Makita DDF481 User Manual

T		ECHNICAL INFORMATION
			PRODUCT
			P 1/ 11

Model No. DDF481 (XFD07*1)

Description

18V Cordless driver drill

*1 Model number for USA

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		18
			Capacity: Ah		1.5/ 2.0/ 3.0/ 4.0/ 5.0
	Battery		Energy capacity: Wh		27/ 36/ 54/ 72/ 90
			Cell		Li-ion
			Charging time (approx.): min.		15/ 24/ 22/ 36/ 45 with DC18RC
	Max output:		W		640
	No load speed: min.ˉ¹= rpm			High	0 - 2,100
				Low	0 - 550
	Capacity of drill chuck: mm (")				1.5 (1/16) - 13 (1/2)
	Capacity: mm (")			Steel	13 (1/2)
				Wood	76 (3)
	Torque setting				21 stage + drill mode
	Clutch torque setting: N.m (in.lbs)				1.0 - 10.0 (9 - 89)
	Max lock torque: N.m (in.lbs)				125 (1,090)
	Max fastening torque:			Soft joint	60 (530)
		N.m (in.lbs)		Hard joint	115 (1,020)
	Electric brake				Yes
	Mechanical speed control				Yes (2 speed)
	Variable speed control				Yes
	Reversing switch				Yes
	LED job light				Yes
	Weight according to				2.4 (5.2)*2/ 2.6 (5.8)*3
	EPTA-Procedure 01/2003*4: kg (lbs)
	*4: with Grip assembly

L

		H
	W
	Dimensions: mm (")
	Length (L)	205 (8-1/8)
	Width (W)	79 (3-1/8)
	Height (H)	249 (9-3/4)*2
		266 (10-1/2)*3

*2: with BL1815N

*3: with BL1830 or BL1840

Standard equipment
Battery ......................................................	1 or 2*5
Charger .....................................................	1*5
Battery cover ............................................	1*6
+ – 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	Battery BL1840
Charger DC18SD	Drill bits for wood
Charger DC24SC	Drill bits for steel
Automotive charger DC18SE	Driver bits
Quad Port Charger DC18SF	Belt clip
Battery BL1815N	Bit holder
Battery BL1820
Battery BL1830
Battery BL1840
Battery BL1850

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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	removing Drill chuck (If it is impossible to remove Drill chuck by the steps
			mentioned here)
	1R404	Drill chuck removing tool	removing Drill chuck without disassembling Gear assembly
	1R404-A	Frame assembly
	1R404-B	Frame support
	1R404-C	Pinion gear complete	the components of Drill chuck removing tool (1R404)
	921477-5	M8x55 Hex bolt
	922127-5	M4x16 Hex socket head bolt
	---	Hex wrench 10	removing Drill chuck

[2] LUBRICATION

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

[3] DISASSEMBLY/ASSEMBLY				Fig. 1
[3] -1. Drill chuck
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.					4x18 Tapping
(1) Remove four 4x18 Tapping screws, and then separate Gear assembly from
					screw (4 pcs.)
Housing set. (Fig. 1)
(2) Remove M6x22 (-) Flat head screw by turning it clockwise with Slotted
screwdriver.				Fig. 2
Note: Use Impact driver to unscrew M6x22 (-) Flat head screw if it cannot be
					M6x22 (-) flat head screw
removed manually. (Fig. 2)
					Drill chuck
(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)						Gear assembly
Secure Gear assembly to 1R404-A by tightening two 922127-5. (Fig. 3)						1R404-C
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)	Fig. 3				Fig. 4
Note: Face the flat surface of the shaft of	Lever portion of Gear assembly					922127-5
1R404-C to the threaded hole in
1R404-B, and pass the shaft through		Pin 4 (2 pcs.) of				(2 pcs.)
the hole of 1R404-B. (Fig. 6)
		1R404-A
Fig. 5
921477-5 (2 pcs.)
1R404-B
1R404-A		1R404	Wide side
	Narrow side				1R404	1R404-A
	Fig. 6
	Face the flat surface to
	M5x10 Thumb screw.
Lever portion of
Gear assembly	Shaft of	M5x10 Thumb screw
	1R404-C	of 1R404-B

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Repair

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

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.)

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

Fig. 7

	1R404	Set Gear assembly
		in drill mode.
		1R404

narrow side

wide side

Fig. 8

Keep 1R404-B parallel	M5x10
with 1R404-A.	Thumb
	screw
	Shaft of
1R404-A	1R404-C
	1R404-B
Lever portion of Gear assembly
921477-5	(2 pcs.)

1R264

1R298

1R404

1R404

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

Speed change lever assembly
Motor section	Gear assembly

Fig. 9

		Rear cover
	Housing L	Housing R	4x18 Tapping
			screw (9 pcs.)
		Fig. 12
		Rotor
		Stator

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.

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

Rotor

Stator complete

Fig. 16

(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

Stator Gear

assembly

Drill chuck

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.

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.

	Drill chuck	2. Push Speed change lever assembly
	side	toward Rotor side until it stops to
	The front Compression spring 4	have space between the pin of
		Gear assembly and the rear
	compressed by the lever of
		Compression spring 4.
	Gear assembly.

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

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

side

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

the next page.)