Makita 6203DWAE User manual

Y
Cordless Driver Drill
Capacities
Steel Wood Wood screw Machine screw
____
10 mm 25 mm , 6.4 mm x 76 mm ,llm 1,,4,,1
1318'7 11") 1114" x 3")
Equipped with Electric Brake
MODEL 6203DWAE
Dimensions Net
(L x W x HI
No load speed 1RPMI
weight
,,200 ~ 4oo 233 mm x 77 mm x 241 mm 1.7 kg
(3 8 lbsl
High Low
19-118''
x 3" x 9~1/2")
With Fast Charger
Battery Cartridge 9122
Voltage
96V
INSTRUCTION MANUAL
Model DC1410 Fast Charger
Input Output Charging time
__
A C onlv 50 H2 60 H2 DC 72V ~ 14.4V 1 Hr
S PEC I FICAT1 0 N S
Model 6203DA
* Manufacturer reserves the right to change specifications without notice.
* Note: Specifications may differ from country to country.
WARNING: For your personal safety, READ and UNDERSTAND before using
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

GENERAL SAFETY RULES
(For All Battery Operated Tools)
WARNING! Read and understand all instructions. Failure
tofollow all instructions listed below, may result
in electric
shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
Work Area
*Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do notoperate power tools inexplosive atmospheres, such as inthe presence
of flammable liquids, gases, or dust. Powertools create sparks which may ignite
the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause
you to loose control.
Electrical Safety
Do not abuse the cord. Never use the cord to carry the tool. Keep cord away
from heat, oil, sharp edges, or movingparts. Replacedamaged cords immedi-
ately. Damaged cords may create a fire.
A battery operated tool with integralbatteriesor a separate battery pack must
be recharged only with the specified charger for the battery.
A charger that
may be suitable for one type of battery may create a risk of fire when used with
another battery.
Use battery operated toolonly with specifically designated battery pack. Use
of any other batteries may create a risk of fire.
Personal Safety
*Stay alert, watch whatyou are doing, and use commonsense when operating
a power tool.
Do notusetoolwhile tired or underthe influenceof drugs, alcohol,
or medication.
A momentof inattention while operating power tools may result
in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Containlong hair. Keep
your hair, clothing, and gloves away from movingparts. Loose clothes, jewelry,
or long hair can be caught
in moving parts.
*Avoid accidental starting. Be sure switchis
in the locked or off position before
inserting battery pack. Carryingtools withyour finger on
the switch or inserting
the battery pack into a tool
with the switch on invites accidents.
Remove adjusting keys or switches before turning the tool on. A wrench or
a key that is left attachedtoa rotatingpart of the tool may result
in personal injury.
Do notoverreach. Keep proper footing and balance at all times. Proper footing
and balance enable better control of the tool in unexpected situations.

Use safety equipment.Always wear eye protection.Dust mask, non-skid safety
shoes, hard hat, or hearing protectionmust be usedfor appropriate conditions.
Tool Use and Care
Use clamps or other practical way to secure and support the workpiece to a
stable platform. Holdingthe work by handor against your body is unstableand
may lead to
loss of control.
Do not force tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which
it is designed.
*Do not use tool if switch does not turn
it on or off. A tool that cannot be
controlled
with the switch is dangerous and must be repaired.
Disconnect battery pack from tool or place the switch in the locked or off
position before making any adjustments, changingaccessories, or storing the
tool. Such preventive safety measures reduce the risk of starting the tool
acciden
t a I I y.
Store idle tools out of reach of childrenand other untrainedpersons. Tools are
dangerous in the hands of untrained users.
When battery pack is not in use, keep it away from other metal objects like:
paper clips, coins, keys, nails, screws, or other small metal objects that can
makea connectionfrom one terminalto another. Shortingthe batteryterminals
together may cause sparks, burns, or a fire.
Maintaintools with care. Keepcuttingtools sharp and clean. Properly maintained
tools
with sharp cutting edge are less likely to bind and are easier to control.
Check for misalignment or bindingof moving parts, breakage of parts, and any
other conditionthat may affect the tool’s operation. Ifdamaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
Use only accessories that are recommended by the manufacturer for your
model. Accessories that maybe suitable for one tool maycreate a risk of injury
when used on another tool.
Service
*Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel may result
in a risk of injury.
Whenservicing a tool, use only identical replacement parts. Followinstructions
in the Maintenancesectionof this manual. Use of unauthorized parts or failure
to follow Maintenance Instructionsmay create a risk of shock of injury.
3

Specific Safety Rules
1. Holdtool by insulatedgrippingsurfaces when performinganoperation where
the cutting tool may contact hidden wiring. Contact
with a "live" wire will
also make exposed metal parts of the tool "live" and shock the operator.
2. Be aware that this tool is always in an operating condition, because it does
not have to be plugged into an electrical outlet.
3. Always be sure you have a firm footing.
Be sure no one is below when using the tool
in high locations.
4. Hold the tool firmly.
5. Keep hands away from rotating parts.
6. Do not leave the tool running. Operate the tool only when hand-held.
7. Do not touch the drill bit or the workpiece immediatelyafter operation; they
may be extremely hot and could burn your skin.
4

SYMBOLS
The followings show the symbols used for tool.
?.J
n
A
Ab
.../ min
........... volts
................................. amperes
................................. hens
................................. seconds
................................. alternating current
................................. direct current
................................. no load speed
................................. alternating or direct current
................................. Class II Construction
................................. splash-proof construction
................................. watertight construction
................................ revolutions or reciprocation per minute
@ ................................. number of blow
5

IMPORTANT SAFETY INSTRUCTIONS
FOR CHARGER &
BATTERY CARTRIDGE
I. SAVE THESE INSTRUCTIONS - This manual
Length of Cord (Feet)
25
AWG Size of Cord 18
50 100
150
18 18
16
6

ADDITIONAL SAFETY RULES
FOR CHARGER
& BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (5OOF)
2. Do notattempt touse a step-uptransformer, anengine generator or DCpower
3. Do not allow anything to cover or clog the charger vents.
4. Always cover the battery terminals 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) Avoidstoringbatterycartridge in a containerwithother 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
SAVE THESE INSTRUCTIONS.
7

Installing or removingbattery cartridge
*Always switchoff the tool before insertion
or removalof the battery cartridge.
*To remove the battery cartridge, withdraw
it from the tool while pressing the buttons
on both sides of the cartridge.
*To insert the battery cartridge, align the
tongue on the battery cartridge with the
groove inthe housingand slip it into place.
Always insert it all the way until it locks in
place with a little click. If not, it may acci-
dentally fall out of the tool, causing injury
to you or someone aroundyou.
Button
Battery cartridge
*Do not use force when inserting the battery cartridge. If the cartridge does not slide in
easily, it is not being inserted correctly
Charging
*Your newbattery cartridge is not charged.
You will need to charge it before use. Use
the fast charger Model DC1410 to charge
the batterycartridge.
*Plug the fast charger into the proper A.C.
voltage source.The charginglight will flash
in green color.
*Insert the battery cartridge
so that the plus
and minus terminals on the battery car-
tridge are on the same sides as their
respective markings on the fast charger.
Insert the cartridge fully intothe port
so that it restson the chargerport floor.
redand chargingwill begin.The charginglight will remain lit steadily during charging.
chargingtime is approximatelyone hour.
*When the battery cartridge is inserted, the charginglight color will changefrom green to
*When charging
is completed, the charging light color will change from red to green. The
*After charging, unplugthe chargerfrom the power source.
CAUTION:
*The fast charger Model DC1410 is for charging Makita battery cartridge. Never use it for
other purposesor for other manufacturer’s batteries.
*When you chargea newbatterycartridge 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 indicatea problem. You can rechargethe battery cartridgefully after discharging
it completely and recharging
a coupleof times.
8

*If you charge a battery cartridgefrom a just-operatedtool or a battery cartridgewhich has
been left in
a locationexposedto direct sunlight or heatfor a longtime, the charginglight
may flash in redcolor. If this occurs,wait for
a while. Charging will beginafter the battery
cartridge cools. The battery cartridge will cool faster if you remove the battery cartridge
from the fast charger.
*If the charginglight flashes alternately in green and redcolor
a problemexists and charg-
ing 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 you wish to chargetwo battery cartridge, allow 15 mimutes between charging on the
fast charger.
ASSEMBLY
Installingor removingdriver bitor drillbit
CAUTl ON :
Always be sure that the tool is switched off and the battery cartridge is removed before
installingor removing the bit
Hold the ring and turn the sleeve counter-
clockwise to open the chuck jaws. Place
the bit in the chuck as far as it will go. Hold
the ring firmly and turn the sleeve clock-
wise
to tighten thechuck.
To remove the bit, hold the ring and turn
the sleevecounterclockwise.
When not usingthe driver bit, keep it in the
bit holders.Bits 45 mm (1-3/4") longcan be
kept there.
Tighten
Slee
Ring
:ve
-
Bit -
I Bit holder 2
9

OPERATION
Switchaction
CAUTION:
Before inserting the battery cartridge into the tool, always check to see that the switch
trigger actuates properly and returnstothe
"OFF" positionwhen released
To start the tool, simply pull the trigger.
Tool speed is increased by increasing pres-
sure on the trigger. Release the trigger to
stop.
77-
Switch trigger
Reversingswitch action
CAUTION:
*Always check thedirection of rotation beforeoperation
*Use the reversing switch only after the tool comes to
a complete stop. Changing the
direction of rotationbeforethetool stops maydamage the
tool
This tool has a reversing switch to change
the direction of rotation. Depress the
reversing switch lever from the A side for
clockwise rotation
or from the B side for
counterclockwiserotation.When the switch
lever is in the neutral position, the switch
trigger cannot bepulled.
Speedchange
To change the speed, first switch off the
tool and then slide the speed change lever
to the
"11" side for high speed or "1" side
for low speed. Be sure that the speed
change lever is set to the correct position
before operation. Use the right speed for
your
job.
Reversing switch lever -
Clockwise Counterclockwise
Low speed
0
High speed
a
Speed change lever
10

CAUTION:
*Always set the speed change lever fully to the correct position. If you operate the tool
with the speed change lever positioned half-waybetweenthe
"I" side and "11" side, the
tool may be damaged.
*Do not usethe speed change leverwhile the tool is running.The tool may be damaged.
Adjustingthefasteningtorque
The fastening torque can be adjusted in 18
steps by turning the adjusting ring so that
its graduationsare alignedwith the pointer
on the tool body. The fastening torque is
minimum when the number
1 is aligned
with the pointer, and maximum when the
8 marking is alignedwith the pointer.
The clutch will slip
at various torque levels
when set at the number
1 to 5. The clutch
is designed not to slip at the
8 marking.
Before actual operation, drive
a trial screw
into your material or
a piece of duplicate
materialto determinewhich torque level is requiredfor
a particular application.
NOTE:
*The adjusting ring does not lock when the pointer is positioned only half-way between
*Do not operate the tool with the adjusting ring set between the number 5 and the 8
the graduations.
marking.The
tool may bedamaged.
Screwdrivingoperation
Place the point of the driver bit in the
screw head and apply pressure to the tool.
Start the tool
slowly and then increasethe
speed gradually. Release the trigger as
soonas the clutch cuts in.
11

NOTE:
*Make sure that the driver bit is inserted straight in the screw head, or the screw and/or
bit may be damaged.
Nominal diameter of
wood screw lmm)
*When driving wood screws, predrill pilot
holes to make driving easier and to pre-
vent splitting of the workpiece. See the
chart.
Recommended size
of pilot hole Imm)
3 5 19/64")
3.8 15/32")
I 2 2 - 2 5 13/32" - 3/32")
1 2 5 - 2.8 (3132'' - 7/64',)
*If the tool is operated continuously until the battery cartridge has discharged,allow the
tool to rest for
15 minutes before proceedingwith a fresh battery.
Drillingoperation
First, turn the adjusting ring so that the pointer on the tool body points to the fi marking.
Then proceedas follows.
*Drilling inwood
When drilling in wood, best results are obtained with wood drills equipped with a guide
screw.The guide screw makes drilling easier by pullingthe bit into theworkpiece.
To prevent the bit from slippingwhen starting a hole, make an indentation with
a center-
punch and hammer at the point to be drilled. Placethe point of the bit inthe indentation
and start drilling.
Use a cutting lubricant when drilling metals. The exceptions are iron and brass which
shouldbe drilled dry.
*Drilling in metal
CAUTION:
*Pressing excessivelyon the tool will not speed up the drilling. Infact, this excessive pres-
sure 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 thetime of holebreakthrough.Hold
the tool firmly and exert care when the bit beginsto breakthrough theworkpiece.
*A stuck bit can be removedsimply by setting the reversing switch to reverse rotation in
order to back out. However,the tool may back out abruptly
if you do not hold it firmly.
*Always securesmallworkpieces in
a vise or similar holddowndevice.
*If the tool is operated continuously until the battery cartridge has discharged, allow the
tool to rest for
15 minutes before proceedingwith afresh battery.
12

MAINTENANCE
CAUTION:
Always be sure that the tool is switched off and the battery cartridge is removed before
attempting to perform inspection or maintenance
Replacingcarbon brushes
Remove and check the carbon brushes
regularly.Replacewhen they wear downto
the limit mark. Keep the carbon brushes
clean and free to slip in the holders. Both
carbon brushes should be replaced at
the same time. Use only identical carbon
brushes.
Use
a screwdriver to remove the brush
holder caps. Take out the worn carbon
brushes, insert the new ones and secure
the brushholdercaps.
L Limit mark
Brush holder cap
Screwdriver
To maintainproduct SAFETY and RELIABILITY, repairs, maintenanceor adjustment should
be performed by Makita Authorized or Factory Service Centers, always using Makita
replacementparts.
13

ACCESSORIES
784206-5
784207-3
CAUTION:
These accessories or attachments are recommended for use with your Makita tool specified in this
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 Drill bits
Tested best inMakita driver-drills for smoothfast drill-
ing and more holes per battery change. High speed
steel. For drilling inmetal, wood and plastic. Jobbers
length. Special surface treatment for lubricity gives
smoother drilling.
Size Part
No.
Phillips
No. 2 711000-A-A 6 pc. set: 1/16", 118". 3/16", 114".
5/16", 318'' Best selling bits in
110(4-3/8")
150(5-7/8") convenient
case.
-
Square drill bit 784606-0A 711011-A 1/16" 1/16"
- 711012-A 3/32" 3/32"
Part No. Size L (mm)
784203-1 65 (2-5/8")
Flute
length
718"
1-114"
1-518"
2"
2-5/16"
2-112"
2-314"
2-5/16"
3-311
6"
3-7/16"
3-518''
Overall
length
1-718''
2-114"
2-314"
3-118"
3-112"
3-314"
4/"
4-114"
4-112"
4-314"
5"
Rubber pad assembly Wool bonnet Battery cover
Part No. 123001-2 Part No. 743401-6 Part No. 414938-7
Foam polishing pad
Part No. 743023-2
Fast charger
Model DC1410
Part No. 113150-3
@ C'
Double-ended Phillips I
Battery cartridge 91 22
Slotted bit Part No. 192596-6
1-3/4" long
Part
No. 784637-8
Plastic carrying case
14

July-O9-'96 US
CORDLESS DRIVER DRILL
Model 6203DWA
Note: The switch and other part configurations
may differ from country to country.
15

MODEL 6203DWA
';,'OM :&, DESCRIPTION
14
15
16
17
18
19
20
21
22
23
24
25
26
July-19-'96 US
';;M $FD DESCRIPTION
1
1
1
1
1
1
1
1
4
3
2
2
1
10
11
12
13
Name Plate
Tapping Screw Bind PT 3x16
Bit Holder
Housing Set IWith Item
211
Change Lever
CompressionSpring 4
CompressionSpring 4
FIR Change Lever
Switch
Holder
Spring Terminal
I + 1
Spring Terminal I ~ I
Pan Head Screw M3x8
11
29
32
41
51
61
71
81
91
1
1
1
1
DC Motor
GEAR ASSEMBLY
Sleeve 10
Keyless Drill Chuck 10
Hex. Socket Head Bolt M5x21
Leaf Spring
Makita Label
Housing Set lWilh Item 41
Pan Head Screw M3x12
Tapping Screw ST 4x8
Brush Holder Cap
Carbon Brush
High Capacity Battery
9122
Note: The switch and other part specifications may differ from country to country.
16

Recycling the Battery
The only way to dispose of a Makita battery is
to recycle it. The law prohibits any other
method
of disposal.
I Ni-Cd
To recycle the battery:
1. Remove the battery from the tool.
2. a). Take the battery to your nearest Makita Factory Service Center
or
b). Take the battery to your nearest Makita Authorized Service Center or
Distributor that has been designated
as a Makita battery recycling location.
0 Call your nearest Makita Service Center or Distributor to determine the location
that provides Makita battery recycling. See your local Yellow Pages under
”Tools-Electric’
MAKITA LIMITED ONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to
be free of defects from workmanship and materials for the period of ONE YEAR from the date of
original purchase. Should any trouble develop during this one-year period, return the COMPLETE
tool, freight prepaid, to one of Makita’s Factory or Authorized Service Centers. If inspection shows
the trouble
is caused by defective workmanship or material, Makita will repair (or at our option,
replace) without charge.
This Warranty does not apply where:
repairs have been made or attempted by others:
0 repairs are required because of normal wear and tear:
e The tool has been abused, misused or improperly maintained;
0 alterationshave 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 OFTHE PRODUCT. THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERM OFTHISWARRANTY.
This Warranty gives you specific legal rights, 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 limitation or exclusion may not apply to you. Some states do not allow
limitation onhow long an implied warranty lasts,
so the above limitation may not apply to you.
i
Makita Corporation of America
2650 Gainesville Hwy., Buford, GA 30518
884077 - 063
PRINTED IN USA