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BHR200-TE


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T      ECHNICAL INFORMATION
    Models No.                   BHR200S
                                                                                                                             NEW TOOL
                                                                                                                               P 1 / 23
                                                                                                               L
    Description                  Cordless Rotary Hammer 20mm (3/16")                       CH

CONCEPTION AND MAIN APPLICATIONS
   The above mentioned model is 20 mm (13/16") cordless
   rotary hammer. Its brief benefits and features are as follows.
   * Equipped with newly developed 24V/3.0Ah Ni-MH battery.                                H
   * 3 working modes, they are "rotation with percussion",
     "percussion only" and "rotation only".
   * SDS-plus bit can be used
   Below listed standard type model is only available.                                                                        W
    Model No.          Battery                  Charger Plastic case
                                                                                                    Dimensions : mm ( " )
    BHR200SF B2430, Ni-MH 24V/3.0Ah DC24SA                     Yes
                                                                                               Width ( W )          86 (3-3/8)
                                                                                               *Height ( H )       235 (9-1/4)
                                                                                               Center height (CH)   35 (1-3/8)
                                                                                                Length ( L )         316 (12-1/2)
                                                                                             *Height ( H ) : 210mm (8-1/4") when battery
  Specification                                                                                              B2417 is attached.
                  Voltage (V)                            24
     Battery     *Capacity (Ah)                          3.0                       *Capacity (Ah): 1.7Ah when battery B2417 is attached.
                 *Energy (Wh)                            72                        *Energy (Wh) : 40.8Wh when battery B2417 is attached.
     No load speed : (min-1= rpm)                        0 - 1,100
     Blows per min : (min-1= bpm).                       0 - 4,700
     Bit type                                            SDS-plus
     Diameter of bit shank : mm ( " )                    10 (3/8)
                          Concrete                       20 (13/16)
     Capacity : mm ( " ) Steel                           13 (1/2)
                          Wood                           27 (1-1/16)
     Reverse switch                                      Yes
     Electric brake                                      Yes
     Clutch                                              Yes

 Standard equipment
   * Depth gauge (Stopper pole) ............................... 1 pc.
   * Grease for bit .................................................... 1 pc.

   < Note > The standard equipment for the tool shown may differ from country to country.


  Optional         accessories
   * SDS-plus type TCT. hammer bit                                               * Chuck adapter assembly
     4.0mm(5/32") - 20mm(13/16")                                                 * Battery B2430
   * Bull point                                                                  * Battery B2417
   * Cold chisel                                                                 * Charger DC24SA
   * Scaling chisel                                                              * Dust extractor attachment
   * Grooving chisel                                                             * Foot for battery B2417
   * Drill chuck assembly
   * Chuck key S13
   * Grease for bit
   * Dust cup 5
   * Dust cup 9
   * Blow out bulb
Features   and benefits                                                                                       P 2 / 23




                                                              3 mode change lever for
                                                              * Rotation with percussion,
                                                              * Rotation only
                                                              * Percussion only
                                                              All of competitors' models are 2 mode type, or
                                                              a chisel adapter is required, when the machine is
                                                              operated as a percussion hammer.
        One touch slide lock chuck
        for quick bit replacement
                                                                                       Palm-fitly soft grip


                                                                                        D-form handle for efficient
                                                                                        transmission of pressure
                                                                                        power to the tip of bit

                                                                                       Long life D/C motor with
                                                                                       externally accessible carbon
  Comfortable work thanks                                                              brush
  to incredible low vibration




                    Removable foot for flat bottom.                    Newly developed 24V Ni-MH battery
                                                                        We can provide 2 kinds of Ni-MH batteries
                                                                        for BHR200S. They are,
                                                                         * Battery B2417, 1.7Ah (optional accessory)
                                                                         * Battery B2430, 3.0Ah




                                Foot

      When operation with              When operation with
      battery B2417 (small type),      battery B2430 (large type),
      foot can be removed.             foot can be attached.
Comparison                       of products                                                                                 P 3 / 23


   Comparison No.1

               Model No.                    MAKITA             Competitor A           Competitor B         Competitor C
   Spec.                                    BHR200S                   A                      B                  C
       Voltage (V)                              24                   24                     24                24
 Battery




      Capacity (Ah)                        3.0      1.7         3.0      1.7           2.5      1.7           2.0
      Energy (Wh)                          72      40.8         72      40.8           60      40.8           48
       Cell                                    Ni-MH               Ni-Cd                   Ni-Cd             Ni-Cd
       Weight : Kg                         1.46     0.98       1.96      1.32         1.95      1.26         1.35
   Charging time (min.)                    60       30           27      15             65      45            60


                    concrete : mm (")       20 (13/16)           20 (13/16)              16 (5/8)           20 (13/16)
   Drilling in




                    steel      : mm (")      13 (1/2)            10 (3/8)                                   13 (1/2)


                    wood      : mm (")       27 (1-1/16)         20 (13/16)                                 30 (1-3/16)

 No load speed                               0 - 1,100            0 - 1,000              0 - 820            0 - 1,100
     : (min -1= rpm)
 Blows per min                                                                           0 - 4,010          0 - 4,200
                                             0 - 4,700            0 - 4,400
     : (min -1= bpm).
   Energy of blow




                    calculated by
                                               2.1 J                                       2.0 J              2.2 J
                    our own method

                    Figure                     2.1 J                 1.3 J                 2.0 J              2.0 J
                    on catalog
 Working mode                                3 modes            * 2 modes                2 modes           2 modes
    One touch
  Chuck system




    slide lock
    Two touch
    slide lock
                    Revolving lock
  Externally accessible
                                                Yes                   No                       No             No
  carbon brush
                    Length : mm             316      316      329            329       398        398         355
  Dimensions




                            (")           (12-1/2) (12-1/2)   (13)           (13)   (15-5/8)    (15-5/8)      (14)
     Height : mm             235      210     233      216        196        196                               215
              (")          (9-1/4) (8-1/4) (9-1/8) (8-1/2)      (7-3/4) (7-3/4)                              (8-1/2)
     Width : mm              86       86      72        72        116         77                              100
              (")          (3-3/8) (3-3/8) (2-13/16) (2-13/16) (4-9/16)       (3)                           (3-15/16)
     measured                4.09     3.58    4.18     3.54       4.98       4.29                             3.98
 Weight




     by us      : Kg (lbs) (9.02) (7.89) (9.22)       (7.80)    (10.98) (9.46)                               (8.77)
     Figure                   4.0     3.5      4.2     3.5         4.8       4.2                              4.2
     on catalog: Kg (lbs) (8.8) (7.7)        (9.3)    (7.7)      (10.6)     (9.3)                            (9.3)
 Plastic carrying case            Yes              Yes                  Yes                                   Yes
                                            Grease for bit    Depth gauge            Dust cup               Grease for bit
  Standard equipments                       Depth gauge                              Grease for bit         Depth gauge
                                                                                     Depth gauge
                                                                                     Cleaning cloth

                            * 2 modes :In case of Competitor A, a chisel adapter (optional accessory) is required to be operated
                                       as a demolition hammer.
Comparison                      of products                                                 P 4 / 23

 Comparison No.2

                           Model No.     MAKITA            Competitor D      Competitor E
  Spec.                                  BHR200S                 D               E
      Voltage (V)                           24                  24              24
 Battery



     Capacity (Ah)                      3.0      1.7       2.0     3.0          2.0
     Energy (Wh)                        72      40.8        48     72           48
      Cell                                  Ni-MH         Ni-Cd Ni-MH          Ni-Cd
      Weight : Kg                       1.46     0.98      1.31    1.4         1.37
  Charging time (min.)                  60       30         15     22           18


                   concrete : mm (")     20 (13/16)         20 (13/16)        20 (13/16)
  Drilling in




                   steel    : mm (")     13 (1/2)                             13 (1/2)


                   wood    : mm (")       27 (1-1/16)                         27 (1-1/16)

 No load speed                          0 - 1,100           0 - 950           0 - 1,150
     : (min -1= rpm)
 Blows per min                                                                0 - 4,400
                                        0 - 4,700           0 - 4,600
     : (min -1= bpm).
  Energy of blow




                   calculated by
                                          2.1 J               2.9 J             2.2 J
                   our own method

                   Figure                 2.1 J
                   on catalog
 Working mode                           3 modes              2 modes           2 modes
    One touch
 Chuck system




    slide lock
    Two touch
    slide lock
                   Revolving lock
 Externally accessible                        Yes              No                No
 carbon bruch
                   Length : mm           316      316      291      291         292
 Dimensions




                           (")         (12-1/2) (12-1/2) (11-1/2) (11-1/2)    (11-1/2)
     Height : mm             235      210     199       199                      210
              (")          (9-1/4) (8-1/4) (7-7/8) (7-7/8)                     (8-1/4)
     Width : mm              86       86      68       107                       100
              (")          (3-3/8) (3-3/8) (2-11/16) (4 -1/4)                 (3-15/16)
     measured                4.09     3.58    3.45      3.54                     3.79
 Weight




     by us      : Kg (lbs) (9.02) (7.89) (7.6)         (7.8)                    (8.36)
     Figure                   4.0     3.5      3.6      3.6                       3.7
     on catalog: Kg (lbs) (8.8) (7.7)        (7.9)     (7.9)                     (8.2)
 Plastic carrying case            Yes              Yes                           Yes
                                         Grease for bit     Grease for bit   Depth gauge
                                         Depth gauge        Depth gauge
 Standard equipments                                        Dust cup
                    Comparison            of products                                                                         P 5 / 23
                     Comparison in working speed, and working amount per one fully charged battery


                    Working speed



                        Slow
                                                                Bit diameter: 6.5 mm     Depth of hole : 40 mm
                     10.0
                     9.0
                     8.0
Time : sec./ 40mm




                     7.0
                     6.0
                                                                                                                            6.1
                     5.0                           5.1                                                           5.3
                                    4.6                                4.8
                     4.0                                                                  4.5
                     3.0
                     2.0
                     1.0
                     0.0
                        Fast MAKITA             Competitor A    Competitor D       Competitor E          Competitor C   Competitor B
                             BHR200S             Model A         Model D            Model E               Model C         Model B




                       Drilled holes with one fully charged battery


                     200                                        Bit diameter: 6.5 mm     Depth of hole : 40 mm

                     180
                     160
                     140
                                                         148
                     120
          Holes




                     100             111                                   108
                      80                                                                    94
                      60                          67                                                                              71
                               64                                     59
                      40                                                                                     57
                                                                                                                             43
                      20
                       0
                           1.7Ah 3.0Ah          1.7Ah 3.0Ah     2.0Ah 3.0Ah               2.0Ah             1.7Ah        1.7Ah    2.5Ah
                               MAKITA           Competitor A     Competitor D          Competitor E      Competitor C    Competitor B
                               BHR200S            Model A         Model D               Model E           Model C          Model B
             Comparison                 of products                                                                               P 6 / 23

                    Working speed
                       Slow
                                                                  Bit diameter: 8.5 mm     Depth of hole : 40 mm
                    10.0
                    9.0
                    8.0
                    7.0                                                                                                        7.6
                                                    7.4
Time : sec./ 40mm




                    6.0                                                                                        6.4
                                 6.2                                     5.8               5.9
                    5.0
                    4.0
                    3.0
                    2.0
                    1.0
                    0.0
                       Fast MAKITA             Competitor A      Competitor D       Competitor E          Competitor C      Competitor B
                            BHR200S             Model A           Model D            Model E               Model C            Model B




                          Drilled holes with one fully charged battery


                       200                                         Bit diameter: 8.5 mm     Depth of hole : 40 mm

                       180
                       160
                       140
                       120
               Holes




                       100
                                                          102
                       80
                                       88
                                                                               80                78
                       60
                                                                                                                                      60
                       40       50                  49
                                                                         44                                         47
                                                                                                                                 36
                       20
                          0
                              1.7Ah 3.0Ah        1.7Ah 3.0Ah       2.0Ah 3.0Ah              2.0Ah              1.7Ah          1.7Ah   2.5Ah
                                MAKITA            Competitor A       Competitor D         Competitor E       Competitor C     Competitor B
                                BHR200S            Model A            Model D              Model E            Model C           Model B
      Comparison                     of products                                                                         P 7 / 23
                           Working speed
                       Slow
                    16.0                                     Bit diameter: 12.5 mm   Depth of hole : 40 mm

                    14.0

                    12.0
Time : sec./ 40mm




                    10.0
                                                                                      9.7
                     8.0                                                                                                9.0
                               8.5               8.0                                                      7.8
                     6.0                                              7.0

                    4.0

                     2.0

                     0.0
                       Fast MAKITA         Competitor A        Competitor D     Competitor E        Competitor C    Competitor B
                            BHR200S         Model A             Model D          Model E             Model C          Model B




                            Drilled holes with one fully charged battery



                    100                                     Bit diameter: 12.5 mm Depth of hole : 40 mm

                     90
                     80                                88
                     70
                     60                                                 68
                                     67
     Holes




                     50
                                                                                       52                                     50
                     40                         43
                     30      38                                                                              39
                                                                 37
                                                                                                                       31
                     20
                     10
                      0
                           1.7Ah 3.0Ah       1.7Ah 3.0Ah      2.0Ah 3.0Ah            2.0Ah                1.7Ah      1.7Ah 2.5Ah
                             MAKITA          Competitor A       Competitor D     Competitor E        Competitor C    Competitor B
                             BHR200S          Model A            Model D          Model E             Model C          Model B
          Comparison                    of products                                                                          P 8 / 23


                           Working speed
                       Slow
                    16.0                                      Bit diameter: 14.5 mm   Depth of hole : 40 mm

                    14.0

                    12.0
Time : sec./ 40mm




                                                                                                                         12.2
                    10.0                                                              11.3
                                                 10.5
                                  9.9
                     8.0                                                                                   9.4
                                                                      8.7
                     6.0

                    4.0

                     2.0

                     0.0
                       Fast MAKITA            Competitor A     Competitor D      Competitor E        Competitor C    Competitor B
                            BHR200S            Model A          Model D           Model E             Model C          Model B




                            Drilled holes with one fully charged battery



                    100                                      Bit diameter: 14.5 mm Depth of hole : 40 mm

                     90
                     80
                     70
                     60
     Holes




                                                        64
                     50
                                        55                             54
                     40
                     30                                                                 40
                                                                                                                                37
                             32                  31              29                                        32
                     20                                                                                                 23
                     10
                      0
                           1.7Ah 3.0Ah        1.7Ah 3.0Ah      2.0Ah 3.0Ah           2.0Ah              1.7Ah        1.7Ah 2.5Ah
                             MAKITA           Competitor A     Competitor D       Competitor E        Competitor C   Competitor B
                             BHR200S           Model A          Model D            Model E             Model C         Model B
         Comparison                   of products                                                                            P 9 / 23



                           Working speed
                       Slow
                    16.0                                     Bit diameter: 16.5 mm   Depth of hole : 40 mm

                    14.0
                                                                                                                         15.1
                    12.0                        13.1
Time : sec./ 40mm




                                                                                     12.0
                    10.0                                                                                  11.7
                               10.9                                   10.5
                     8.0

                     6.0

                    4.0

                     2.0

                     0.0
                       Fast MAKITA          Competitor A      Competitor D      Competitor E        Competitor C     Competitor B
                            BHR200S          Model A           Model D           Model E             Model C           Model B




                            Drilled holes with one fully charged battery



                    100                                     Bit diameter: 16.5 mm Depth of hole : 40 mm

                     90
                     80
                     70
                     60
     Holes




                     50
                                                       53
                     40           49
                                                                        45
                     30                                                                36
                             28                 26                                                                              30
                     20                                          25                                          26         18
                     10
                      0
                           1.7Ah 3.0Ah       1.7Ah 3.0Ah      2.0Ah 3.0Ah           2.0Ah               1.7Ah         1.7Ah 2.5Ah
                             MAKITA          Competitor A       Competitor D      Competitor E        Competitor C    Competitor B
                             BHR200S           Model A           Model D           Model E             Model C          Model B
Comparison                               of products                                                                             P 10 / 23

                                       Chipped amount with one fully charged battery
                          4 Kg

                                             3.05 Kg                                       2.95 Kg
                          3 Kg
Chipped amount




                                           12.5 minutes                                  18.5 minutes
                          2 Kg


                          1 Kg


                          0
                                             MAKITA                                    Competitor A
                                             BHR200S                                    Model A

                                       Vibration under loaded condition
                                       Working mode : Rotation with percussion
                                       Measured and evaluated in conformity with CE Regulations.
                          20.0 m/s2
                          18.0 m/s2
                          16.0 m/s2                                           18.5
                                                              16.2                                              16.3
                          14.0 m/s2
Vibration




                                                                                                                                 14.7
                          12.0 m/s2                                                              14.0
                                          13.0
                          10.0 m/s2
                           8.0 m/s2
                           6.0 m/s2
                           4.0 m/s2
                           2.0 m/s2

                                        MAKITA         Competitor A       Competitor D       Competitor E    Competitor C     Competitor B
                                        BHR200S         Model A            Model D            Model E         Model C           Model B


                                       Sound pressure level
                                       Working mode : Rotation with percussion
                                       Measured and evaluated in conformity with CE Regulations.
                              100 dB
                               90 dB
                                           91                 95
                               80 dB                                                                                                87
   Sound pressure level




                                                                               89                    89          90
                               70 dB
                               60 dB
                               50 dB
                               40 dB
                               30 dB
                               20 dB
                               10 dB


                                        MAKITA         Competitor A       Competitor D        Competitor E     Competitor C     Competitor B
                                        BHR200S         Model A            Model D             Model E          Model C           Model B
Repair                                                                                                         P 11 / 23
 Lubrication
 Put grease on the following places in order to protect parts and machine from unusual abrasion and overheating.
 Recommendable is our genuine grease, "MAKITA Grease R No.1".

  All of O rings built in BHR200S
   Teeth of all gears built in BHR200S

                 (1) Cap 31                                              Inside of rip portion



                 (9) Pin 8                                               Bottom of cylindric portion


                                                                        Inside of oil seal
                 (12) Oil seal 25



                 (15) O ring case                                         Grooved portion inside of O ring case

                                                                          Grooved portion for O ring
                 (19) Impact bolt


                 (21) Plane bearing 26                                    Inside of plane bearing 26


                 (22) Tool holder

                                                                                             Whole Inner part of tool holder
                 (23) Steel ball 7.0


                                                                            Grooved portion for O ring
                 (29) Striker



                 (30) Piston cylinder                                                   Inside of perforated holes




                 (38) Spur gear 10                                                      Cam portion




                 (39) Clutch cam
                                                                                         Cam portion




                 (40) Cam shaft                                                   Whole part




                 (41) Swash bearing 10                                            Cam and shaft
Repair                                                                                                           P 12 / 23
 Removing

 < 1 > Removing chuck section
     (1) Pull down chuck cover and detach cap 31 as illustrated in Fig. 1, and then, remove chuck cover and
         compression spring 38 as illustrated in Fig. 1A.


                                       Cap 31
                                                                                       Chuck cover
                                         Pull down
                                         chuck cover.                                  Compression spring 38
                                                                                        Tool holder
                                                                                        Ring spring 17
                                           Chuck cover


                                          Fig. 1                                    Fig. 1A

     (2) Lever up ring spring 17 with screwdriver, expanding it with 1R004 "retaining ring plier" and remove
        ring spring 17 from tool holder as illustrated in Fig. 2.



                                                                         1R004 Retaining ring plier


         Ring spring 17
                                          Fig. 2.

     (3) Remove ring spring 30.5 from chuck ring, and then, detach spring guide and compression spring 35 as illustrated
         in Fig. 3.
                          Ring spring 30.5
                                 Spring guide     Compression spring 35
                                                            Chuck ring




                     Leaf spring 26
                     installed on
                     chuck ring
                                          Fig. 3.

     (4) Remove leaf spring 26 with 1R003 "retaining ring plier" from chuck ring, and then, detach pin 8
         as illustrated in Fig. 4. Remove chuck ring, steel ball 7.0 and guide washer from tool holder
         as illustrated in Fig. 4A.
                                                               Chuck ring
                            Leaf spring 26                                   Guide washer
                                                    Pin 8                                       Steel ball 7.0




Remove from
chuck ring expanding
                          Chuck ring                                Tool holder
with 1R003
"retaining ring plier".
                                          Fig. 4                                Fig. 4A
Repair                                                                                                             P 13 / 23

 < 2 > Disassembling housing.
    (1) Pull down chuck cover and detach cap 31 as illustrated in Fig. 1.
    (2) Set change lever to the "rotation with percussion" mode as illustrated in Fig. 5.
        Otherwise, cam shaft is lifted up and ball bearing 606ZZ, cup washer
        and conical compression spring 7-14 easily come out from housing L.
        See Fig. 5A.
                                                   Cup washer                                   Fig. 5




     Ball bearing 606ZZ

                  Conical compression
                  spring 7-14

                        Housing L


                                                                                              Fig. 5A



     (3) Remove foot by unscrewing 2 pcs. of tapping screws 4x18, if it is attached.

     (4) Dismount housing R from housing L by unscrewing 14 pcs. of tapping screws 4x18.

 < 3 > Disassembling clutch section.
     (1) Disassemble the chuck section as per < 1 > and < 2 >, and take out tool holder unit from housing.
         See Fig. 6.

                            Ball bearing 6905LLB
           Tool holder.
                                      Spur gear 49
                                               Plane bearing 26

                                                      Piston joint
       Ring spring 26                             Piston cylinder
           Flat washer 29        Compression spring 29



     (2) Remove the following parts from tool holder.                                Fig. 6
          * Oil seal 25   * Ball bearing 6905LLB      * Plane bearing 26
          * Piston joint  * 2 pcs. of flat washers 12 * Piston cylinder
          * Striker
         Ball bearing 6905LLB can be easily removed by using 1R045 "Large gear extractor".
                                         Tool holder.
                 Oil seal 25
                                             Ring spring 26 Plane bearing 26
                                                                                                         Flat washers 12



                                                                                                     Piston join
                                                                Striker
                            Flat washer 29
                                                                      Piston cylinder
                                                                                            Flat washers 12
                Ball bearing 6905LLB           Compression spring 29

                                                                                            Fig. 7
Repair                                                                                                             P 14 / 23

     (3) Expand ring spring 26 with 1R045 "retaining ring plier", So the ring spring 26 is to be pushed out from
         the groove of tool holder by compression spring 29. And then, it can be removed with screwdriver.
             < Note > Remove ring spring 26 putting tool holder unit on the working table as illustrated in Fig.8.
                      Otherwise, the parts on the tool holder are ejected together with compression spring 29.

                                          Spur gear 49

                                Compression spring 29


                                Ring spring 26
                                                                    Flat washer 29


                                                Working table          Fig.8

     (4) Remove spur gear 49 from the tool holder.
                                  Spur gear 49




                                                                       Fig. 9

 < 4 > Disassembling impact bolt
    (1) Disassemble the chuck section as per < 1 >, < 2 > and < 3 >, and take out tool holder unit from housing.
        See Fig. 6.

     (2) If the cut section of ring spring 21 is located in the holes of tool holder as illustrated in Fig. 10,
         set the ring spring 21 as illustrated in Fig. 10A by sliding its cut section with slotted head screwdriver.




                                                 * The same hole is bored on the opposite side of tool holder.



                                        Inside groove



                                                                                                          Ring spring 21
     Cut section of
     ring spring 21




                                                                                                       O ring case
                                  O ring case                                                          Fig. 10A
                      Fig. 10
Repair                                                                                                          P 15 / 23

     (3) Insert a slotted head screwdriver between ring spring 21 and O ring case as illustrated in Fig. 11.
         And push out the ring spring 21 from the inside groove of tool holder, with the slotted head screwdriver



                                                                                      Ring spring 21




                                                                                  O ring case
                                 In case may be, you can remove the ring spring 21 by hitting the screwdriver.

                                       Fig. 11

     (4) Insert 1R236 "round bar for arbor 7mm" in tool holder and remove the following parts from tool holder
        by pressing with arbor press. See Fig. 12. After removing, clean the inside of tool holder in order to prevent
        O ring's wearing away.

        * Ring spring 21
        * O ring case with O ring 11
        * O ring 12
        * Ring 12
        * Impact bolt
                                                                            < Note >
                                                                            Press "round bar for arbor 7mm" vertically.
 1R236                                                                      Otherwise, impact bold can not be removed,
 "Round bar for arbor 7mm"                                                  because "the round bar for arbor" may sticks
                                                                            into the space between the tool holder
                                                                            and impact bolt as illustrated in Fig. 12A.




                                       Fig. 12
                                                               Fig. 12A


 < 5 > Removing swash bearing 10
     (1) Disassemble housing as per < 2 >, and then, take out the cam shaft unit from housing L.
     (2) Remove ring 6 and ball bearing 626DDW with 1R269 "bearing extractor" as illustrated in Fig. 13.

                                                   Ball bearing 626DDW


                                                   Ring 6




                                                                                     1R269 "Bearing extractor"




                                                               Fig. 13
Repair                                                                                                         P 16 / 23
     (3) Hold zerol bevel gear 32 with 1R022 "bearing extractor plate" as illustrated in Fig. 14.
         And press cam shaft with arbor press. Swash bearing can be removed from cam shaft.


                                                                  Zerol bevel gear 32




                                                  1R022 Bearing extractor plate

                                                  Fig. 14
 < 6 > Removing change lever
    (1) Disassemble housing as per < 2 >, and then, take out the cam shaft unit and tool holder unit
        from housing L.
    (2) Set change lever to percussion mode as illustrated in Fig. 15.

                                                                     < Note > It is impossible to remove change plate
                                                                               in the other mode.




                                                   Fig. 15

    (3) Remove change plate and compression spring 4, And detach guide plate by unscrewing
        2 pcs. of tapping screws 4 x 12 as illustrated in Fig. 16.


    (4) Detach retaining ring S-18, And pull out change lever with pressing lock button as illustrated in Fig. 16.

                                                                             Compression spring 4


                                                  Guide plate                              Change plate

                                                                                          Tapping screws 4 x 12

                                                                               Retaining ring S-18




          Change lever

                               Lock button




                                                        Fig. 16
  Repair                                                                                                            P 17 / 23
    < 7 > Removing armature
        (1) Disassemble housing as per < 2 >, and then, take out brush holder on housing R side, by unscrewing
            2 pcs. of tapping screws 4 x 18 as illustrated in Fig. 17. ( No need to remove brush holder assembled
            in housing L.)
        (2) Remove armature together with yoke unit
            as illustrated in Fig 17.

                                                                  Armature (including zerol bevel gear 11,
                                                                   ball bearing 608LLU, fan 64, and
                                                                   ball bearing 626DDW)
                                                                               Yoke unit
                                                                                < Note > Ball bearing 626DDW attached on
       Housing L                                                                         the commutator side, is not
                                                                                         assembled by pressing.
                                                                                         Be careful not to lose ball
                                                                                         bearing 626DDW, when removing
                                                                                         armature.
               Brush holder



                                                                         Brush holder
                                                                         on housing R side

                                                                     Fig. 17


Assembling
  < 8 > Assembling armature
        (1) Insert armature into yoke unit as illustrated in Fig 18.
            < Note > Armature is dragged into yoke unit easily, with its very strong magnetic force.
                      Be careful not to damage the armature wire, zerol bevel gear 11 and commutatror
                      in this process.




                                                                     Fig. 18
        (2) Assemble yoke unit and armature to housing L




                                                  Cut : Fit this cut on the rib of housing L.

                                                                     Fig. 19

        (3) Attach brush holders to housing L, and fasten them with 2 pcs. of tapping screw 4 x 12.
 Repair                                                                                                              P 18 / 23
< 9 > Assembling equipment for mode change
    (1) Attach compression spring 4, lock button and O ring 17 to change lever as illustrated in Fig.20.

                                              Lock button

                                              Compression spring 4

                                                    O ring 17
                                                                                          Lock button has to be pressed
                                                  Change lever
                                                                                          into change lever until its hook
                                                                                          engages change lever.
                                                       Fig.20

     (2) Attach the above change lever to housing L. And assemble retaining ring S-18 as illustrated in Fig.21.
        Set the change lever to percussion mode as illustrated in Fig. 21A. Assemble guide plate to housing L with
        2 pcs. of tapping screws 4 x 12.
                                                                              Guide plate




                                                  Retaining ring S-18




                                                            Change lever set in
                                                            percussion mode
      Change lever




              Fig.21
                                                                                    Fig.21A

    (3) Assemble change plate as follows.
           1. Set compression spring 4 to change plate as illustrated in Fig.22A.
           2. Set compression spring 4 assembled on change plate, to guide plate as illustrated in Fig. 22B
           3. Mount the whole change plate on guide plate, setting the under edge of the change plate to the rib of
              guide plate as illustrated in Fig 22C.
           4. Set change lever on the rotary hammer mode to prevent that the change plate slips off from
              the guide plate's rib.

                          Compression spring 4
                                                                              Change plate
                                    Guide plate



                                    Top view of the above parts                                 Side view of the above parts
                                                                                                assembled to guide plate
                                                                        Compression spring 4
                           Compression spring 4
                                                                              Change plate
                                    Change plate
                                                                            Guide plate

                Fig.22A                                   Fig. 22B

                                                            Set the under edge of the change            Fig 22C
                                                            plate to the rib of guide plate.
   Repair                                                                                                                   P 19 / 23
   < 10 > Assembling impact bolt
      (1) Assemble O ring 12 (thin type) to impact bolt, and insert the impact bolt deep into tool holder.
         < Note > The impact bolt has to be inserted as illustrated in Fig. 23.
                                                      O ring 12 (thin type)

             Tool holder                                                  Tool holder
                                                         Impact bolt
                                            Fig. 23

      (2) Insert the parts into the tool holder in the following order as illustrated in Fig. 24.
           1. Ring 12      2. O ring 12 (thick type)     3. O ring case in which O ring 11 has been inserted in advance.
                                            O ring 11
                                                                                                          Press with arbor press.

                     Tool holder
                                                                                                                            22mm


                                            Fig. 24

       (3) Press ring spring 21 into the tool holder with 1R248        1R248 "Round bar for arbor 22mm"
           "Round bar for arbor 22mm" until it fits in the groove                        Ring spring 21
           which is grooved inside of tool holder. See Fig. 25.
           And make sure that the ring spring 21 is fit in the groove.
                                                                                         Fig. 25
< 11 > Assembling spur gear 49 and other parts to tool holder
      (1) Set 1R272 "Ring Spring Setting Tool A" on the tool holder
          which is assembled as mentioned in < 10 >. And then set
          spur gear 49, compression spring 29 and flat washer 29 as
          illustrated in Fig.26.
      (2) Set ring spring 26 on the 1R272 "Ring Spring Setting ool A" as illustrated in Fig. 26.


               Ring spring 26
               Flat washer 29                                1R272
                                                             "Ring Spring Setting Tool A

      Compression spring 29                                        Flat washer 29 has to     Ring spring 26 side
                                                                   be faced as Fig. A,
                                                                   when assembling.                                Fig. A
                        Spur gear 49                                                         Spur gear 49 side
                                                                Set cam bulge of spur gear 49
                                                                in the concave portion of tool holder


                  Tool holder                                                                   Fig. 26



                                                       < Note > Be careful, not to hurt yourself with this edge, because
                                                               it is sharpened.

                  1R272
                   Ring Spring Setting Tool A
Repair                                                                                                             P 20 / 23

   (3) Put 1R273 "Ring Spring Setting Tool B" on the top of tool holder. Press it with arbor press as illustrated
      in Fig. 27 to set ring spring 26 in the goove of tool holder.

  Ring spring 26                                      Press with arbor press.

                                                                                Ring spring 26 set in
                                                                                the tool holder's
                                                                                groove.




                                                                                                             Tool holder


                                    1R273                                                                    Flat washer 29
                                    "Ring Spring                                                             Compression
                                    Setting Tool B"                                                          spring 29


                                                                                                           Spur gear 49

                                            Fig. 27

  (4) Make sure that ring spring 26 is set in the groove of tool holder completely.


< 12 > Assembling tool holder section
  (1) Assemble the following parts to the tool holder assembled as per < 11 >. See Fig. 28.
       * Ball bearing 6905LLB
       * Retaining ring S-25 (for shaft)
       * Oil seal 25
       * Plane bearing 26
       * Striker with O ring 15
       * Piston cylinder
       * 2 pcs. of Flat washers 12
       * Piston joint
                                                                                               Piston cylinder
                        Retaining ring S-25                                 Plane bearing 26
                        (for shaft)                                                                          Flat washers 12




                                                                                       Striker with     Piston joint
                                                Tool holder section assembled
               Oil seal 25   Ball bearing       as per < 11 >                          O ring 15
                             6905LLB




                                                                                Do not assemble striker with O ring 15,
     Hammer bit Side             Ball bearing 6905LLB side
                                                                                as illustrated above.
       Oil seal 25 has to be faced as illustrated above.
Repair                                                                                                           P 21 / 23
< 13 > Assembling chuck section
     (1) Assemble the following parts to the tool holder as illustrated in Fig. 29.
       * Guide washer       * Steel ball 7.0     * Leaf spring 26       * Compression spring 35     * Ring spring 30.5
       * Chuck ring         * Pin 8              * Ring spring 17       * Spring guide
                               Compression
         Ring spring 30.5                  Ring spring 17
                               spring 35                     Guide washer
                                                       Pin 8              Tool holder




                             Spring guide    Chuck ring
                              Leaf spring 26        Steel ball 7.0

                                                                  Fig. 29                  Guide washer has to be faced as
                                                                                           illustrated below.

     Chuck ring
                              Leaf spring 26

                                                                   Chuck ring           Side of               Side of
                                                                                        Leaf spring 26        tool holder
                                                                  Leaf spring 26



     The concave portion of leaf sing 26
     has to be aligned with the same of        The hole of leaf spring 26
     chuck ring as illustrated above.          has to be located on the bit
                                               setting side as illustrated above.

     (2) It is recommended to use 1R212 "Plier's Nail" for easy mounting of ring spring 17 and 26.

       Owing to the concave nail,
       you can operate without
       sliding of Ring Spring and
       Concentric Retaining Ring.


                              Ring Spring
                                                   1R212 Plier's Nail               Retaining Ring S Plier
                                                                                    (1R003)
                                                        Fig. 30

         < Note > Be careful not to expand ring spring 17 too wide in order to prevent its deformation.

 < 14 > Assembling the tool holder section to housing.
     (1) Assemble the tool holder section by setting oil seal 25, ball bearing 6905LLB and plane bearing 26
         in the concave portion for them as illustrated in Fig. 31.
                                            Ball bearing 690-5LLB
                                                                      Oil seal 25
                                Plane bearing 26
Repair                                                                                                              P 22 / 23
< 15 > It is recommended to replace the following parts in the square, when replacing carbon brush.


                              Compression
       Ring spring 30.5                   Ring spring 17
                              spring 35                     Guide washer
                                                      Pin 8              Tool holder




                            Spring guide    Chuck ring
                             Leaf spring 26
                                                  Steel ball 7.0


                                                                                             Piston cylinder
                                                          Plane bearing 26
                                                                                                             Flat washers 12




                                                                                    O ring 15       Piston joint
                     Tool holder section assembled                   Striker
                     as per < 11 >



                                                                                 O ring 11 to be assembled
                          Tool holder       Impact bolt                          to O ring case
                                                           Ring 12




                                                                               O ring case


                          O ring 12                        O ring 12
                          (Thin type) for                  (Thick type)
                          impact bolt
                                                                                                             P 23 / 23
Circuit   diagram
                                                                                    Brush holder
                                                 M2                                 (Housing R side)
                      Orange                                     Red
                                                                                   A

                                                  M1
                      Black                                      Black              Brush holder
                                                                                    (Housing L side)
Wiring    diagram
           Put slack part of lead wires      Pass lead wires between boss
           here.                             and inner wall of housing.

                                                                             Bend the connecting terminals of
                                                                             brush holders' lead wires as illustrated
                                          Boss                               below, when they are connected with
                                                                             switch.
                                                                                                        Bend approx.
                                                                                                        45



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