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TW0200-TE


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T    ECHNICAL INFORMATION
   Models No.                    TW0200
                                                                                                                  PRODUCT
                                                                                                                    P 1 / 13
                                                                                                           W
   Description                   Impact Wrench                                                         L
CONCEPTION AND MAIN APPLICATIONS
   The advanced version of the existing model 6904VH has been
   released with the following features.
    * Aluminum hammer case with high durability
    * Compact body size ; 251mm (9-7/8")
    * Ergonomical palm fitting soft grip
                                                                                                                       H

                                                                                Dimensions : mm ( " )
                                                                           Length ( L )  251 (9-7/8)
                                                                           Width ( W )    72 (2-13/16)
                                                                           Height ( H )  220 (8-5/8)

 Specification
                                                                               Continuous Rating (W)
      Voltage (V)              Current (A)                Cycle (Hz)                                       Max. Output(W)
                                                                              Input           Output
           110                    3.6                      50 / 60            380              160              300
           120                    3.3                      50 / 60            380              160              300
           220                    1.8                      50 / 60            380              160              300
           230                    1.7                      50 / 60            380              160              300
           240                    1.7                      50 / 60            380              160              300

   No load speed (min-1=rpm)                                      0 - 2,200
   Impact per minute (min-1=bpm)                                  0 - 2,200
   Square drive : mm ( " )                                       12.7 (1/2)
              Standard bolt                                 M10 - M16 (3/8" - 5/8" )
   Capacities
              High Tensile bolt                             M10 - M12 (3/8" - 1/2" )
   Max. fastening torque : N.m (ft.lbs)                          200 (150)
                                                                 2.5 (8.2)
   Power supply cord : m ( ft )
                                                           2.0 (6.6) for Australia
   Net weight: kg (lbs)                                          2.1 (4.6)

 Standard equipment
    * Socket 17-38 ....................................   1 pc.
    * Socket 19-52 ....................................   1 pc.
    * Socket 21-38 ....................................   1 pc.
    * Plastic carrying case ........................      1 pc.
   < Note > The standard equipment for the tool shown may differ from country to country.
 Optional        accessories
   * Socket 17-38                   * Socket 24-45
   * Socket 17-52                   * Socket 24-52
   * Socket 19-38                   * Socket 26-50
   * Socket 19-52                   * Socket 26-78
   * Socket 19-78                   * Extension bar
   * Socket 21-38                   * Universal joint
   * Socket 21-52                   * Bit adaptor
   * Socket 21-78
   * Socket 21-150
   * Socket 22-38
   * Socket 22-52
   * Socket 23-38
   * Socket 23-52
Features   and benefits                                                                                        P 2 / 13

                                        TW0200

                                                    Compact body : 251 mm (9-7/8")
     Aluminum hammer case
     with high durability
                                                                                    Cylinder-formed housing
                                                                                    with high rigidity and durability

     12.7mm (1/2")                                                                          Externally accessible
      square drive                                                                          carbon brush for easy
                                                                                            replacement
     Variable switch ;
     Easy to operate even when
     fastening lag bolt.                                                   Palm-fitting soft grip
                                Push button type
                                reverse switch




                                                                              Carry hook




Comparison     of products

                     Model No.                      MAKITA                    Competitor A
    Specifications                      TW0200               6904VH             Model A
    Max. fastening torque                 200                  196               196
    : N.m (ft.lbs) in catalog            (150)                (145)             (145)
    Square drive : mm                     12.7                12.7               12.7
                     (")                  (1/2)               (1/2)              (1/2)

     Power input : W                      380                 360                 360

     Rated amperage
                                          3.3                  4.6
     for North America : A
     No load             High                              0 - 2,400            0 - 2,400
                                       0 - 2,200
      speed :min-1=rpm Low                                 0 - 2,100            0 - 1,900
     Impact per          High                              0 - 3,000            0 - 3,000
                                       0 - 2,200
      minute :min-1=bpm Low                                0 - 2,500            0 - 2,300
                                                              Plastic
     Material of hammer case           Aluminum                                Aluminum
                                                         Clam shell type
     Externally accessible brush          Yes                   No               Yes
     Soft grip                             Yes                  No                No
     Electric brake                        No                   No                No
    Overall length: mm                     251                  265               264
                    (")                  (9-7/8)             (10-3/8)          (10-3/8)
    Net weight: kg (lbs)                2.1 (4.6)            1.8 (4.0)         2.1 (4.6)
Comparison               of products                                                  P 3 / 13

 Fastening high tensile bolt M16
 < Note >
 The definition of the max. fastening torque according to MAKITA standard ;
 The figure which is measured at 3 seconds after start of driving, is the max. fastening
 torque in catalog.
 The max. fastening torque of TW0200 is based on the same definition.

                   300
                                           MAKITA TW0200
                                           MAKITA 6904VH
                   250
                                           Competitor A Model A
    Torque (N.m)




                   200


                   150


                   100



                    50



                     0
                         0             1           2              3       4                5
                                                   Time : S.
Repair                                                                                                  P 4 / 13
< 1 > Lubrication
     Apply MAKITA grease N. No.1 to the following portions marked with black triangle to protect
     parts and product from unusual abrasion.


                                           Hammer            10               14               17      20
                2               7
                                                                         13




                                                                                    Cup
                                                      9
                                                                                    washer 19
                                                                  Compression
                                                                  spring 32

      Position No.         Descriptions           The portion to be lubricated                 Amount : g (oz)

            2                                  Cylindric portion where                        Approx. 0.1 (0.01)
                           Hammer case
                                               7 anvil reciprocates.
                                               * The hole portion where 17 spindle
            7              Anvil                  contacts.                                   Approx. 0.5 (0.02)
                                               * The portion where hammer
                                                 contacts.
                         31 pcs. of
            9
                         Steel balls 3.5                                                      Approx. 0.5 (0.02)
                                               * The side where 9 steel balls 3.5             in total
           10           Flat washer 32
                                                 contact.
                         2 pcs. of
          13                                                                                  Approx. 0.5 (0.02)
                         Steel balls 6.4
           14            2 cps. of Spur
                                                                                              Approx. 2.0 (0.07)
                         gears 32               Teeth portion
                                                                                              in total
          20            Internal gear 71
                                               * The groove portion where 13 steel
                        Spindle                   balls 6.4 move.                             Approx. 0.5 (0.02)
          17
                                               * The hole portion where armature
                                                 gear is inserted.
Repair                                                                                                            P 5 / 13
< 2 > Removing armature
   ( 1 ) After removing brush holder cap and carbon brushes, remove bumper with a slotted head screwdriver. See Fig. 1.
   ( 2 ) Unscrew 4 pcs. of hex socket head bolts M5x50 together with urethane rings and cup washers each 4 pcs.
        Then, hammer case section can be removed from motor housing together with armature. See Fig. 2.

                         Brush holder cap                                   Hex socket head bolts M5x50 5
      Bumper             Carbon brush                                                     Urethane rings 5
                                                                           Armature      Cup washers 5




     Brush holder cap                                     Hammer case                                        Motor housing
     Carbon brush                                                 Internal gear cover

                                                                  Hammer case
                                                                  section

                        Fig. 1                                                          Fig. 2


   ( 3 ) Do not separate internal gear cover from hammer case, because the grease leaks out, or inner parts can fall off
         the hammer case. Then, holding hammer case together with internal gear cover, pull off the armature
         as illustrated in Fig. 3.




                                                                             Armature

                                                     Hammer caseInternal gear cover

                                                                  Fig. 3

< 3 > Disassembling mechanical section
   ( 1 ) Separate internal gear cover from hammer case. Take off the following parts from hammer case. See Fig. 4.
                * Flat washer 19          * Internal gear 71
                * Anvil                   * O ring 58
                * Hammer section
         Remove O ring 12 from internal gear case.

                 Flat washer 19          Hammer section               Internal gear cover
                                                          O ring 58


                                                                                                                      Anvil

                                 Anvil
                                                                        O ring 12
            Hammer case                        Internal gear 71
       
        * Flat washer 19 can remain in hammer case.
        * Inner parts can be removed from hammer case
          by hand. However, if it is difficult to remove by
          hand, strike anvil with plastic hammer. See Fig. 4A.                                   Fig. 4A

                                   Fig. 4
Repair                                                                                                          P 6 / 13
< 4 > Assembling mechanical section
    Before assembling, apply MAKITA grease N. No.1 with referring to "< 1 > Lubrication" at page 4.

    1. Mount O ring 58 to internal gear cover. Aligning the tabs of internal gear with the accepting holes of
       internal gear cover, mount internal gear 71 to internal gear cover. See Fig. 5.

                                                     Align these Tabs with the
                                                     accepting holes of internal
                                                     gear cover.




                      Internal gear 71      O ring 58       Internal gear cover

                                                  Fig. 5

    2. Mount hammer section with engaging spur gears 32 with internal gear 71. see Fig. 6.

                                 Spur gears 32    Internal gear 71
                                                               Internal gear cover




                                                                      Fig. 6
                                         Hammer section


    3. Mount flat washer 19 and anvil to hammer case. And mount hammer section, internal gear 71 and internal
       gear cover to hammer case. Mount O ring 12 to internal gear cover. See Fig. 7.

           Internal gear cover                                                                   O ring 12
              Internal gear 71
              Hammer section


                           Anvil

                                                          Flat washer 19 : This part can remain
                                                                           in hammer case, when
                                                                           disassembling the mechanical
                 Hammer case                                               section.

                                                             Fig. 7


< 5 > Disassembling hammer section
    1. Remove flat washer 18 and 2 pcs. of pin 6 from spindle. Then, 2 pcs. of spur gear 32 can be removed. See Fig. 8.

                                       Flat washer 18
                                                                               Pin 6
                                                  Pin 6                                Spur gear 32

                                   Spur gear 32                                        Spindle

                                                                                       Hammer
                                                             Fig. 8
Repair                                                                                                          P 7 / 13
   2. Pull hammer toward spur 32 side with "No.1R045 Gear extractor", and in order to take out steel ball 6.4
      align the top of cam groove of spindle with the opening portion of hammer. See Fig. 9.




                                                 No.1R045
                                                 Gear extractor




                                                                              Steel ball 6.4
                                              The top of cam groove
                                                       and
                                          The opening portion of hammer
                                                         Fig. 9

   3. Loosen the handle of "No.1R045 Gear extractor" slowly until the spindle is free from the compression spring 32.
      See Fig. 10. Then, the hammer section can be disassembled as illustrated in Fig. 11. And then, 31 pcs.of steel ball 3.5
      and flat washer 21 can be removed from hammer as illustrated in Fig. 11A.




                                                  Spindle                                                31 pcs. of steel
                                                                                                         balls 5.5
                                              Cup washer 19

                                                 Compression                                      Flat washer 21
    Hammer
                                                 spring 32
                                                                              Hammer                   Fig. 11A




                                Spindle              31 pcs. of steel ball 3.5
                                                     and flat washer 21 remain
            Fig. 10                                  in hammer in this stage.
                                                                    Fig. 11

         < Note >
         Do not hold the hammer section as illustrated in Fig. F.
         Because, steel balls 3.5 fall off the hammer, when separating spindle
         from hammer.



                                                                                                      Fig. F
Repair                                                                                                          P 8 /13
< 6 > Assembling hammer section
     1. Put 31 pcs. of steel ball 3.5 and flat washer 32 into hammer. See Fig. 12
        After mounting compression spring 32, cup washer 19 and spindle to hammer, press the hammer toward the spur
        gear installing side with "No.1R045 gear extractor" . See Fig. 13.




                       Flat washer 32

                                                                           No.1R045
                                                    Spindle                Gear extractor

                       31 pcs. of
                                               Cup washer 19
                       steel balls 3.5
                                               Compression
                                               spring 32

                                                  Hammer
             Fig. 12


                                                                                Fig. 13



    2. Align the top of cam groove of spindle with the opening portion of hammer. And then, mount 2 pcs. of
       steel ball 6.4 to spindle. See Fig. 14. Mount spur gears 32, pins 6 and flat washer 18 to spindle. See Fig. 15.

                              Steel ball 6.4




                                                               Flat washer 18
                                                                                                 Pin 6
                                                                        Pin 6
                                                                                                          Spur gear 32


                                                                                                      Spindle
                                                        Spur gear 32

                                                                                                     Hammer

             The top of cam groove
                      and
         The opening portion of hammer

                             Fig. 14                                               Fig. 15


    3. Mount the assembled hammer section to the machine with referring to "< 4 > Assembling mechanical
       section" at page 6.
Repair                                                                                                               P 9 / 13
< 7 > Removing baffle plate
   1. Slide baffle plate to the overhang portion of handle cover. And remove it by pulling in the direction of
      black arrow.
                                                        Baffle plate

                    Baffle plate




             Overhang portion
             of handle cover


                     Handle cover



                                                                Fig. 16


< 8 > Removing handle cover and F/R change lever
    1. After removing hook, unscrew 3 pcs. of tapping screw 4x18, and disengage switch from F/R change lever.
       See Fig. 17.

                                                                F/R Change lever                F/R Change lever
                                               Handle cover
                                                                                                                   Switch



                                    Tapping screws
             Hook                   4x18




                                                     Fig. 17


    2. Push F/R change lever in the direction of the arrow 1. Pull the lever in the direction of 2, and then, pull out in the
       direction of 3. So, F/R change lever can be removed from handle cover. See Fig. 18.




                     Handle cover



                                                                              1



                   F/R change lever

                                         2
                                                                          3
                                                      Fig. 18
Repair                                                                                                             P 10 /13
< 9 > Mounting handle cover and F/R change lever
     1. Push F/R change lever in the direction of the arrow 1. Push the lever in the direction of 2, and then, push in the
        direction of 3. So, F/R change lever can be mounted to handle cover. See Fig. 19.

                   The groove for engaging with switch is carved
                   another side of this portion

                                             Marking about material

              2                                      3

                                           < Note >
                                           Face the marking about material
                                           to the mechanical section side
                                           ( up side) as per the illustration,
                                           so the groove for engaging with switch
                                           faces automatically to switch, and
                                           possible to mount F/R change lever
         1
                                           to handle cover and engage it with
                                           switch.
                                 Fig. 19


     2. Engaging the tab of switch with the groove
        of F/R change lever, mount switch to
        handle cover. See Fig. 20.                                                                      Tab of switch




                                                             F/R Change lever




                                                                           Fig. 20


     3. Mount handle cover to motor housing and fasten it with 3 pcs. of tapping screw 4x18. Mount hook.
        See Fig. 21.

                                   F/R Change lever


             Handle cover



             Tapping screws
             4x18

                                                               Hook




                                                   Fig. 21
Circuit   diagram without Line Coil                                                                                      P 11 / 13

    Color index of lead wires                                                          Left
   Black                                                                               (viewing from
   White                                                                               armature fan side)
   Red
   Orange
   Blue
                                           Right                                      The following illustration of
   Purple                                                                             field shows the view from
   Brown
                                           (viewing from
                                                                                      armature fan side.
   See-through                             armature fan side)



                                                                                                      Choke coils
                                                                                                      clamped on field

          Right                                                                                       Left
          viewing from                                                Field                           viewing from
          armature fan side                                                                           armature fan side




                                                                      Switch
                                                          3                      1
               Connect this grounding
               terminal with field core.                          4                   M1
                                                                                           2
                                                              1         2
                                                                            C2   M2
                                                                      C1




                                                                                                       Noise
                                                                                                       Suppressor
                                           Power Supply
                                           Cord




    < Note >
     * Choke coils are not used for all countries.
     * Noise suppressor is not used for all countries.
     * Noise suppressor of two lead wire type is used for some countries in stead of
       three lead wire type.
Circuit   diagram with Line Coil                                                                                        P 12 /13

    Color index of lead wires
   Black                                                                                  Left
   White                                                                                  (viewing from
   Red                                                                                    armature fan side)
   Orange
   Blue
   Purple
                                          Right                                       The following illustration of
   Brown
                                          (viewing from                               field shows the view from
   See-through                                                                        armature fan side.
                                          armature fan side)


                                                                                                     Choke coils
                                                                                                     clamped on field

           Right                                                                                      Left
           viewing from                                              Field                            viewing from
           armature fan side                                                                          armature fan side

                                                                                                                      Insulated
                                                                                                                      Terminals

                                                                     Switch
                                                         3                      1
              Connect this grounding
              terminal with field core.                          4                   M1
                                                                                          2
                                                             1         2
                                                                           C2   M2
                                                                     C1

                                                                                                   Line
                                                                                                   Coil

                                                                                                      Noise
                                          Power Supply




                                                                                                      Suppressor
                                          Cord




                                                                                               White lead wires can be used for
                                                                                               connecting insulated terminals
                                                                                               to line coil.
Wiring   diagram                                                                                 P 13 / 13


   Mount field paying attention to the following matters.
   1. Poke in terminal side has to be
      faced to armature fan side.                                                    Insulation cover
   2. Orange lead wire side has to be                     Insulation cover
      located on switch side.

      Poke in terminals                                           Armature              Armature
                                                                   Fig.A                 Fig.B
                                                     Insulation covers have to be mounted as per Fig. A.
         Orange                                      Do not mount them as per Fig. B.
         lead wire                                                         Insulation cover
                                Switch

 Pass the field lead wires along the
 wall of motor housing.

      The lead wire of tab terminal
      has to be put in the space between
      rib and wall of motor housing.
      Do not put on the rib.
                             Wall of
                             motor housing
                                                                             Put the slack portion of
                                                                             lead wires into the space
                                                                             between field core and
                                                                             the wall of motor housing.
                                                             Switch
                              Rib

                       Tab terminal




                                          Line coil
                     Handle cover         if it is used.                            Insulated
                                       Noise                                        terminal
                     Sponge sheet      suppressor,
                                       if any.                                  Put lead wires of power
               Put sponge sheet                                                 supply cord on the right
               into the illustrated                                             side of rib.
               position
                                         Rib



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