Makita 6202D User manual

Cordless Driver Drill
Battery Cartridge 9101 I9101A
Voltage
Equipped with Electric Brake
MODEL 62021)
MODEL 6202DW
With Fast Charger
MODEL 6202DWG
With Fast Charger
Model DC1201 Fast Charger
Input output Chargingtime
INSTRUCTION MANUAL
9.6 V
SPEC IF I CAT I 0 N S
~
A.C. only 50 Hz - 60 Hz
D.C. 7.2 V - 12 V
1 Hr.
Model 6202D
~___________ ~
Dimensions
IL x W x H)
Capacities No load speed 1RPMl
Steel I Wood I Wood screw 1 Machine screw 1 Hiah 1 Low
I weight Net
10 mm I 21 mm I 6.1 mm x 55 mm 1
I
1 237 mm x 57 mm x 243 mm I 1.7 kg
(318'7 113116")
1114" x 2-3/16") I ~ l'loo - 350 19-318'' x 2-114' x 9-9/16',) 13.7 lbsl
mm ,114"1

IMPORTANT
SAFETY INSTRUCTIONS
(For All Tools)
WARNING:
WHEN USING ELECTRICTOOLS, BASIC SAFETY
PRECAUTIONSSHOULD ALWAYS BE FOLLOWED TO REDUCE
THE RISK OF FIRE, ELECTRIC SHOCK, AND PERSONAL
INJURY, INCLUDING THE FOLLOWING:
READ ALL INSTRUCTIONS.
1. KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
2. CONSIDER WORK AREA ENVIRONMENT. Don't use power tools in damp
or wet locations. Keep work area well
lit. Don't expose power tools to rain.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
2
Don't use tool in presence of flammable liquids or gases.
KEEP CHILDREN AWAY. All visitors should be kept away from work area.
Don't let visitors contact tool or extension cord.
STORE IDLETOOLS. When not
in use, tools shouldbestored in dry, andhigh
or locked-up place
- out of reach of children.
DON'T FORCETOOL.
It will dothejob betterandsafer at the ratefor which
it was intended.
USE RIGHT TOOL. Don't force small tool or attachment todo thejob of a
heavy-dutytool. Don't usetoolfor purposenot intended; for example, don't
use circular saw for cutting tree limbs or logs.
DRESSPROPERLY. Don't wear looseclothingorjewelry. They can becaught
in moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering tocontain longhair.
USE SAFETY GLASSES. Also use face or dust mask if cutting operation is
dusty.
DON'T ABUSE CORD. Never carry tool by cordor yank
it todisconnect from
receptacle. Keep cord from heat, oil, and sharp edges.
SECURE WORK. Use clamps or a vise to hold work. It's safer than using
your hand and
it frees both hands to operate tool.
DON'T OVERREACH. Keep proper footing and balance
at all times.
MAINTAINTOOLS WITH CARE. Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricatingand changing acces-
sories. Inspecttoolcordsperiodicallyandifdamaged, have repairedbyautho-
rized service facility. Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean, and free from oil and grease.
DISCONNECTTOOLS. When not
in use, beforeservicing, and when chang-
ing accessories, such as blades, bits, cutters.

14. REMOVEADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keysand adjusting wrenches are removedfromtoolbeforeturning
it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry toolwithfinger onswitch.
Be sure switch is
OFF when plugging in.
16. EXTENSIONCORDS. Make sure your extension cord is in good condition.
When using an extension cord, be sure to use one heavy enough to carry
the current your product will draw. An undersized cord will cause a drop
inline voltage resulting in loss of power and overheating. Table 1 shows the
correct size touse depending oncord lengthand nameplate ampere rating.
If in doubt, use the next heavier gage. The smaller the gage number, the
heavier the cord.
TABLE 1 MINIMUM GAGE FOR CORD SETS
0- 6
6 - 10
10
- 12
12
- 16
I
Total Length of Cord in Feet
18 16 16 14
18
16
16 16 14
14 12
Not Recommended
l4 I ::
I 0 - 25 I 26 - 50 I 51 - 100 I 101 - 150
I I I I
Ampere Rating
More Not More
Than Than
AWG
17. OUTDOOR USE EXTENSIONCORDS. Whentoolisusedoutdoors, use only
extension cords intended for use outdoors and
so marked.
18. STAY ALERT. Watch what you aredoing, usecommon sense. Don't operate
tool when you are tired.
19. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other
part that is damaged should be carefully checked to determine that
it will
operate properly and perform itsintendedfunction. Check for alignment of
moving parts, bindingof moving parts, breakageof parts, mounting, andany
other conditions that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced by an authorized serv-
ice center unless otherwise indicated elsewhere
in this instructionmanual.
Have defective switches replaced by authorized service center. Don't use
tool if switch does not turn
it on and off.
20. GUARD AGAINST ELECTRICSHOCK. Prevent bodycontact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
21 . REPLACEMENTPARTS. When servicing, useonly identicalreplacementparts.
22. POLARIZEDPLUGS. To reducethe risk of electric shock, this equipment has
a polarized plug (one blade is wider than the other). This plug will fit in a
polarized outlet only one way.
If the plug does not fit fully in the outlet,
reversethe plug.
If it stilldoes not fit, contacta qualified electriciantoinstall
the proper outlet. Do not change the plug in any way.
3

VOLTAGE WARNING: Before connecting the tooltoa power source (receptacle,
outlet, etc.) be sure the voltage supplied is the same as that specified on the
nameplate of the tool.
A power source with voltage greater than that specified
for the tool can result in
SERIOUS INJURY tothe user - as well as damage to
the tool.
If in doubt, DO NOT PLUG IN THE TOOL. Using a power source with
voltage less than the nameplate rating is harmful to the motor.
4

IMPORTANT SAFETY INSTRUCTIONS
FOR CHARGER &
BATTERY CARTRIDGE
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
SAVE THESE INSTRUCTIONS - This manual
contains important safety and operating instructions for battery charger.
Before using battery charger, read all instructions and cautionary markings
on
(1) battery charger, (2) battery, and (3) product using battery.
CAUTION
- To reduce risk of injury, charge only MAKITA Battery Cartridge
9100 & 9101. Other types of batteries may burst causing personal injury
and damage.
Do not expose charger to rain or snow.
Use of an attachment not recommended or sold by the battery charger
manufacturer may result
in arisk of fire, electric shock, or injury topersons.
To reduce risk of damage toelectric plug and cord, pull by plug rather than
cord when disconnecting charger.
Make sure cord is located
so that it will not be stepped on, tripped over, or
otherwise subjected to damage or stress.
An extension cord should not be used unless absolutely necessary. Use of
improper extension cord could result in a risk of fire and electric shock.
If
extension cord must be used, make sure:
a. That pinsonplugof extension cord are thesame number, size, and shape
b. That extension cord isproperlywiredand
in goodelectrical condition; and
c. That wire size is at least as large as the one specified
in the table below.
TABLE
1
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSION CORDS
FOR BATTERY CHARGERS
as those of plug on charger;
I Length of Cord (Feet) I 25 I 50 I 100 I 150 1
Do not operate charger with damaged cord or plug - replace them im-
mediately.
Donotoperatechargerif it hasreceivedasharp blow, beendropped, or other-
wise damaged
in any way; take it to a qualified serviceman..
11. Do not disassemble charger or battery cartridge; take it to a qualified
serviceman when service or repair is required. Incorrect reassembly may
result
in a risk of electric shock or fire.
12. To reduce risk of electric shock, unplugcharger from outlet before attempt-
ingany maintenanceor cleaning.Turningoff controls
will notreducethis risk.
5

ADDITIONAL SAFETY RULES
FOR CHARGER & BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (5OOF)
2. Donotattempttousea step-uptransformer, an enginegenerator or DCpower
3. Do not allow anything to cover or clog the charger vents.
4. Always cover the batteryterminals with the battery cover when the battery
5. A battery short can cause a large current flow, overheating, possible burns
or ABOVE 4OoC (104OF).
receptacle.
cartridge is not used.
and even a breakdown.
(1) Do not touch the terminals with any conductive material.
(2) Avoid storing battery cartridge in acontainer withother metalobjects such
(3) Do not expose battery cartridge to water or rain.
ture may reach or exceed 5OoC (122OF).
completely worn out. The battery cartridge can explode
in a fire.
as nails, coins, etc.
6. Do not store the tool and Battery Cartridge in locations where the tempera-
7. Do not incinerate the Battery Cartridge even if it is severely damaged or is
ADDITIONAL SAFETY RULES
FOR CORDLESS DRIVER DRILL
1. Be aware that this tool is always in an operating condition, because it does
2. Always be sure you have a firm footing.
3. Hold the tool firmly.
4. Keep hands away from rotating parts.
5. When drilling into walls, floors or wherever "live" electrical wires may be
encountered, DO NOT TOUCH ANY METAL PARTS OF THE TOOL!
Holdthetoolonly by the insulated grasping surfacestoprevent electric shock
if you drill into a "live" wire.
not have to be plugged into an electrical outlet.
Be sure no one is below when using the tool
in high locations.
6. Do not leave the tool running. Operate the tool only when hand-held.
7. Do nottouchthe drill bit or the workpiece immediately after operation; they
may be extremely hot and could burn your skin.
SAVE THESE INSTRUCTIONS.
6

Installingor removingbattery cartridge
.Always switch offthe tool before insertion or removal or the battery cartridge.
.To remove the battery cartridge, pull out
the
set plate on the tool and grasp both
sides of the cartridge while withdrawing
it
from the tool.
.To insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip it into
place. Snap the
set plate back into place.
Be sure to close the
set plate fully before
using the tool.
Battery cartridge 1
\I
Set plate
0 Do not use force when inserting the battery cartridge.
If the cartridge does not slide in easily,
it is not being inserted correctly.
Charging
0 Your new battery cartridge is not charged.
You will need to charge
it before use. Use
the fast charger Model DC1201 to charge
the battery cartridge.
.Plug the fast charger into the proper A/C
voltage source. The charging light will
flash in green color.
.Insert the battery cartridge
so that the
plus and minus terminals on the battery
cartridge are on the same sides
as their
respective markings on the fast charger.
Charging light
Insert the cartridge fully into the port so that it rests on the charger port floor.
.When the battery cartridge
is inserted, the charging light color will change from green to
red and chargingwill begin. The charging light will remain
lit steadily during charging.
.When charging
is completed, the charging light color will change from red togreen and
a tone will sound steadily for about 5 seconds. The chargingtime is approximately one
hour.
.After charging, unplugthe charger fromthe power source.
CAUTION
:
.The fast charger Model DC1201 is for charging Makita battery cartridge. Never use it for
other purposes or for other manufacturer's batteries.
When you charge a new battery cartridge or a battery cartridge which has not been used
for a long period of time, it may not accept a full charge. This is a normal condition and
does not indicate
a problem. You can recharge the battery cartridge fully after discharg-
ing
it completely and recharging a couple of times.

If you charge a battery cartridge from a just-operated tool or a battery cartridge which
has been left in
a location exposed to direct sunlight or heat for a longtime, the charg-
ing light may flash in red color. If this occurs, wait for a while. Chargingwill begin after
the battery cartridge cools. The battery cartridge will cool faster
if you remove the
battery cartridge fromthe
fast charger.
If the charging light flashes alternately ingreen and red color and a tone sounds "beep,
beep, beep,
.. ." for about 20 seconds, a problem exists and charging is not possible.
The terminals on the charger or battery cartridge are clogged with dust or the battery
cartridge
is worn out or damaged.
If youwish to charge two battery cartridges, allow 15 minutes between chargings on the
fast charger.
Installing or removing driver bit or drill bit
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
installing or removing the bit.
To install the bit, push the
sleeve up to-
ward the "FREE" side and turn the
sleeve
counterclockwise while holding the ring
with your other hand
as illustrated at right.
Place the bit in the chuck as far as it will
go. Hold the ring firmly and turn the sleeve
clockwise to tighten the chuck. Then push
the
sleeve down toward the "LOCK" side.
See illustration.
A FREEside
-
L
\ LOCK side
\- Ring
To remove the bit, push the sleeve up toward the "FREE" side and turn the sleeve
counterclockwise while holdingthe ringwith your other hand.
CAUTION
:
0 Do not attempt to turn the sleeve forcibly when the sleeve is inthe "LOCK" position.
The sleeve may be damaged.
.Always push the
sleeve down toward the "LOCK" side before operation. Ifyou operate
the tool with the sleeve in the"FREE" position, the chuck may loosen and the bit may
come out unexpectedly.
8

Switchaction I
Tool speed is increased by increasingpres-
sure on the trigger. To start the tool, simply
pull the trigger.
Release the trigger to stop.
Switch trigger3.p '\\
CAUTION :
Before inserting the battery cartridge into the tool, always check to see that the switch
trigger actuates properly and returns tothe "OFF" position when released.
Reversing switch action
This tool has
a reversing switch to change
the direction of rotation. Slide the revers-
ing switch to the left for clockwise rota-
tion or to the right for counterclockwise.
CAUTION
:
*Always check the direction of rotationbefore operation.
.Move the reversingswitch only after the tool comes to
a complete stop. Changing the
direction of rotationbefore the tool stops may damage the tool.
Speed change
To change the speed, slide the speed change
lever to the
"H" side for high speed or
"L" side for low speed. To slide the
speed change lever easily, pull the trigger
slightly while pushing the speed change
lever. Be sure that the speed change lever
is set to the correct position before opera-
tion. Use the right speed for your job.
CAUTION :
\
-
Speed
change lever
Always set the speed change lever fully intothe correct position. If you operate the tool
with the speed change lever positioned halfways betweenthe
"H" side and "L" side, the
tool may be damaged.
9

Adjusting fasteningtorque
4.5 (1 1/64',)
4.8 13/16")
5.1 113164'1
5.5 17/32',)
The fastening torque can be adjusted in six
stages by turning the adjusting ring so that
the pointer on the adjusting ring points to
a number on the tool body. The fastening
torque
is minimumwhen the pointer points
to the number
1 and maximum when it
points to the marking. The clutch
will slip
at varying torque levels when the
pointer is set at the numbers 1 to 5. The
clutch
is designed not to slip at the *\-
marking.
2.9 - 3.2 17/64' - 118'7
3.1
- 3.4 (1/8" - 9/64")
3.3
- 3.6 (1/8" - 9/64"]
3.7
- 3.9 19/64" - 5/32',)
Before actual operation, drive a trial screw into your material or a piece of duplicate
material todetermine which torque
level is required for a particular application.
NOTE
:
The adjusting ring cannot be locked with ihe pointer positioned half-way between the
numbers.
Screwdriving operation
Place the point of the driver bit in the
screw head and apply pressure to the tool.
Start the tool slowly and then increase the
speed gradually.
Release the trigger as soon
as the clutch cuts in.
NOTE
:
0 Make sure that the driver bit is inserted straight in the screw head, or the screw and/or
bit may be damaged.
*When driving wood screws, predrill pilot
holes to make driving easier and to pre-
vent splitting of the workpiece. See the
chart.
5.8 17/32")
6.1 (15/64')
I 4.0 - 4.2 (5132'' - 11/64',)
I 4.2 - 4.4 (11/64" - 11/64")
10

Drillingoperation
First, turn the adjusting ring
so that the pointer on the adjusting ring points to the *\-
marking. Then proceed as follows.
0 Drilling inwood
When drilling in wood, best results are obtained with wood drills equippedwith
a guide
screw. The guide screw makes drilling easier by pullingthe bit into the workpiece.
0 Drilling in metal
To prevent the bitfrom slippingwhen starting a hole, makean indentation with a center-
punch and hammer
at the point to be drilled place the point of the bit inthe indenta-
tion and start drilling.
Use
a cutting lubricant when drilling metals. The exceptions are iron and brass which
should be drilled dry.
CAUTION
:
.Pressing excessively on the tool will not speed up the drilling. In fact, this excessive
pressure will only serve to damage the tip of your bit, decrease the tool performance
and shorten the service life of the tool.
.There
is a tremendous force exerted on the tool/bit at the time of hole breakthrough.
Hold the tool firmly and exert care when the bit begins to break through the workpiece.
.A stuck bit can be removed simply
by setting the reversingswitch to reverse rotation in
orderto backout. However,the tool may back out abruptly if youdo not hold
it firmly.
.Always secure small workpieces in
a vise or similar hold-downdevice.
Overload
protector
The overload protector automatically cuts out to break the circuit whenever heavy work
is prolonged. Wait 20-30 seconds before resumingoperation.
CAUTION
:
Always withdraw the tool from the workpiece before resuming operation. If the tool
cannot be withdrawn, hold the tool firmly when turning on the tool, to overcome
a
strong reaction.
Hook
A hook is provided as a standard equip-
ment. This hook is convenient for tem-
porarily hanging the tool. To install the
hook, first insert one end of the hook into
one slot in the tool body and then insert
the other end into the other slot. Secure
the hook with the screw. The hook can be
installed on either left or right side of the
tool.
11

MAINTENANCE
CAUTION:
Always be sure that the tool is switched off and the battery cartridge is removed
before attempting to perform inspection or maintenance.
To maintain product SAFETY and RELIABILITY, repairs, maintenance or adjustment
should be performed by Makita Authorized or Factory Service Centers, always using
Makita replacement parts.
12

ACCESSORIES
CAUTION:
These accessories or attachments are recommended for use with your Makita
tool specified inthis
manual. The use
of any other accessories or attachments might present a risk of injury to persons.
The accessories or attachments should
be used only in the proper and intended manner.
Bits
I Size I Part NO.
Slotted .- 1 #ffF 1 784010-0A
Square drill bit 7846 0 6 - 0 A
L=l-t=j 784011 -0A
-
Rubber pad assembly
Part No. 123001-2
Foam polishing pad
Part No. 743023-2
Wool bonnet
Part No. 743401-6
Plastic carrying case
Fast charger
Model DC1201
Part No. 113126-0
Battery cartridge 91 00
Part No. 192019-4
High capacity battery 9101
Part No. 192321-5
Power display battery (High cap.] 9101A
Part No. 192404-1
Battery cover
Part No. 414938-7
Belt clip
Part No. 343951-7
13

Sep.-08-’94 US
CORDLESS DRIVER DRILL
Model 6202D
Note: The switch and other part configurations
may differ from country to country.
14

MODEL 62020 Sep.-08-'94 US
DESCRIPTION :SD DESCRIPTION
MACHINE
__
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
1
1
7
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Housmg Set IWith Item 591
Name Plate
Pan Head Screw M4x22 WthWasher)
Tapptng
Screw BT4x20
Hand Strap
Set Plate
Switch
Lever
Switch
Lever
Pan Head Screw M5x22
Keyless Drill Chuck 10
Spindle
PI" 4
Bearing Retainer 14
Ball Bearing 6000LLB
Stop Ring E-9
Change Ring
Cam Plate
Pan Head Screw M4x12 lWith Washer)
Slider
Flat Washer 10
Thrust
Needle Gauge 1023
Washer 10
Wave Washer 10
Compression Spring
22
Compression Spring 27
Clutch Cam
Spur Gear 49
Flat Washer 6
Ball Bearing 626LLB
Plane
Bearing 4
Gear Complete
MACHINE
~
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
E01
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
Flat Washer 16
Spur Gear 15
Spur
Gear 15
Spur Gear 15
Internal
Gear 48
Flat Washer
18
DC Motor
Sponge 14-72
Sponge 14-72
Plane Bearing 4
Flat Washer 4
Compression Spring 8
Thin Washer 8
Spur
Gear 25
Ring 12
Spur
Gear 40
Thin Washer
8
Compression Spring 8
Stop
Ring E-7
Ball Bearing 608LLB
Spur Gear
8
Key 3
Countersunk Head Screw M4x12
stopper
Leaf Sprang
Lever
Housing Set IWith Item 11
Battery
Holder
Battery 9100
Radiating Plate
Pan Head Screw M3x10 IWkth Washe)
Over Current Relay
Note:
The switchand other part speclflcatnons may differ from country to country
15

Recycling the Battery
The only way to dispose of a Makita battery is
to recycle it. The law prohibitsany other
method
of disposal.
To recycle the battery:
1. Remove the battery from the tool.
2. a).
or
b) .
I Ni-Cd I
Take the battery to your nearest Makita Factory Service Center
Take the battery
to your nearest Makita Authorized Service Center or
Distributorthat has been designatedas a Makita battery recycling location.
Call your nearest Makita Service Center or Distributor to determine the location
that provides Makita battery recycling. Seeyour local Yellow Pages under
”Tools-Electric’:
Warranty Policy
Every Makita tool is thoroughly insDected and tested before leavmg the factory. It 1s warranted to
be free of defects from Horimanship and materials for the pcnod OSC YLAR from the date of
onginal purchase Should any trouble develop dunng this one-yearpcnod. return the COMPLETE
1001,
frewhl DIPD~. I<> one of Waktta’r Factury or Authorized Service Ccnterr If lnroection show
1
1
the trougle & caused by defective workmanship or material, Makita will repar (or it our option,
replace) without charge.
This Warranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
The tool has been abused, misused or improperly maintained ;
alterations have been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES FROM THE SALE
OR USE OF THE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHISWARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS
FOR A SPECIFIC PURPOSE.”
AFTER THE ONE-YEAR TERM OFTHIS WARRANTY.
This Warranty
gives you specific legal nghts, and you may also have other rights which vary from
state to state. Some states do not
allow the exclusion or limitation of incidental or consequential
damages,
so the above hmitation or exclusion may not apply to you. Some states do not allow
limitation
on how long an implied warranty lasts. so the above Limitation may not apply to you.
Makita Corporation
3-11-8, Sumiyoshi-cho,
Anjo, Aichi
446 Japan
883904 - 061
PRINTED IN JAPAN
1994 - 9 - N