Makita DDF481 Manual

CONCEPT AND MAIN APPLICATIONS
Specification
Model No. DDF481
Description 18V Cordless driver drill
Standard equipment Optional accessories
Note: The standard equipment may vary by country
or model variation.
Fast charger DC18RC
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Quad Port Charger DC18SF
Battery BL1815N
Battery BL1820
Battery BL1830
Battery BL1840
Battery BL1850
Drill bits for wood
Drill bits for steel
Driver bits
Belt clip
Bit holder
*4: Battery and charger are not supplied with “Z” model
*5: Supplied with the same quantity of extra Battery
Battery*4
Charger*4
Battery cover*5
+ – bit 2-45
Belt clip
(+) Screw M4x12
Grip assembly
Bit holder
Plastic carrying case
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 205 (8-1/8)
79 (3-1/8)
249 (9-3/4)*1
266 (10-1/2)*2
Battery
Capacity of drill chuck: mm (")
Capacity: mm (")
Max lock torque: N.m (in.lbs)
Electric brake
Variable speed control
Mechanical speed control
Reversing switch
Max fastening torque:
N.m (in.lbs)
Torque setting
Steel
Wood
Soft joint
Hard joint
No load speed: min.ˉ¹= rpm
Energy capacity: Wh
Voltage: V
Capacity: Ah
High
Weight according to
EPTA-Procedure 01/2003*3: kg (lbs)
Low
Cell Li-ion
Charging time (approx.): min.
18
Yes
Yes
Yes (2 speed)
Yes
Yes
2.4 (5.2)*1
2.6 (5.8)*2
13 (1/2)
76 (3)
21 stage + drill mode
Clutch torque setting: N.m (in.lbs) 1.0 - 10.0 (9 - 89)
125 (1,090)
60 (530)
115 (1,020)
0 - 2,100
0 - 550
1.5 (1/16) - 13 (1/2)
Max output: W 640
LED job light
*3: with Grip assembly
*1: with BL1815N or BL1820
*2: with BL1830, BL1840 or BL1850
PRODUCT
P 1/ 11
Model DDF481 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/DDF458.
Note: BL1815 is not compatible.
TECHNICAL INFORMATION
W
H
L
15, 24, 22, 36, 45 with DC18RC
1.5, 2.0, 3.0, 4.0, 5.0
27, 36, 54, 72, 90
OFFICIAL USE
for ASC & Sales Shop

Repair
[3] DISASSEMBLY/ASSEMBLY
[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.
(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)
It is not required to lubricate, because this product has gear mechanism of factory assembled.
Code No. Description Use for
1R298 Hex bar 10 with square socket removing Drill chuck
1R404 Drill chuck removing tool removing Drill chuck without disassembling Gear assembly
1R404-A Frame assembly
1R404-B Frame support
1R404-C
921477-5
Pinion gear complete the components of Drill chuck removing tool (1R404)
1R291 Retaining ring S and R pliers removing Retaining ring (INT) R-15
1R264 Torque wrench removing Drill chuck
1R359 Chuck removing tool removing Drill chuck (If it is impossible to remove Drill chuck by the steps
mentioned here)
M8x55 Hex bolt
922127-5 M4x16 Hex socket head bolt
--- Hex wrench 10 removing Drill chuck
[2] LUBRICATION
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Fig. 2
Fig. 1
Fig. 5
Fig. 3 Fig. 4
M6x22 (-) flat head screw
Drill chuck
Gear assembly
Lever portion of Gear assembly
Lever portion of
Gear assembly
1R404-C
Pin 4 (2 pcs.) of
1R404-A
1R404-A
Wide side
Narrow side
1R404-B
1R404-A
921477-5 (2 pcs.)
1R404
1R404
922127-5
(2 pcs.)
Shaft of
1R404-C
Face the flat surface to
M5x10 Thumb screw.
M5x10 Thumb screw
of 1R404-B
Fig. 6
4x18 Tapping
screw (4 pcs.)
P 2/ 11

[3] DISASSEMBLY/ASSEMBLY
[3] -1. Drill chuck (cont.)
[3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly
DISASSEMBLING
DISASSEMBLING
ASSEMBLING
Fig. 9
Fig. 10
(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.
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 1342/ Loctite 243 to the thread
and tighten the screw using Cordless impact driver with slotted bit.
(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. 11 Fig. 12
wide side
1R298
1R404
Fig. 7
Fig. 8
1R404
narrow
side
1R264
Vise
1R404-A 1R404-B
Keep 1R404-B parallel
with 1R404-A.
M5x10
Thumb
screw
Fig. 6
Lever portion of Gear assembly
921477-5 (2 pcs.)
1R404
Shaft of
1R404-C
1R404
Speed change lever assembly
Gear assemblyMotor section
4x18 Tapping
screw (9 pcs.)
Rear cover
Housing RHousing L
Stator
Rotor
Set Gear assembly
in drill mode.
Repair
P 3/ 11

Fig. 16
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear assembly, Rotor, Stator assembly,
Speed change lever assembly (cont.)
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)
Fig. 13
Fig. 14
* Magnetic loss of Rotors
* Damage on the magnet
portion of Rotor
(1) Put Rotor into Stator complete as drawn in Fig. 15.
(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.
Caution for Handling of Rotor
ASSEMBLING
Fig. 15
Rotor
Stator complete
Fig. 17
Drill chuck
side
Stator Gear
assembly
Drill chuck
side
Drill chuck
side
Pin on the lever
of Gear assembly
front Compression spring 4
1. Apply the front Compression spring 4 of Speed change lever
assembly to the flat side (without pin) of Gear assembly
for Speed change.
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.
3. Fit the pin of Gear assembly to Spring’s coil
with slowly returning Speed change lever
assembly toward 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.)
Pin on the lever of Gear assembly
for fitting into the coil of the rear
Compression spring 4.
Space between the rear Compression
spring 4 and the pin on the lever of
Gear assembly
The front Compression spring 4
compressed by the lever of
Gear assembly.
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.
Repair
P 4/ 11

[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.)
Fig. 18
Fig. 19
(4) Assemble Motor section with Gear assembly and Speed change lever assembly to Housing L at a time.
And assemble Switch and F/R change lever to Housing L. (Fig. 18) Then, assemble Housing R to Housing L.
(5) Assemble Rear cover to Housing set. (Figs. 19 and 9) and tighten nine PT3x16 Tapping screws to fasten Housing L,
Housing R and Rear cover.
Other side viewed from Housing L
Leaf spring (2 pcs.)
Speed change lever assembly
Make sure that two Leaf springs
are set in place in advance.
Depressions
Terminal of Stator must be on the center line of Motor section and Gear assembly.
Depression
in Rear cover
Protrusion on
Housing R Fit the depression in Rear cover into
the protrusion on Housing R.
Fit the protrusions of Housing L
into the depressions of Stator
complete
F/R Change lever
Before assembling Switch to Housing L,
fit the prong of F/R change lever to
the projection of Switch.
prong portion
projection
Repair
P 5/ 11

[3] DISASSEMBLY/ASSEMBLY
[3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.)
[3] -3. Grip assembly
Refer to Fig. 22 for the components of Grip assembly.
(1) Remove Retaining ring (INT) R-15 with 1R291.
(2) Remove M8x65 Hex bolt from Pole complete by turning
the bolt counterclockwise.
(3) Remove Arm R complete from Arm L.
(4) Remove Arm L from Pole complete by turning the arm
clockwise.
Note: Grip assembly for DHP481 has M5x10 Thumb screw
and M5 Hex nut, and therefore, the grip is different
from that of DDF481. Loosening the thumb screw
will cause the M5 Hex nut to be removed from Arm L.
Be careful about the loss of the M5 Hex nut when
DHP481 is disassembled.
(1) Screw Pole complete in Arm L to the full.
(2) Insert the rod of Arm complete R into the hole of Arm L. (Fig. 23)
(3) Connect the male thread of M8x65 Hex bolt with the female thread of Pole complete as drawn in Fig. 24.
(4) Set Retaining ring (INT) R-15 in place of Arm R complete.
M5 Hex nut
(for DHP481 only)
M5x10
Thumb screw
(for DHP481 only)
Arm L Arm R complete Retaining ring
(INT) R-15
Pole complete
The components of Grip assembly
M8x65 Hex bolt
Fig. 22
Fig. 23 Fig. 24
ASSEMBLING
DISASSEMBLING
Hole of Arm L Rod of Arm R complete Five to six turns of the thread of M8x65 Hex bolt must be
connected with Pole complete before DDF481/ DHP481
is setting in place.
Clamp the designated positions carefully not to leave
the clearance between Housing L and R when tightening
PT3x16 Tapping screws.
Fig. 20 Fig. 21
Note: • Be sure to route the lead wires for LED circuit to the space between ribs of Gear assembly after setting
Gear assembly in place. (Fig. 20)
If the routing is done before assembling Gear assembly, the breakage or pinching of the lead wires will happen.
• When Housing L are fastened to Housing R, the clearance is left because of the existence of Gear assembly in
Housing L and Housing R. Therefore, clamp them with a waterpump pliers carefully. (Fig. 21.)
Ribs of Gear assembly
Lead wires
for LED
circuit
Repair
P 6/ 11

Circuit diagram
Color index of lead wires' sheath
Black
White
Red Gray
Controller
Terminal
Yellow
Switch Stator complete
LED circuit
Orange
Blue
Purple
Brown
Fig. D-1
Red lead wire is used
for some country
instead of white.
P 7/ 11

Wiring diagram
Fig. D-2
Rib A
Stator
Rib B
Boss
LED circuit
A’
A
See the following illustration
for the cross section
between A and A’.
LED circuit
(Insert it
as drawn above,)
View before setting Switch and F/ R change lever in place
Front view around the lead wires for LED circuit after setting Gear assembly in place
Note:
Be sure to route the lead wires for LED circuit
to the space between ribs of Gear assembly
after setting Gear assembly in place.
If the routing is done before assembling Gear
assembly, the breakage or pinching of the lead
wires will happen.
Ribs of Gear assembly
Lead wires for LED circuit
Place Connector this space among Rib A,
Rib B and Boss.
Thick lead wires from Stator
must be put on the other thin
lead wires.
P 8/ 11

Fig. D-3
Boss A
Boss B
Controller
Capacitor of Controller
Rib of Controller
Terminal
Rib C
Rib E
Rib E
Rib D
Stator complete
The slack of Lead wire (Red) from
Terminal must not be piled on/under
Capacitor of Controller.
Do not put any lead wires
on these ribs.
Thick lead wires from Stator complete
must be put on the other thin lead wires
for the designated area .
Lead wires from Stator complete must be
routed between Boss A and Rib C.
Lead wire (Red) from Terminal must be;
• placed under Lead wires from Stator complete
• routed between Rib D and Rib E.
Lead wires from Terminal must be
placed under Rib of Controller.
Flag terminal
Switch
Lead wire
(white)
Set Flag terminal to Switch
as shown above.
Wiring diagram
P 9/ 11

Trouble shooting
Whenever you find any trouble in your machine, first, refer to this list to check the machine for solution.
(1) Use the full charged battery which has the star mark. (Fig. D-4)
(2) When Housing is disassembled, check the conditions of the electrical parts
(Connectors, Lead wires, Switches, etc.), Armature, Stator, Gear section, etc.
(3) Do the running test in Low speed mode (when the trigger is being pulled just a little)
to check the following functions by repeating 10 times;
• F/R change lever • Operation mode change ring • High/Low speed change lever
• Variable speed control trigger
Note in Repairing
Check List for Trouble Shooting
Motor runs when the machine
is switched on.
In case of running inconstantly,
go to “No”.
LED indicator lamps
are on.
LED job light are on.
The machine does not
have any trouble.
Symptom Cause Corrective action
Rotation speed can
be changed.
Forward/ Reverse
rotation are OK
Controller is broken. Replace Stator complete.
(See the next page.)
Connect it firmly.
Check Lead wires,
or replace it.
LED indicator lamps
are on.
Switch is broken.
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Controller is broken.
Rotor is broken.
Stator is broken.
Replace Stator complete.
(See the next page.)
No
Controller is broken.
Connectors are in incomplete
connection.
Lead wires are broken.
Replace Stator complete.
Check the items from the top of the following list. (Description of the item is referred to Circuit diagram in Fig. D-1.)
Change Stator complete if your problem cannot be solved although its corrective action has been carried out.
Check Terminal,
or replace it.
Replace Switch.
Replace Rotor.
Replace Stator complete.
Switch is broken. Replace Switch.
Connect it firmly.
Check Lead wires,
or replace it.
LED circuit is broken.
Connectors are in incomplete
connection.
Lead wires are broken.
Replace LED circuit.
Switch is broken. Replace Switch.
LED job light are on.
Rotor is rubbed to
Stator.
Yes
Yes
No
Connect it firmly.
Check Lead wires,
or replace it.
Connectors are in incomplete
connection.
Lead wires are broken.
Switch is broken. Replace Switch.
LED is broken. Replace LED.
Terminal is broken.
Star mark
Fig. D-4
P 10/ 11

Trouble shooting
Fig. D-5
Fig. D-7
Fig. D-6
Test for recognizing the trouble on FET (Field effect transistor) in Controller
(1) Set Digital tester (1R402) in the diode mode ( mark on the tester: Refer to Fig. D-5.)
(2) Switch, Terminal, Controller and Stator are connected each other as drawn in Fig. D-6.
Do the following steps.
Test 1: Attach Black tester bar to the terminal of white lead wire end on B1 terminal of Switch. (Fig. D-7.)
Attach Red tester bar to one of UVW terminal connected with Red, White, Blue lead wires. (Fig. D-8)
Check the figure in the tester.
Test 2: Attach Red tester bar to minus terminal of Terminal (connected with black lead wire). (Fig. D-9)
Attach Black tester bar to one of UVW terminal connected with Red, White, Blue lead wires. (Fig. D-10)
There is no fault on FET of Controller if the tester indicates within 0.39V - 0.41V in both Test 1 and Test 2.
If either Test 1 or Test 2 results in the improper figure, Controller is broken. Change Stator complete.
Red tester bar
Stator complete
Stator complete
Black tester bar
Switch
Red tester bar
Terminal
Controller (the component
of Stator complete)
Black tester bar
Fig. D-9
Fig. D-8
Fig. D-10
Terminal Switch
Stator complete
(A modular part of Controller, lead wires and Stator)
P 11/ 11