Makita 4112S Manual

Model No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
P 1 / 6
Specification
Standard equipment
Optional accessories
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
230
No load speed: min.-1= rpm
Wheel size: mm (")
Clutch
Soft start
Box wrench 17 ................................... 1 pc.
Plastic carrying case ........................... 1 pc.
Diameter
Hole diameter
11 50 / 60 2,400 1,600 3,700
Current (A)
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 648 (25-1/2)
240 (9-1/2)
273 (10-3/4)
Note: The standard equipment for the tool shown above may differ by country.
3,500
305 (12)
Yes
(SJS - Super Joint System)
Yes
25.4 (1)
Thickness 2.6 (3/32)
Protection against electric shock Double insulation
Cord length: m (ft) 2.5 (8.2)
Net weight*: kg (lbs) 10.3 (22.7)
*Without wheel and cord
Assorted diamond wheels
Assorted abrasive cut off wheels
Base set
Elbow joint 32 (for connecting to vacuum cleaner)
Plastic carrying case
Ring 20
4112S
Angle Cutter 305mm (12")
TECHNICAL INFORMATION
The above product is the low speed-high torque version
of the current Model 4112HS, having the main benefits
as follows;
"SJS - Super Joint System" that provides smooth
approach and long service life of gear section
Soft start to minimize startup shock

P 2 / 6
Repair
[2] LUBRICATION
Apply Makita grease N. No.1 to the following portions designated by black triangle to protect
parts and product from unusual abrasion.
Bearing extractor, small (No.1R269), Retaining ring S and R pliers (No.1R291), Water pump pliers (commercial one)
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Removing Base and Wheel Cover
Fig. 1
Fig. 2 Fig. 3
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the wheel from the machine for safety before repair/ maintenance !
Amount to apply
Spindle17
Lock spring 2426
The surface that contacts Spiral bevel gear 48
Outside surface
Gear housing32
1) Remove Base by unscrewing an M8x20 Wing bolt and two M6 Shoulder hex bolts. (Fig. 2)
2) Remove Pressure plate by unscrewing three M5x14 Hex bolts. (Fig. 3)
Gear room
approx. 1g
approx. 1g
approx. 40g
Pressure plate
Hex bolt M5x14
(3pcs)
Item No. Description Portion to lubricate
Fig. 4
3) By removing two M8x20 Hex bolts, the Wheel cover section can now be removed. (Fig. 4)
Note: Be careful not to lose Plate B.
Spiral bevel gear 57
Shoulder hex bolt M6 (2pcs) Base
Spring washer 8
Flat washer 8
Wing bolt M8x20
Hex bolt M8x20 (2pcs)
Plate B

P 3 / 6
Repair
Fig. 5 Fig. 6 Fig. 7
[3] -2. Disassembling/ Assembling Gear Section and SJS (Clutch) Mechanism
Retaining ring S-15
Flat washer 15
1) Remove the Gear section by unscrewing four M5x14 Hex bolts. See Fig. 5.
2) Remove Ball bearing 6000LLB using Ball bearing extractor, small (No.1R269). (Fig. 6)
3) After removing Retaining ring S-15 with Retaining ring S and R pliers (No.1R291), remove Flat washer 15. (Fig. 7)
4) See Fig. 8. Remove Spindle by pressing down from the Spiral bevel gear installation side with arbor press and Round
bar for arbor: Use a Round bar of 14mm or smaller.
Important: Be careful not to damage the Labyrinth ring 25 of Spindle in this step.
5) Remove the assembly of Spiral bevel gear 57 and Lock sleeve from Bearing box. (Fig. 9)
Fig. 8 Fig. 9
6) Lock sleeve can be separated from Spiral bevel gear 57 by pulling the gear while turning Lock sleeve clockwise with
water pump pliers or the like. (Fig. 10)
7) Lock spring 24 can be separated from Spiral bevel gear 57 by pulling the gear while turning Lock spring 24 clockwise
with water pump pliers or the like. (Fig. 11)
Important: Wrap Lock spring 24 with soft cloth or the like in order not to damage with the pliers.
Water pump pliers Water pump pliersLock sleeve
Fig. 10
Lock spring 24
Fig. 11
Soft cloth
Hex bolt M5x14 (4pcs)
Gear section
No.1R269
Ball bearing 6000LLB
No.1R291
Round bar for arbor
Spindle
Spiral bevel gear 57
Lock sleeve
Labyrinth ring 25 Bearing box
Spiral bevel gear 57Spiral bevel gear 57
DISASSEMBLING

P 4 / 6
Repair
Fig. 12 Fig. 13
[3] -2. Disassembling/ Assembling Gear Section and SJS (Clutch) Mechanism
1) When assembling Lock spring 24 to Spiral bevel gear 57, first apply Makita grease SG. No.0 to the spring.
2) Then tilt and place Lock spring 24 on Spiral bevel gear 57, and press down the portion A (the highest portion) of
the spring using arbor press. As turning the gear counterclockwise, press down the portions B, C, D sequentially.
After one turn of of the gear, the top surface of the spring will be almost flat. Lock spring 24 can now be fit on
Spiral bevel gear 57 by pressing down the entire top surface of the spring. (Fig. 12)
3) Assemble Lock sleeve to Spiral bevel gear 57 the same way as you did to install Lock spring 24. (Fig. 13)
4) Then do the reverse of the disassembling steps.
ASSEMBLING
Lock spring 24
Spiral bevel
gear 57
Arbor press
Lock sleeve
[3] -3. Replacing Armature
1) Separate Base and Wheel cover. (Refer to [3] -1.)
2) After removing Brush holder cap and Carbon brush, separate the Gear housing section from Motor housing
by unscrewing four M5x40 Hex bolts.
3) Armature can now be removed from Gear housing by tapping the end surface of Gear housing with plastic hammer.
Ball bearing 6202DDW still remains in Gear housing in this step.
4) In order to remove Ball bearing 6202DDW;
Remove Retaining ring R-40 and Flat washer 30, and insert the removed Armature lightly into the ball bearing again.
Then pull out the ball bearing with the inserted armature while swaying the commutator end of the armature. (Fig. 14)
5) When fastening the Gear housing section to Motor housing, tighten four M5x40 Hex bolts to the recommended
torque of 7.4 - 15Nm.
Fig. 14
Flat washer 30
Retaining ring R-40
Ball bearing 6202DDW
Ball bearing
6202DDW

P 5 / 6
Circuit diagram
Wiring diagram
Color index of lead wires
Black
White
Orange
Purple
Route the following lead
wires through the hook:
* Field lead wire (black)
* Field lead wire (orange)
Route the following lead
wires through the hook:
* Field lead wire (black)
* Field lead wire (purple)
* Connecting lead wire
(orange) from Brush holder
[1] Wiring in Motor Housing
Insulated receptacle
Soft start
circuit
Noise
suppressor Insulated
connector
Insulated
connector
Switch
Field
Brush holder
(left) Brush holder
(right)
Line filter
Brush holder
(left)
Brush holder
(right)
Power supply cord
red or orange
Field lead wire (purple)
Field lead wire (orange)
Field lead wire (black)
Connecting lead wire (purple)
from Brush holder
Connecting lead wire (orange)
from Brush holder
Hook
Hook

P 6 / 6
Wiring diagram
[2] Wiring in Handle
Be sure to connect so that all slits
of the four Insulated receptacles
face the same direction as illustrated
below.
Insulated receptacle
(viewed from the wheel installation side)
Terminal of Switch
Terminal
Slit in Terminal
Insulator
Switch Insulated receptacle
Connecting Insulated Receptacles
with Terminals of Switch
Fix the following lead wires
with this lead wire holder:
*2 Field lead wires (black)
*Lead wire of Soft start circuit (white)
*Lead wire of Soft start circuit (orange or red)
Rib
Be careful not to route
the lead wires of Power
supply cord over this rib.
If Line filter is used,
route two Field lead
wires (black) through it,
and put in this space.
Fix the following lead wires with this lead
wire holder, and put in this space:
*2 Field lead wires (purple, orange)
*2 Connecting lead wires (purple, orange)
from Brush holder
Put Soft start circuit
in this space.
Put Noise suppressor
in this space if used.
Switch
[Correct] [Wrong]