Makita DDF481 User Manual

Model No.

Description

ECHNICAL INFORMATION

DDF481 (XFD07*1)

18V Cordless driver drill

*1 Model number for USA

PRODUCT

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CONCEPT AND MAIN APPLICATIONS

Model DDF481 (XFD07*1) is a supreme class cordless driver drill powered by 18V Li-ion battery of BL1815N (1.5Ah)/ BL1820 (2.0Ah)/ BL1830 (3.0Ah)/ BL1840 (4.0Ah)/ BL1850 (5.0Ah) . Its main features are:

• Max lock torque: 125N.m. (1,090in.lbs)

• Compact tool size with an overall length of 205mm (8-1/8")

• Efficient Brushless DC motor provides higher power and productivity than that of 18V Cordless driver drill model BDF458.

Note: BL1815 is not compatible.

Specification

Voltage: V

Capacity: Ah

Battery

Max output: W 640

No load speed: min.

Capacity of drill chuck: mm (")

Capacity: mm (")

Torque setting Clutch torque setting: N.m (in.lbs) 1.0 - 10.0 (9 - 89) Max lock torque: N.m (in.lbs)

Max fastening torque:

Electric brake Mechanical speed control Variable speed control Reversing switch LED job light

Weight according to EPTA-Procedure 01/2003*

: with Grip assembly

Energy capacity: Wh Cell Li-ion

Charging time (approx.): min.

High Low

Steel Wood

Soft joint Hard joint

N.m (in.lbs)

ˉ¹= rpm

: kg (lbs)

1.5/ 2.0/ 3.0/ 4.0/ 5.0 27/ 36/ 54/ 72/ 90

15/ 24/ 22/ 36/ 45 with DC18RC

0 - 2,100

0 - 550

1.5 (1/16) - 13 (1/2) 13 (1/2)

21 stage + drill mode

125 (1,090)

60 (530)

115 (1,020)

Yes (2 speed)

2.4 (5.2)*

76 (3)

Yes

Yes Yes Yes

/ 2.6 (5.8)*

Dimensions: mm (")

Length (L) 205 (8-1/8) Width (W)

Height (H)

: with BL1815N

* *3: with BL1830 or BL1840

79 (3-1/8)

249 (9-3/4)*

266 (10-1/2)*3

Standard equipment

Battery ...................................................... 1 or 2*

Charger ..................................................... 1*5

Battery cover ............................................ 1*

+ – bit 2-45 ............................................... 2

Belt clip .................................................... 1

(+) Screw M4x12 ..................................... 1

Grip assembly .......................................... 1

Bit holder ................................................. 1

Plastic carrying case ................................. 1

*5: Battery and charger are not supplied with “Z” model *6: Supplied with the same quantity of extra Battery

Note: The standard equipment for the tool shown above

may vary by country.

Optional accessories

Fast charger DC18RC Charger DC18SD Charger DC24SC Automotive charger DC18SE Quad Port Charger DC18SF Battery BL1815N Battery BL1820 Battery BL1830 Battery BL1840 Battery BL1850

Battery BL1840 Drill bits for wood Drill bits for steel Driver bits Belt clip Bit holder

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Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

Code No. Description Use for

1R264 Torque wrench removing Drill chuck 1R291 Retaining ring S and R pliers removing Retaining ring (INT) R-15 1R298 Hex bar 10 with square socket removing Drill chuck

1R359 Chuck removing tool

1R404 Drill chuck removing tool removing Drill chuck without disassembling Gear assembly

1R404-A Frame assembly 1R404-B Frame support

1R404-C

921477-5 922127-5 M4x16 Hex socket head bolt

Pinion gear complete M8x55 Hex bolt

---

Hex wrench 10

[2] LUBRICATION

It is not required to lubricate, because this product has gear mechanism of factory assembled.

[3] DISASSEMBLY/ASSEMBLY [3] -1. Drill chuck

removing Drill chuck (If it is impossible to remove Drill chuck by the steps

mentioned here)

the components of Drill chuck removing tool (1R404)

removing Drill chuck

Fig. 1

DISASSEMBLING

Note: When Gear assembly is replaced with a new one, separate Drill chuck from Gear assembly in advance. When the repair is independent of Gear assembly, it is not necessary to separate Drill chuck from Gear assembly. (1) Remove four 4x18 Tapping screws, and then separate Gear assembly from Housing set. (Fig. 1) (2) Remove M6x22 (-) Flat head screw by turning it clockwise with Slotted screwdriver. Note: Use Impact driver to unscrew M6x22 (-) Flat head screw if it cannot be

removed manually. (Fig. 2) (3) Engage 1R404-C with Gear teeth in Gear assembly. (Fig. 2) (4) Fit two Pins 4 of 1R404-A into the holes of Gear assembly. (Fig. 3) Secure Gear assembly to 1R404-A by tightening two 922127-5. (Fig. 3) Be careful about each direction. (Figs. 3 and 4 (5) Assemble 1R404-B to 1R404-A so that the lever portion of Gear assembly can be pushed toward 1st gear position. (Fig. 5) Note: Face the flat surface of the shaft of

1R404-C to the threaded hole in 1R404-B, and pass the shaft through the hole of 1R404-B. (Fig. 6)

Fig. 5

921477-5 (2 pcs.)

1R404-B

1R404-A

)

Fig. 3

Lever portion of Gear assembly

Pin 4 (2 pcs.) of 1R404-A

1R404

Narrow side

Fig. 6

Wide side

4x18 Tapping screw (4 pcs.)

Fig. 2

M6x22 (-) flat head screw

Drill chuck

Gear assembly

1R404-C

Fig. 4

922127-5 (2 pcs.)

1R404

1R404-A

Lever portion of Gear assembly

Face the flat surface to M5x10 Thumb screw.

Shaft of 1R404-C

M5x10 Thumb screw of 1R404-B

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -1. Drill chuck (cont.)

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DISASSEMBLING

(6) Set the lever portion of Gear assembly to 1st gear position. (Fig. 6) Set Gear assembly in drill mode. (Refer to Fig. 7.)

Fig. 7

1R404

Set Gear assembly in drill mode.

Tighten two 921477-5 evenly while keeping 1R404-B parallel with 1R404-A, and then tighten M5x10 Thumb screw of 1R404-B. (Fig. 6) (8) Hold 1R404 in Vise as drawn in Fig. 7. Secure 1R298 to Drill chuck and attach 1R264 to 1R298. (Fig. 8) (9) Turn 1R264 counterclockwise to remove Drill chuck. (Fig. 8) Note: When it is impossible to remove Drill chuck, try the steps with 1R359 mentioned in Makita repair tool list.

Fig. 6

Keep 1R404-B parallel with 1R404-A.

M5x10 Thumb screw

Shaft of 1R404-C

1R404-A

1R404-B

narrow side

Fig. 8

1R404

wide side

1R264

1R298

1R404

Lever portion of Gear assembly

921477-5 (2 pcs.)

Vise

ASSEMBLING

Assemble by reversing the disassembly procedure. Note: • When you turn 1R264 clockwise to assemble Drill chuck to Spindle, the tightening torque should be 65 up to 72.5 N∙m (660 up to 740 kgf∙cm).

• M6x22 (-) flat head screw is thread locker type, and therefore, apply ThreeBond 1342H/ Loctite 243 to the thread and tighten the screw using Cordless impact driver with slotted bit.

[3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly

DISASSEMBLING

(1) Remove nine Bind PT3x14 tapping screws and four 4x18 Tapping screw, and then separate Rear cover and Housing R from Housing L. (Fig. 1 of the previous page and Fig. 9) (2) Remove the following parts from Housing L at a time. (Fig. 10)

• Gear assembly with Drill chuck

• Motor section

• Speed change lever assembly (3) Remove Speed change lever assembly from Gear assembly, and then separate Motor section from Gear assembly. (Fig. 11) (4) Put Rotor section on a workbench so that the drive end of Rotor touches the workbench. Press Stator down to separate from Rotor. (Fig. 12)

Fig. 10

Fig. 11 Fig. 12

Speed change lever assembly

Gear assemblyMotor section

Fig. 9

Rear cover

Housing RHousing L

Rotor

Stator

4x18 Tapping screw (9 pcs.)

Repair

[3] DISASSEMBLY/ASSEMBLY [3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.)

Caution for Handling of Rotor

When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 13 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. 14)

ASSEMBLING

(1) Put Rotor into Stator complete as drawn in Fig. 15.

Fig. 15

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Fig. 13

Fig. 14

* Magnetic loss of Rotors * Damage on the magnet

portion of Rotor

1. Holding Stator complete on a workbench, insert Rotor slowly in Stator complete until Rotor’s drive end reaches the workbench.

Rotor

Stator complete

(2) Make sure that Rotor’s gear engages with the super gears of Gear assembly to rotate them smoothly, and push Rotor section (Rotor and Stator) fully in Gear assembly, (Fig. 16) (3) Assemble Speed change lever assembly as drawn in Fig. 17.

Fig. 17

Pin on the lever of Gear assembly

front Compression spring 4

2. When the drive end of Rotor reaches the workbench, lift up Stator complete slowly.

Fig. 16

Stator

Space between the rear Compression spring 4 and the pin on the lever of Gear assembly

Pin on the lever of Gear assembly for fitting into the coil of the rear Compression spring 4.

Gear assembly

Drill chuck side

The front Compression spring 4 compressed by the lever of Gear assembly.

1. Apply the front Compression spring 4 of Speed change lever assembly to the flat side (without pin) of Gear assembly for Speed change.

Drill chuck side

3. Fit the pin of Gear assembly to Spring’s coil

Drill chuck side

4. Slide Speed change lever assembly to High speed mode: (Position 2 shown on Housing: Refer to Fig. 20 in the next page.)

with slowly returning Speed change lever assembly toward Drill chuck side.

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.

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