Makita DS4012 Manual

CONCEPT AND MAIN APPLICATIONS
Specification
Specification Model
Power supply cord*1: m (ft)
No load speed: min.-1 = rpm
Chuck capacity: mm (")
Drill chuck type
Weight according to
EPTA-Procedure 01/2003*2: kg (lbs)
Capacities: mm (") Steel 13 (1/2)
Wood
Reverse switch Yes
36 (1-7/16)
2 - 13 (1/16 - 1/2)
DS4012
Yes
2.5 (8.2)*1
2.8 (6.2)
Variable speed control by trigger
Double insulation
Yes
Model DS4012 is a 13mm (1/2”) Drill with variable speed control and
reverse rotation, and has been developed based on the current models
DS4010 (with variable speed control, and without reverse function) and
DS4011 (without variable speed control, and with reverse function).
The performance of model DS4012 is equivalent to the current model DS4011.
Keyed
0 - 600
*1 2.0m (6.6ft) for Australia, Brazil
*2 With Top grip
Dimensions: mm (")
Width (W)
Height (H)
83 (3-1/4)
390 (15-3/8)
Length (L) 340 (13-3/8)
Output
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Max. Output (W)
110
120
220
230
240
7.2
8.5
3.6
3.5
3.3
50/60
50/60
50/60
50/60
50/60
750
N/A
750
750
750
350
350
350
350
350
550
550
550
550
550
Current (A)
PRODUCT
P 1/ 12
TECHNICAL INFORMATION
Model No.
Description
DS4012
13mm (1/2”)Drill
Standard equipment
Note: The standard equipment may vary by country or model variation.
Chuck key
Top grip
Connector plastic case (Type3) (for “J” model only)
Optional accessories
Depth gauge
Keyless drill chuck set
Keyed drill chuck set
Bits
Hole saws
Wrench 9 (for Hole saw)
Angle attachment
Wrench 17 (for Angle attachment)
W
L
H
OFFICIAL USE
for ASC & Sales Shop

P 2/ 12
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R029 Bearing setting pipe 23-15.2 assembling Ball bearing 6202LLB
1R035 Bearing setting plate 15.2 assembling Ball bearing 6202LLB
1R037
1R139
1R223
1R224
1R269
1R291
1R298
1R340
781024-2
Drill chuck extractor
Torque wrench shaft 20-90 N.m.
Ratchet head 12.7
Bearing extractor
Retaining ring S and R pliers
Hex. bar 10 with square socket
Bearing retainer wrench
Wrench 43
holding spindle when removing Drill chuck
assembling Drill chuck to Spindle
removing Ball bearing 608LLB / 626LLB
disassembling / assembling Retaining ring S-14
disassembling / assembling Bearing retainer 22-36
disassembling / assembling Drill chuck S-13
Bearing setting plate 20.2 removing Ball bearing 6202LLB
[2] LUBRICATION
Apply Makita grease FA. No.2 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion.
Fig. 1
Item No. Description AmountPortion to lubricate
11
Spur gear 4711
10
10
Gear complete 7-41
Gear teeth
Gear teeth 5g approx.
5g approx.

P 3/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature
Fig. 2
DISASSEMBLING
ASSEMBLING
Water pump pliers
Armature
1R269
Ball bearing 608LLB
1. Remove Carbon brushes.
Disassemble Armature as drawn in Fig. 2.
2. Remove four 5x40 Tapping screws, and then
separate Gear housing from Motor housing.
Armature is removed with Gear housing.
3. Pull out Armature
from Gear housing.
1R269
Assemble Armature by reversing the disassembly procedure. Refer to Fig. 2.
Insulation washer
Ball bearing
608LLB
4. Remove Ball bearing 608LLB on
the drive end of Armature with 1R269.
5. Gap between the other Ball bearing 608LLB and Insulation
washer is very tight.
So, while gripping the hooks of 1R269 with a water pump
pliers, remove Ball bearing 608LLB from the commutator
end of Armature as drawn below.
Carbon brush
Armature
Insert the hooks of 1R269 into the gap between Ball bearing 608LLB
and Insulation washer, and hold the hooks with a water pump pliers.

P 4/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Drill chuck
Fig. 3
DISASSEMBLING
Remove Drill chuck as drawn in Fig. 3.
When Drill chuck is out of order, it is impossible to do the above steps. Therefore, remove Drill chuck as drawn in
Fig. 3A after removing M6x22 Flat head screw in Drill chuck.
1. Hold 1R139 in Vise, and fit the flats of
Spindle into the groove of 1R139.
2. Open the chuck fully, and then turn M6x22 Flat head
screw clockwise with Cordless impact driver.
3. Hold the short leg of Hex wrench 10 to Drill chuck. And join steel pipe to long leg of Hex wrench 10
as an extension handle. And turn Hex wrench 10 counterclockwise. Drill chuck is removed.
short leg of
Hex wrench 10
long leg of
Hex wrench 10
M6x22
Flat head screw
flats of Spindle
1R139
Steel pipe
Fig. 3A
781014-2
(1) Hold 1R139 in Vise, and fit the flats of Spindle into the groove of 1R139.
(2) Insert the pin of 781014-1 into a hole of Drill chuck and put the hook of
781014-1 on Drill chuck.
(3) Turn 781014-2 counterclockwise. Drill chuck is removed.

P 5/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Drill chuck (cont.)
Fig. 4
ASSEMBLING
Assemble Drill chuck as drawn in Fig. 4.
4. Assemble M6x22 Flat head screw to Spindle
by turning the screw counterclockwise with
Cordless impact driver.
1. Assemble Drill chuck to Spindle by hand until it stops.
Then fasten 1R298 to Drill chuck.
2.Hold 1R139 in Vise, and fit the flats of Spindle into
the groove of 1R139.
3. Preset fastening torque of 1R223 to 68.6 ~ 78.4 N·m
(700~800 kgf·cm) in advance.
Attach 1R224 to 1R223, and then connect them to 1R298,
then secure Drill chuck to Spindle by turning 1R223 clockwise.
M6x22
Flat head screw
1R298
1R298
1R139
1R139 1R223
1R224
1R298

P 6/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Spindle, Gear section
Fig. 5
DISASSEMBLING
(1) Remove Drill chuck as illustrated in Fig. 3/3A of page 4.
(2) Separate Gear housing from Motor housing, and then disassemble Gear section as drawn in Fig. 5.
4. Remove Retaining ring S-14 from Spur gear 47
with 1R291.
1. Remove four 5x40 Tapping screws, and then separate
Gear housing complete from Motor housing complete.
2. Remove Pin 3 (as a pilot pin for easy assembly
of Gear housing) to prevent the loss. And then,
remove Gasket and Fiber washer 6 from
Gear complete 7-41.
3. Hold Gear housing complete in Vise, and set 1R340 to
Bearing retainer 22-36.
And remove Bearing retainer 22-36 by turning 1R340
clockwise.
5. Remove Spindle section and Ring 15
from Gear housing complete.
Then, separate Key 5 from Spindle.
6. Remove Gear complete 7-41(with Ball bearing 626LLB) and Spur gear 47
by tapping the edge of Gear housing complete with Plastic hammer.
Pin 3
Gasket
Gear housing
Fiber washer 6
Gear complete 7-41
1R340
Bearing retainer 22-36
Spur gear 47
Spindle
Ball bearing
6202LLB
Ball bearing 626LLB
Key 5
Retaining ring S-14
1R291
Gear housing complete
Ring 15
Spur gear 47
Gear complete 7-41
5x40 Tapping screw
(4 pcs.)
Motor housing complete

P 7/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Spindle, Gear section
Fig. 6
Fig. 6A
DISASSEMBLING
(3) Ball bearing 626LLB can be removed as drawn in Fig. 6.
If Ball bearing 626LLB is left in Gear housing complete during the disassembly of gear section, remove Ball bearing
626LLB as drawn in Fig. 6A.
Remove Ball bearing 626LLB
from Gear complete 7-41
with 1R269.
1. Insert the shaft of Gear complete 7-41
into Ball bearing 626LLB again.
3. Ball bearing 626LLB
is removed together
with Gear complete.
2. Tilt the inserted Gear complete 7-41
and tap the edge of Gear housing
complete with Plastic hammer.
Fig. 7
(4) Ball bearing 6202LLB can be removed from Spindle as drawn in Fig. 7.
1R037
Ball bearing 626LLB
Ball bearing
626LLB
Ball bearing
626LLB
1R269
Gear complete 7-41
Gear
complete 7-41
Ball bearing
6202LLB
Ball bearing
6202LLB
Spindle
1. Receive Ball bearing 6202LLB on 1R037, and then press down Spindle from Ball bearing 6202LLB.
Arbor press.
Spindle

P 8/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Spindle, Gear section
Fig. 8
ASSEMBLING
Assemble Spindle and Gear section as drawn in Fig. 8.
1. Assemble Ball bearing 626LLB
to Gear housing complete.
3. Insert Ring 15 over Spindle. Then set Key 5
to the groove of Spindle.
4. Assemble the Spindle section to Gear housing complete.
2. Put Spindle on 1R035. Then, put
Ball bearing 6202LLB on Spindle.
And then, apply 1R029 to
the bearing and press 1R029
with Arbor press.
to mount the bearing to Spindle.
Ball bearing
626LLB
Ball bearing
6202LLB
1R035
1R029
Spindle
Key 5
Ring 15
1R340
5. Hold Gear housing complete in a vise. Then turn
Bearing retainer 22-36 counterclockwise with 1R340.
Bearing retainer 22-36
Key 5
Notch of
Spur gear 47
1R291 Retaining ring S-14
7. Snap Retaining ring S-14
into the groove of Spindle
with 1R291 to secure
Spur gear 47.
8. Insert Gear complete 7-41 into Ball bearing 626LLB. While keeping it
perpendicularly, tap the gear with a plastic hammer to assemble
Gear complete 7-41 to Gear housing complete.
Note: Do not forget to set Pin 3 and Fiber washer 6 in place as shown below.
Ball bearing 626LLB
Gear complete 7-41 Gear complete
7-41
Fiber washer 6
9.
Pin 3
6. While align the notch of Spur gear 47
to Key 5, assemble Spur gear 47 to Spindle.

P 9/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-4. Leaf spring
Fig. 9
ASSEMBLING
Assemble two Leaf springs to Handle L as drawn in Fig. 9.
Face the curve tops toward notches of
Motor housing.
Projections
Projections
Note: Be careful not to fall Leaf springs
in Handle L.
notch
Fit the projections of Leaf spring to
the notches of Handle L.
Notches of Motor housing
Handle L
Handle L

P 10/ 12
Fig. D-1
Circuit diagram
White
Orange
Blue
Brown
Color index of lead wires' sheath
Circuit diagram of Inside of the Switch
Circuit for ON / OFF Circuit for Forward / Reverse control
Black
Purple
Field
Switch
Power supply cord
Line filter
(if used)
AWG18
AWG18
AWG18
AWG18AWG18
AWG18
AWG20
AWG20
*AWG: American wire gauge
AWG18
AWG18
AWG18
When you connect Noise suppressor and Field
lead wires with Switch, solder the stripped wires
in advance, then clamp the soldering portions
with Splices.
Field view from
Armature fan side
Brush
holder
A
Brush
holder
B
in Forward
rotation
in Reverse
rotation
Strain relief
Splice
Splice
Noise
suppressor
(if used)
Black lead wire is used
for some countries.
White lead wire is used
for some countries.

P 11/ 12
Wiring diagram
Wiring of Field lead wires
When Line filter is used, pass Field lead wires (orange, purple) through the hole and wind them around
as shown below. Then, connect Lead wire (orange) to Terminal No.3 of Switch, and Lead wire (purple)
to Terminal No. 4 of Switch. (See Fig. D-1 of page 10.)
Line filter
to terminal No. 4
to terminal No. 3
Motor housing
Pass Field lead wires through this hole
to Handle section.
Note: Be careful not to scratch or
damage them by the edges.
Line filter
Field
Hole
Handle section
Field lead wires must be
tight in Motor housing.
Fig. D-2

P 12/ 12
Wiring diagram
Wiring in Handle
Setting Noise suppressor
Noise suppressor
Handle L
Wire connected side of
Noise suppressor
Rib B
Rib A Boss
Round wall
Face the wire connected side to Handle L
and assemble Noise suppressor to Handle L
as drawn in below left.
Fig. D-3
Inner wall
Line filter Put Field lead wires between
Boss and Round wall.
Note: Be careful not to put
their wires on Rib A.
Put Line filter to the place designated in gray color when it is used.
When it is not used, put the slack of Lead wires to the place.
Put Field lead wires (black)
between Inner wall and Rib B.
Note: Be careful not to put
their wires on Rib B.
Switch