 0 - 1,500 0 - 400 0 - 22,500 0 - 6,000 1.5 (1/16) - 13 (1/2) 13 (1/2) 38 (1-1/2) 13 (1/2) 16 stage + drill mode 1.0 - 5.0 (9 - 44) 45 (400) 25 (220) 45 (400) Yes Yes (2 speed) Yes Yes Yes 1.5 (3.3)*1 1.7 (3.8)*2
W [Drawn above is the image with BL1830, BL1840 or BL1850.]
Dimensions: mm (") 192 (7-9/16) Length (L) 78 (3-1/16) Width (W) 238 (9-3/8)*1 Height (H) 256 (10-1/8)*2 *1 With Battery BL1815, BL1815N or BL1820 *2 With Battery BL1830, BL1840 or BL1850
Standard equipment Battery*3 Charger*3 Battery cover*4 + – bit 2-45 Belt clip Plastic carrying case*3
Optional accessories Li-ion Battery BL1850 Li-ion Battery BL1840 Li-ion Battery BL1830 Li-ion Battery BL1820 Li-ion Battery BL1815N Li-ion Battery BL1815
*3: Battery, charger and Plastic carrying case are not supplied with “Z” model *4: Supplied with the same quantity of extra Battery Note: The standard equipment may vary by country or model variation.
Charger DC18SD Charger DC24SC Fast charger DC18RC Automotive charger DC18SE Four port multi charger DC18SF Two port multi fast charger DC18RD
Drill bits for wood Drill bits for steel Drill bits for masonry Phillips bits
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Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”. [1] NECESSARY REPAIRING TOOLS Code No.
Description
1R359
Drill chuck removing tool Hex wrench 10
Use for (Use this tool if Drill chuck cannot be removed by the method of described in “[3]-1 Drill chuck disassembling”.) removing/ mounting Drill chuck
[2] LUBRICATION It is not required to lubricate the gear section because the portion is replaced as a factory- lubricated gear unit.
[3] DISASSEMBLY/ASSEMBLY [3] -1. Drill Chuck DISASSEMBLING Note: It is required to remove Drill chuck when replacing Gear assembly, but you need not when replacing the parts that are independent of Gear assembly. (1) Remove M6x22 Flat head screw. (Fig. 1) (2) Preset the machine. (Fig. 2) And set Hex wrench 10 to Vise. (Fig. 3) (3) While holding Hex wrench 10 with Drill chuck firmly, remove Drill chuck from Gear assembly. (Fig. 4) Fig. 1 Fig. 2 Speed change lever Set Change ring Open Drill chuck fully and remove M6x22 Set Speed change lever to Drill mode. Flat head screw by turning it clockwise. to Low speed mode Change ring designated with 1. Note: Use Impact driver to unscrew M6x22 Flat head screw if it F/R change lever could not be removed Set F/R Change lever manually. to Reverse (counterclockwise) rotation. M6x22 Flat head screw (Left handed thread) Attach Battery. Fig. 3
Setting of Hex wrench10 CORRECT Hold the long end. Hex wrench 10
WRONG Grip flat surfaces of Hex wrench 10. Vise
[A]
Vise Fig. 4
Do not hold edges of Hex wrench 10.
Do not hold the short end.
[A]
Hex wrench 10, viewed from side [A]
Hex wrench 10, viewed from side [A]
Counterclockwise Counterclockwise*2 force to be applied by operator
Clockwise
Clockwise*1 recoil force of Machine
Hex wrench 10 Vise
Note: The rotational direction is viewed from operator. 1. Hold Hex wrench 10 with Drill chuck and grip Machine. Important: Grip Machine tightly with both hands to provide the sufficient counterclockwise*2 force against clockwise*1 recoil force of Machine. 2. Pull Switch trigger slowly. 3. Spindle rotates counterclockwise*2 and consequently Drill chuck is removed from spindle.
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Drill Chuck (cont.) ASSEMBLING (1) Seat Drill chuck on Spindle. (Fig. 5) (2) Set the machine to Drill mode, Low gear mode and Forward rotation mode. (Fig. 6) (3) Set Hex wrench 10 to vise. (Refer to Fig. 3) (4) Tighten Drill chuck. (Fig. 7) Fig. 6
Fig. 5 Turn Drill chuck clockwise by hand until it is seated on the end of the threaded portion of Spindle. Drill chuck
Set Speed change lever to Low speed mode designated with 1. Speed change lever
Set F/R Change lever to Forward (clockwise) rotation.
Set Change ring to Drill mode. Change ring
F/R change lever Attach Battery. End of the threaded portion of Spindle
Fig. 7 Note: The rotational direction is viewed from operator. 1. Hold Hex wrench 10 with Drill chuck and grip Machine. Important: Grip Machine hard with both hands to provide sufficient clockwise*1 force against counterclockwise*2 recoil force of Machine. 2. Pull Switch trigger slowly to turn Spindle clockwise*1. Note: Pull the Trigger so that Spindle’s rotating reaches full speed in one second. 3. Drill chuck is tightened and consequently Spindle is locked. 4. Open Drill chuck fully, and tighten Drill chuck with M6x22 Flat head screw by turning it counterclockwise with Impact driver. Clockwise Clockwise*1 force to be applied by operator
Counterclockwise Counterclockwise*2 recoil force of Machine Hex wrench 10
M6x22 Flat head screw (Left handed thread) Note: Apply adhesive (ThreeBond 1342 or Loctite 242) to threaded portion when re-using the removed M6x22 Flat head screw.
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Gear Assembly, Rotor Section DISASSEMBLING (1) Disassemble Rotor section and Gear assembly. (Figs. 8 and 9) Fig. 8 1. By unscrewing nine 3x16 tapping screws, remove Housing R from Housing L.
2. Remove Gear assembly together with Rotor section and Speed change lever.
3. Remove Speed change lever and Rotor section from Gear assembly.
Speed change lever
3x16 Tapping screw (9 pcs.)
Gear assembly Rotor section
Housing L Gear assembly Rotor section
Housing R 4. Push Speed change lever assembly toward Rotor side until it stops to have space between the pin on the lever of Gear assembly and rear Compression spring 4. Rotor side
5. While lifting up Rotor side of Speed change lever assembly, pull it toward the direction designated with black arrow.
Drill chuck side
Drill chuck side
Rotor side rear Compression spring 4 Space between rear Compression spring 4 and the pin on the lever of Gear assembly.
Pin on the lever of Gear assembly front Compression spring 4 compressed by the lever of Gear assembly
(2) Separate Rotor from Stator. (Fig. 9) Fig. 9 Put Rotor section on a workbench so that the drive end of Rotor touches the workbench. Press Stator down to separate it from Rotor.
Rotor
Stator
Rotor
Stator
Caution for Handling of Rotor When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 10A because Rotor has 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 Rotors. (Fig. 10B) Fig. 10A Fig. 10B * Magnetic loss of Rotors * Damage on the magnet portion of Rotors
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Gear Assembly, Rotor Section (cont.) ASSEMBLING (1) Assemble Gear assembly and Rotor section in the reverse order of disassembly. (Refer to Figs. 9 and 8) Note: Be careful not to pinch your fingers between Stator and Rotor’s fan when assembling Rotor. (Fig. 11) Fig. 11 1. While holding Stator on workbench, insert Rotor into Stator slowly until the drive end of Rotor reaches the workbench.
2. When the drive end of Rotor reaches the workbench, lift up Stator slowly.
Rotor Stator
3 Before pushing Rotor section (Rotor and Stator) fully in Gear assembly, make sure that Rotor’s gear engages with the super gears of Gear assembly to rotate them smoothly.
Rotor’s gear
Rotor section
Spur gears
Gear assembly
(2) Assemble Speed change lever assembly. (Fig. 12) Fig. 12 front Compression spring 4 Pin on the lever of Gear assembly Drill chuck side
Rotor side
rear Compression spring 4 Drill chuck side
Rotor side
Space between the rear Compression spring 4 and the pin on the lever of Gear assembly.
Rotor side
1. Apply the front Compression spring 4 of Speed change lever assembly to the flat side (without pin) of Gear assembly for Speed change. 2. Push Speed change lever assembly toward Rotor side until it stops to have space between the pin of Gear assembly and the rear Compression spring 4.
The front Compression spring 4 compressed by the lever of Gear assembly.
Drill chuck side
Pin on the lever of Gear assembly fit to the coil of the rear Compression spring 4
3. Fit the pin of Gear assembly to Spring’s coil with slowly returning Speed change lever assembly toward Drill chuck side. 4. Slide Speed change lever assembly to the either position 2 (High speed mode) or 1 (Low speed mode).
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Gear Assembly, Rotor Section (cont.) ASSEMBLING Assemble Gear assembly and Rotor section to Housing L. (Fig. 13) Fig. 13 Projection of Gear assembly
Groove of Housing L 1. Make sure to put Leaf spring in place as drawn below.
Housing L
Leaf spring
2. Mount Gear assembly and Rotor section to Housing L with the projection on the groove.
3. Make sure that the ribs of Housing L are fitted tightly in the notches of Stator.
Housing L Rib Notch of Stator
Stator
Notch of Stator Rib
[3]-3. F/R change lever F/R Change lever can be assembled to Switch. (Fig. 14) Fig. 14 Before assembling Switch to Housing L, fit the prong of F/R change lever to the projection of Switch.
F/R change lever
prong portion projection
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Circuit diagram Fig. D-1 Color index of lead wires' sheath Black White Red
Yellow Orange Blue LED Light
Stator
Switch B2
Connector
Printed wiring board
B1
Terminal
Connector
Controller
Terminal
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Wiring diagram Fig. D-2
Wiring to Switch Flag connectors of Lead wires must be connected to Switch so that their wires come to Housing L side.
Switch
Flag connectors Lead wires
Housing L
Fig. D-3
Wiring of LED Lead wire Rib B
Rib C
Rib D
LED bushing
LED Lead wires must be routed around Pin. Pin
Boss Lead wire holders
Fix LED lead wires with either of two Lead wire holders.
Rib A LED Lead wires must be tightened between LED bushing and Lead wire holder when routing these wires between the following Ribs and Boss: * the space between Ribs A and C * the space between Ribs A and B * the space between Ribs A and D * the space between Rib A and Boss
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Wiring diagram Fig. D-4
Wiring in Housing L Be careful not to put Lead wires on this place. Printed wiring board Be careful not to put Lead wires on Ribs A, B and D.
Put the slack portion of Lead wires of Stator and those of Printed wiring board in this place.
Stator
Rib B Rib D Rib A Route Lead wires of Circuit board and those of Stator between Rib A and Boss.
Switch Be careful not to put Lead wires on this Boss.
Boss Fix Lead wires of Stator and those of Circuit board in the bottom of either Lead wire holders.
Be careful not to put Lead wires on these Ribs. Connecting terminals Be careful not to put Connecting terminals under or on Capacitor. Capacitor
Put one or more Lead wires of Stator into both Lead wire holders. Controller Projection of Controller
Terminal
While routing Lead wires connecting to Terminal over the projection of Controller, assemble Controller and Terminal to Housing L.
Housing L projection of Controller Terminal
Controller
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Wiring diagram Fig. D-5
Wiring and Mounting of Printed Wiring Board to Stator By fastening four screws, assemble Printed wiring board to Insulator without wobbling. Note: The screws must be tightened to 0.3N·m of torque.
Lead wires of Printed wiring board must be faced to the opposite side of Lead wires of Stator. Stator
Printed wiring board
Printed wiring board
Four Screws
Insulator
Four Screws
Lead wires of Stator
Lead wires of Printed wiring board
