Makita DS4012 Manual

CONCEPT AND MAIN APPLICATIONS

Specification

Specification Model

Power supply cord*1: m (ft)

No load speed: min.-1 = rpm

Chuck capacity: mm (")

Drill chuck type

Weight according to

EPTA-Procedure 01/2003*2: kg (lbs)

Capacities: mm (") Steel 13 (1/2)

Wood

Reverse switch Yes

36 (1-7/16)

2 - 13 (1/16 - 1/2)

DS4012

Yes

2.5 (8.2)*1

2.8 (6.2)

Variable speed control by trigger

Double insulation

Yes

Model DS4012 is a 13mm (1/2”) Drill with variable speed control and

reverse rotation, and has been developed based on the current models

DS4010 (with variable speed control, and without reverse function) and

DS4011 (without variable speed control, and with reverse function).

The performance of model DS4012 is equivalent to the current model DS4011.

Keyed

0 - 600

*1 2.0m (6.6ft) for Australia, Brazil

*2 With Top grip

Dimensions: mm (")

Width (W)

Height (H)

83 (3-1/4)

390 (15-3/8)

Length (L) 340 (13-3/8)

Output

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Max. Output (W)

110

120

220

230

240

7.2

8.5

3.6

3.5

3.3

50/60

750

N/A

750

350

550

Current (A)

PRODUCT

P 1/ 12

TECHNICAL INFORMATION

Model No.

Description

DS4012

13mm (1/2”)Drill

Standard equipment

Note: The standard equipment may vary by country or model variation.

Chuck key

Top grip

Connector plastic case (Type3) (for “J” model only)

Optional accessories

Depth gauge

Keyless drill chuck set

Keyed drill chuck set

Bits

Hole saws

Wrench 9 (for Hole saw)

Angle attachment

Wrench 17 (for Angle attachment)

OFFICIAL USE

for ASC & Sales Shop

P 2/ 12

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 assembling Ball bearing 6202LLB

1R035 Bearing setting plate 15.2 assembling Ball bearing 6202LLB

1R037

1R139

1R223

1R224

1R269

1R291

1R298

1R340

781024-2

Drill chuck extractor

Torque wrench shaft 20-90 N.m.

Ratchet head 12.7

Bearing extractor

Retaining ring S and R pliers

Hex. bar 10 with square socket

Bearing retainer wrench

Wrench 43

holding spindle when removing Drill chuck

assembling Drill chuck to Spindle

removing Ball bearing 608LLB / 626LLB

disassembling / assembling Retaining ring S-14

disassembling / assembling Bearing retainer 22-36

disassembling / assembling Drill chuck S-13

Bearing setting plate 20.2 removing Ball bearing 6202LLB

[2] LUBRICATION

Apply Makita grease FA. No.2 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 4711

Gear complete 7-41

Gear teeth

Gear teeth 5g approx.

5g approx.

P 3/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Armature

Fig. 2

DISASSEMBLING

ASSEMBLING

Water pump pliers

Armature

1R269

Ball bearing 608LLB

1. Remove Carbon brushes.

Disassemble Armature as drawn in Fig. 2.

2. Remove four 5x40 Tapping screws, and then

separate Gear housing from Motor housing.

Armature is removed with Gear housing.

3. Pull out Armature

from Gear housing.

1R269

Assemble Armature by reversing the disassembly procedure. Refer to Fig. 2.

Insulation washer

Ball bearing

608LLB

4. Remove Ball bearing 608LLB on

the drive end of Armature with 1R269.

5. Gap between the other Ball bearing 608LLB and Insulation

washer is very tight.

So, while gripping the hooks of 1R269 with a water pump

pliers, remove Ball bearing 608LLB from the commutator

end of Armature as drawn below.

Carbon brush

Armature

Insert the hooks of 1R269 into the gap between Ball bearing 608LLB

and Insulation washer, and hold the hooks with a water pump pliers.

P 4/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Drill chuck

Fig. 3

DISASSEMBLING

Remove Drill chuck as drawn in Fig. 3.

When Drill chuck is out of order, it is impossible to do the above steps. Therefore, remove Drill chuck as drawn in

Fig. 3A after removing M6x22 Flat head screw in Drill chuck.

1. Hold 1R139 in Vise, and fit the flats of

Spindle into the groove of 1R139.

2. Open the chuck fully, and then turn M6x22 Flat head

screw clockwise with Cordless impact driver.

3. Hold the short leg of Hex wrench 10 to Drill chuck. And join steel pipe to long leg of Hex wrench 10

as an extension handle. And turn Hex wrench 10 counterclockwise. Drill chuck is removed.

short leg of

Hex wrench 10

long leg of

Hex wrench 10

M6x22

Flat head screw

flats of Spindle

1R139

Steel pipe

Fig. 3A

781014-2

(1) Hold 1R139 in Vise, and fit the flats of Spindle into the groove of 1R139.

(2) Insert the pin of 781014-1 into a hole of Drill chuck and put the hook of

781014-1 on Drill chuck.

(3) Turn 781014-2 counterclockwise. Drill chuck is removed.

P 5/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Drill chuck (cont.)

Fig. 4

ASSEMBLING

Assemble Drill chuck as drawn in Fig. 4.

4. Assemble M6x22 Flat head screw to Spindle

by turning the screw counterclockwise with

Cordless impact driver.

1. Assemble Drill chuck to Spindle by hand until it stops.

Then fasten 1R298 to Drill chuck.

2.Hold 1R139 in Vise, and fit the flats of Spindle into

the groove of 1R139.

3. Preset fastening torque of 1R223 to 68.6 ~ 78.4 N·m

(700~800 kgf·cm) in advance.

Attach 1R224 to 1R223, and then connect them to 1R298,

then secure Drill chuck to Spindle by turning 1R223 clockwise.

M6x22

Flat head screw

1R298

1R139

1R139 1R223

1R224

1R298

P 6/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Spindle, Gear section

Fig. 5

DISASSEMBLING

(1) Remove Drill chuck as illustrated in Fig. 3/3A of page 4.

(2) Separate Gear housing from Motor housing, and then disassemble Gear section as drawn in Fig. 5.

4. Remove Retaining ring S-14 from Spur gear 47

with 1R291.

1. Remove four 5x40 Tapping screws, and then separate

Gear housing complete from Motor housing complete.

2. Remove Pin 3 (as a pilot pin for easy assembly

of Gear housing) to prevent the loss. And then,

remove Gasket and Fiber washer 6 from

Gear complete 7-41.

3. Hold Gear housing complete in Vise, and set 1R340 to

Bearing retainer 22-36.

And remove Bearing retainer 22-36 by turning 1R340

clockwise.

5. Remove Spindle section and Ring 15

from Gear housing complete.

Then, separate Key 5 from Spindle.

6. Remove Gear complete 7-41(with Ball bearing 626LLB) and Spur gear 47

by tapping the edge of Gear housing complete with Plastic hammer.

Pin 3

Gasket

Gear housing

Fiber washer 6

Gear complete 7-41

1R340

Bearing retainer 22-36

Spur gear 47

Spindle

Ball bearing

6202LLB

Ball bearing 626LLB

Key 5

Retaining ring S-14

1R291

Gear housing complete

Ring 15

Spur gear 47

Gear complete 7-41

5x40 Tapping screw

(4 pcs.)

Motor housing complete

P 7/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Spindle, Gear section

Fig. 6

Fig. 6A

DISASSEMBLING

(3) Ball bearing 626LLB can be removed as drawn in Fig. 6.

If Ball bearing 626LLB is left in Gear housing complete during the disassembly of gear section, remove Ball bearing

626LLB as drawn in Fig. 6A.

Remove Ball bearing 626LLB

from Gear complete 7-41

with 1R269.

1. Insert the shaft of Gear complete 7-41

into Ball bearing 626LLB again.

3. Ball bearing 626LLB

is removed together

with Gear complete.

2. Tilt the inserted Gear complete 7-41

and tap the edge of Gear housing

complete with Plastic hammer.

Fig. 7

(4) Ball bearing 6202LLB can be removed from Spindle as drawn in Fig. 7.

1R037

Ball bearing 626LLB

Ball bearing

626LLB

Ball bearing

626LLB

1R269

Gear complete 7-41

Gear

complete 7-41

Ball bearing

6202LLB

Ball bearing

6202LLB

Spindle

1. Receive Ball bearing 6202LLB on 1R037, and then press down Spindle from Ball bearing 6202LLB.

Arbor press.

Spindle

P 8/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Spindle, Gear section

Fig. 8

ASSEMBLING

Assemble Spindle and Gear section as drawn in Fig. 8.

1. Assemble Ball bearing 626LLB

to Gear housing complete.

3. Insert Ring 15 over Spindle. Then set Key 5

to the groove of Spindle.

4. Assemble the Spindle section to Gear housing complete.

2. Put Spindle on 1R035. Then, put

Ball bearing 6202LLB on Spindle.

And then, apply 1R029 to

the bearing and press 1R029

with Arbor press.

to mount the bearing to Spindle.

Ball bearing

626LLB

Ball bearing

6202LLB

1R035

1R029

Spindle

Key 5

Ring 15

1R340

5. Hold Gear housing complete in a vise. Then turn

Bearing retainer 22-36 counterclockwise with 1R340.

Bearing retainer 22-36

Key 5

Notch of

Spur gear 47

1R291 Retaining ring S-14

7. Snap Retaining ring S-14

into the groove of Spindle

with 1R291 to secure

Spur gear 47.

8. Insert Gear complete 7-41 into Ball bearing 626LLB. While keeping it

perpendicularly, tap the gear with a plastic hammer to assemble

Gear complete 7-41 to Gear housing complete.

Note: Do not forget to set Pin 3 and Fiber washer 6 in place as shown below.

Ball bearing 626LLB

Gear complete 7-41 Gear complete

7-41

Fiber washer 6

Pin 3

6. While align the notch of Spur gear 47

to Key 5, assemble Spur gear 47 to Spindle.

P 9/ 12

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Leaf spring

Fig. 9

ASSEMBLING

Assemble two Leaf springs to Handle L as drawn in Fig. 9.

Face the curve tops toward notches of

Motor housing.

Projections

Note: Be careful not to fall Leaf springs

in Handle L.

notch

Fit the projections of Leaf spring to

the notches of Handle L.

Notches of Motor housing

Handle L

P 10/ 12

Fig. D-1

Circuit diagram

White

Orange

Blue

Brown

Color index of lead wires' sheath

Circuit diagram of Inside of the Switch

Circuit for ON / OFF Circuit for Forward / Reverse control

Black

Purple

Field

Switch

Power supply cord

Line filter

(if used)

AWG18

AWG18AWG18

AWG18

AWG20

*AWG: American wire gauge

AWG18

When you connect Noise suppressor and Field

lead wires with Switch, solder the stripped wires

in advance, then clamp the soldering portions

with Splices.

Field view from

Armature fan side

Brush

holder

Brush

holder

in Forward

rotation

in Reverse

rotation

Strain relief

Splice

Noise

suppressor

(if used)

Black lead wire is used

for some countries.

White lead wire is used

for some countries.

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