ECHNICAL INFORMATION
PRODUCT
P 1 / 13
T
Models No.
Description
BHR202
W
Cordless Combination Hammer
H
CONCEPT AND MAIN APPLICATIONS
The subject model features 18V Li-ion Battery and 3 mode selection
for ensuring an operator its easy handling and versatility.
The highly durable tool head mechanism is the same as AC model HR2470.
L
These new products are available in the following variations.
Battery
Type
Plastic
carrying case
Model No.
Charger
Dimensions: mm (")
Length (L) 358 (14-1/8)
Quantity
BHR202RFE
BHR202RF
BHR202Z
2
1
Yes
DC18RA
No
BL1830
No
Width (W)
Height (H)
84 (3-5/16)
Yes
No
259 (10-1/4)
---
The variations for USA, Canada, Mexico and Panama are as follows.
Battery
Type
Plastic
carrying case
Model No.
Charger
Quantity
BHR202
BL1830
No
2
DC18RA
No
Yes
No
BHR202Z
---
Specification
No load speed: (min-1= rpm)
Blows per min: (bpm=min-1)
Max. Output(W)
0 - 1,100
0 - 4,000
330
Voltage: V
18
Battery
Cell and Capacity
Charging Time
Li-ion 3.0 Ah
approx. 22 min. with DC18RA
Chuck Capacity: mm ( " )
Bit Shank
10 (3/8)
SDS plus
13 (1/2)
26 (1)
Steel
Capacity
Wood
: mm ( " )
* Concrete: 24 (15/16) for North
America
20 (13/16)
3 modes
* Concrete
Operation mode
(Rotation only/ Rotation with Hammering/ Hammering only)
Variable switch
Reverse switch
Yes
Yes
Yes
Clutch (Torque Limiter)
Electric Brake
LED Light
Yes
Yes
Net Weight: kg (lbs)
3.2 (7.0) including Battery BL1830
Standard equipment
* Grip Assembly ................ 1 set
* Depth Gauge (Stopper Pole) ............ 1 pc.
Note: The standard equipment for the tool shown above may differ by country.
Optional accessories
* SDS-Plus bits
* Drill chuck S13
* Grooving chisels * Bit grease
* Scaling chisels * Blow out bulb
* Keyless drill chuck * Bull points * Safety goggle
* Grip assembly * Dust cup set
* Scraper Assembly * Dust cups
* Cold chisels * Grease Vessel 30g * Hose
* Hammer service kit
* Charger DC18RA
* Charger DC18SC
* Taper shank T.C.T bits * Chuck key S13
* Taper shank adapter
* Cotter
* Dust extractor attachment * Charger DC24SA
* Joint 25 * Charger DC24SC
* Drill chuck assembly
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P 3 / 13
Repair
[2] LUBRICATION (cont.)
Item No. Description
Portion to lubricate
Lubricant
Amount
40
O ring 16
Whole portion
Makita grease R No. 00
(f) Inside where Striker moves
(g) Hole for accepting Piston joint
41
Piston cylinder
(h) Surface where 30 Tool holder complete contacts.
Molybdenum disulfide
lubricant
(Refer to Fig. 1.)
49
50
Spur gear 10
Cam shaft
Gear teeth where 28 Spur gear 51 engages (Refer to Fig. 1.)
Surface where 51 Clutch cam and 49 Spur gear 10 contact
(i) Outside groove
Makita grease R No. 00 a little
Molybdenum disulfide
lubricant
51
Clutch cam
(j) Side where 52 Swash bearing 10 engages
Pole portion which is inserted into Piston joint
Bearing portion
52
53
63
Swash bearing 10
4g
Helical gear 25 Teeth portion
17g
Makita grease R No. 00
Inner housing
complete
Space where Armature's drive end and 53 Helical gear 25
engages
a little
Gear housing
complete
17
5g
(k) Crank room
Swash Bearing Section
Flat washer 12
Fig. 2
Makita grease R No. 00
Molybdenum disulfide
lubricant
40
41
(f)
Piston joint
Compression spring 7 Striker
Ball bearing 606ZZ
(h) (g)
Armature
(k) Crank room
(g)
(j)
(i)
Retaining ring S-7
49
50
51
52 53
63
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Tool Holder Section
DISASSEMBLING
Disassemble Tool holder section as illustrated in Fig. 3.
Fig. 3
Chuck cover
Ring 21
1R003
1R212
Guide washer
Cap 35
Conical compression
spring 21-29
Steel ball 7.0
Ring
spring 19
Ring 21
Ring 21
Chuck cover
Disassemble Cap 35 and remove
Ring spring 19 with 1R003 and 1R212.
Note: Replace the tips of 1R003 to
those of 1R212.
Disassemble Chuck cover.
And remove Steel ball 7.0
while pressing down Ring 21.
After disassembling Steel ball 7.0,
the Tool holder section can be
disassembled as illustrated above.
ASSEMBLING
Do the reverse of the disassembling step. Refer to Fig. 3.
Note: Be sure to place the flat portion of Ring spring 19 on Steel ball 7.0.
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P 4 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Change Lever
DISASSEMBLING
Disassemble Change lever as illustrated in Figs. 4 and 5.
Fig. 4
Fig. 5
Change lever
Drill mode
Lock button
Pushing Lock button into Change lever,
turn Change lever fully to Drill mode
until it stops.
Remove Change lever by levering up it with Slotted head screwdriver,
inserted between Gear housing complete and Change lever.
ASSEMBLING
1) Assemble Change lever to Gear housing complete in the order of Figs. 6 and 7.
2) Make sure that Change lever stops at every operation mode exactly after assembling.
Fig. 6
Fig. 7
Hammer drill
mode
Lock button
small pin
of Change
lever
Lock plate
Drill mode
large pin of Change
lever
Lock plate can be seen through the hole
for Change lever insertion before
mounting Change lever.
When inserting Change lever into Gear
housing complete, contact the small pin
to this Lock plate as designated in gray
color. Change lever can be inserted in
Hammer drill mode.
Pushing Lock button into Change
lever, turn Change lever fully
to Drill mode until it stops.
Pushing Lock button into Change
lever, tap Change lever.
Change lever can be assembled to
Gear housing complete.
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P 5 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Armature
DISASSEMBLING
1) Remove Holder cap cover by inserting Slotted screwdriver between Holder cap cover and Motor housing complete.
(Fig. 8) Then remove Holder cap and Carbon brushes.
2) Seperate Gear housing complete from Motor housing complete by loosening 4x40 Tapping screws (4 pcs.).
Armature is left on Gear housing complete in this step. (Fig. 9)
3) Pull Armature out from Gear housing complete by hand. (Fig. 10) This way is easier than using Plastic hammer to strike
Gear housing portion. (Ball bearing 6000DDW of Armature is tightly fit into the bearing room in Gear housing complete
using O ring 26. )
Fig. 8
Holder cap cover
Fig. 9
Gear housing
complete
Fig. 10
Ball bearing 6000DDW
of Armature (behind the Fan)
Motor housing
complete
bearing room of
Gear housing complete
4x40 Tapping screws (4 pcs.)
ASSEMBLING
Do the reverse of the disassembling step.
[3] -5. Torque Limiter Section
DISASSEMBLING
1) Disassemble Tool holder section as illustrated in Fig. 3.
2) Disassemble Change lever as illustrated in Figs.4 and 5.
3) Separate Gear housing complete from Motor housing. Then remove Armature from Gear housing complete. (Figs. 8 to 10)
4) Disassemble Torque limiter section as illustrated in Figs. 11 and 12.
5) Remove the Ring spring 29 to separate Washer 31, Compression spring 32 and Spur gear 51 (Figs. 13 and 14)
Fig. 12
Fig. 11
Torque limiter section
Piston cylinder
Gear housing complete
Torque limiter
section
Remove Torque limiter
section from Gear housing
complete by striking
Chuck assembling portion
with Plastic hammer.
Flat washer 28
Inner housing complete
Remove Torque limiter section from Piston
cylinder and Inner housing complete.
Ball bearing 606ZZ remains fixed in Gear housing complete.
Fig. 13
Fig. 14
Assemble two pcs. of 1R022 to 1R306 and hold them to the ram
of arbor press. Put Torque limiter section on the table of arbor press.
While compressing Compression spring 32 by
pressing down Washer 31 using arbor press,
remove Ring spring 29 using 1R004.
Spur gear 51 can be removed.
1R036
ram of arbor press
1R022 (2 pcs.)
Ring spring 29
1R004
Washer 31
Washer 31
Ring spring 29
Table of arbor press
Spur gear 51
Compression spring 32
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P 6 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Torque Limiter Section (cont.)
ASSEMBLING
Do the reverse of disassembling steps.
Note: Do not forget to assemble Flat washer 28 between Torque limiter section and Inner housing complete. Refer to Fig. 12.
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Needle Bearing Complete and Oil Seal 25
DISASSEMBLING
1) Disassemble Torque limiter section and Inner housing complete from Gear housing complete.
See Disassembly of [3] -5. Torque Limiter Section.
2) Insert Inner housing complete into Gear housing complete. (Fig. 15)
3) Remove Needle bearing complete and Oil seal 25. (Fig. 16)
Fig. 16
Fig. 15
Oil seal 25
Needle bearing
complete
As the side for joining to Motor
housing is not flat, Gear housing
complete can not stand vertically
without support.
1R252
1R252
Therefore, insert Inner housing
complete into Gear housing
complete as a support.
Applying 1R252, press it with Arbor press.
Needle bearing complete is removed
together with Oil seal 25 from Gear
housing complete.
Gear housing complete
Inner housing complete
ASSEMBLING
1) Assemble Oil seal 25 to Gear housing complete in the order of Figs. 17 and 18.
2) Assemble Needle bearing complete as illustrated in Figs. 19 and 20.
Fig. 17
Fig. 18
With 1R232 and arbor press, insert Oil seal 25 until it stops.
Oil seal 25 is not yet inserted completely in this step,
because the outer diameter of 1R232 is bigger than that of
Oil seal setting hole.
Press Oil seal 25 to the initial position with arbor press
and the outer diameter 34mm end surface of 1R164.
1R232
outer diameter: 30mm
1R164
1R164
outer diameter: 36mm
Oil seal 25
The diameter of Oil seal 25 setting
hole is less than 36mm.
outer diameter: 34mm
The initial position of Oil seal 25
Fig. 20
Fig. 19
Face the flat portion of Needle bearing complete to
the belly side of Gear housing complete.
1R164
Press Needle bearing with
arbor press and the outer
diameter 34mm end
surface of 1R164 until
Needle bearing complete
stops.
flat portion
Needle bearing complete
belly side
back side
Needle bearing complete
Oil seal 25
Gear housing complete
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P 7 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Impact Bolt Section
DISASSEMBLI NG
1) Referring to "[3] -5. Torque Limiter Section", disassemble Ring spring 29, Washer 31, Compression spring 32
and Spur gear 51 from Tool holder complete. Refer to Figs. 11 to 14.
2) Holding Gear housing complete in vise and 1R038, Tap Ring spring 28 in Tool holder complete as illustrated in Figs. 21
and 22.
3) Remove Ring spring 28 from Tool holder complete and disassemble Impact bolt section. (Figs. 23 to 24)
Fig. 21
Fig. 23
end of Ring spring 28
Ring spring 28
Ring spring 28
Ring spring 28 can be pulled off from Tool holder
complete when completely removed from the
groove.
When the end of Ring spring
28 is in the hole of Tool holder
complete, slide the end to the
blind side using a slotted
screwdriver.
Note: Be sure to replace Ring spring 28
when assembling Tool holder section.
Fig. 22
Fig. 24
Tool holder
complete
Tap Ring spring 28 from
the two holes alternately
to push downward.
1R038
Impact bolt section
Sleeve 9
Tool holder
complete
Impact bolt
Ring 10
Disassemble Impact bolt
section by striking Tool
holder complete against
workbench.
Vise
Ring spring 28
Cushion ring 13
O ring case
ASSEMBLING
1) Referring to Figs. 25, 26 and 27 assemble the Impact bolt section to Tool holder complete as illustrated in Fig. 28.
Fig. 25
Fig. 26
Fig. 27
Note: Do not put the end of the ring spring 28 into
Note: Make sure O ring 9
is mounted to O ring
case in advance.
Note: This end has to be inserted
into Sleeve 9.
the two holes on Tool holder complete.
Incorrect assembling causes
trouble in hammering.
O ring case
Correct
end of
Impact bolt
hole
Ring spring 28
Wrong
20mm 15.5mm
O Ring 9
Fig. 28
Tool holder
complete
Sleeve 9 Impact bolt
Cushion ring 13
O ring 9
Ring 10
O ring case
Ring spring 28
Impact Bolt Section
assembled in Tool holder
complete
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P 8 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Impact Bolt Section (cont.)
ASSEMBLING
2) Push Ring spring 28 with Piston cylinder until it fits to the inner groove of Tool holder complete. (Fig. 29)
Fig. 29
Note: Use an extra Piston cylinder as a jig. Never use Piston cylinder that is to be
assembled to the machine.
Piston cylinder
as a repairing jig
Piston cylinder
as a repairing jig
Inner groove of
Tool holder complete
Ring spring 28
Tool holder
complete
Ring spring 28
O ring case
[3] -8. Swash Bearing Section
DISASSEMBLING
1) Disassemble Tool holder section as illustrated in Fig. 3.
2) Disassemble Change lever as illustrated in Figs. 4 and 5.
3) Separate Gear housing complete from Motor housing complete. And then, remove Armature from Gear housing complete.
(Refer to Figs. 8 to 10.)
4) Remove Stop ring E-4, Flat washer 5 and Compression spring 6 from pin of Inner housing complete. (Fig. 30)
5) Remove two M4x12 Hex socket bolts that fasten Bearing retainer to Inner housing complete. (Fig. 31)
Fig. 30
Fig. 31
Pin of Inner housing complete
M4x12 Hex socket
head bolt (2 pcs.)
Stop ring E-4
Flat washer 5
Compression spring 6
Change plate
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P 9 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -8. Swash Bearing Section (cont.)
DISASSEMBLING
6) Move Piston cylinder to the rear dead center position (Fig. 32).
7) Remove Swash bearing section from Inner housing by pulling in the direction of the arrow. Then, remove Change plate
from the groove of Clutch cam. (Fig. 33).
Fig. 32
Fig. 33
Piston cylinder
in the rear dead center position
Swash bearing section
Inner housing complete
Change plate
Piston
cylinder
Swash bearing section
Change plate
Clutch cam
8) Remove Ball bearing 606ZZ from Gear housing complete using the removed Swash bearing section as a jig as follows;
* Insert Cam shaft of Swash bearing section into the Ball bearing again.
* Tilt the Ball bearing a little bit by moving Swash bearing section as illustrated to left in Fig. 34.
* Ball bearing 606ZZ can now be removed by lightly tapping the edge of Gear housing complete with plastic
hammer as illustrated to right in Fig. 34.
Fig. 34
Gear housing
complete
Swash bearing section
used as a jig
Ball bearing 606ZZ
9) Remove Ring 8 using 1R022, 1R023, 1R281 and arbor press as illustrated in Fig. 35.
10) Remove Ball bearing 608ZZ using 1R269. Flat washer 8 and Bearing retainer can now be removed by hand. (Fig. 36)
Fig. 35
Ring 8
Fig. 36
Ball bearing 608ZZ
1R269
Ring 8
1R281
1R022
Bearing retainer
Flat washer 8
1R022
Ball bearing
608ZZ
1R023
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P 10 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -8. Swash Bearing Section (cont.)
DISASSEMBLING
11) Remove Helical gear 26 using 1R022, 1R023 and 1R281.
as illustrated to left in Fig. 37. Swash bearing 10 and Clutch cam can now be removed by hand (right in Fig. 37).
12) Remove Retaining ring S-7 using 1R291 (left in Fig. 38). Compression spring 7 and Spur gear 10 can now be removed
by hand. (right in Fig. 38).
Fig. 37
Fig. 38
Swash
bearing 10
Cam shaft
1R281
1R022
Clutch cam
Helical gear 26
Retaining
ring S-7
Spur gear 10
Compression
spring 7
1R291
1R023
ASSEMBLING
1) Assemble Swash bearing section using 1R032, 1R033, 1R291 and arbor press as illustrated in Fig. 39.
Note: Be sure to put Flat washer 8 in place, or else Bearing retainer will be clamped between Ball bearing 608ZZ
and Helical gear 26.
Fig. 39
Swash
Helical gear 26
bearing 10
Cam shaft
Clutch cam
1R032
1R033
Retaining ring S-7
Compression spring 7
Cam shaft
Spur gear 10
Flat washer 8
Bearing retainer
Ring 8
Ball bearing
608ZZ
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P 11 / 13
Repair
[[3] DISASSEMBLY/ASSEMBLY
[3] -8. Swash Bearing Section (cont.)
ASSEMBLING
2) Assemble Piston joint and two Flat washers 12 to Piston cylinder as illustrated in Fig. 40.
Note: Do not forget to apply Makita grease R No.00. Refer to Fig. 2.
3) Insert Piston cylinder into Inner housing complete. (Fig. 41).
Fig. 40
Fig. 41
Inner housing
Correct
Wrong
Piston cylinder
Piston joint
Flat washer 12
Flat washer 12
4) Move Piston cylinder to the rear dead center position. (Fig. 42)
5) Insert the pole of Swash bearing 10 into the hole of Piston joint as illustrated in Fig. 43.
Fig. 42 Fig. 43
Piston cylinder
hole of Piston joint
Piston cylinder at
rear dead center
position
hole for the pole of
Swash bearing 10
Flat
washer 12
pole of Swash
bearing 10
Front
Rear
Flat
washer 12
Ring 8
Tilt Swash bearing 10 to insert the pole.
Piston joint
6) Insert Ring 8 (the end of Swash bearing section) into Inner housing complete. (Fig. 44)
7) Fitting the tip of Change plate in the groove on Clutch cam, insert Change plate over the pins of Inner housing complete.
(Fig. 45)
Note: Ball bearing 608ZZ of Swash bearing section is not yet inserted into Inner housing complete in this step.
Fig. 45
Fig. 44
Inner housing complete
Ball bearing 608ZZ
pins of Inner housing complete
Change plate
Ball bearing
608ZZ
Clutch cam
tip of Clutch cam
Swash bearing section
Ring 8
groove
8) Insert Ball bearing 608ZZ of Swash bearing section into Inner housing complete, and fasten Swash bearing section to
Inner housing complete with two M4x12 hex socket head bolts. Then, put Compression spring 6 and Flat washer 5
through the upper pin of Inner housing complete, and secure them with Stop ring E-4 (Fig. 46)
Fig. 46
Flat washer 5 Compression spring 5
Note: If reusing M4x12 hex.
socket head bolts, be sure
to apply ThreeBond 1321B
or 1342, or Loctite 242
Stop ring E-4
to the threads before
fastening.
Upper pin of
Inner housing complete
Ball bearing 608ZZ
Ring 8
M4x12 Hex socket head bolt ( 2 pcs.)
(with threadlocker coated)
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P 12 / 13
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-9. F/R Change Lever
Fig. 47
oval hole of
ASSEMBLING
F/R change
lever
Fit the protrusion of Switch into Oval hole of F/R change lever
and assemble them to Housing L. F/R change lever is symmetric
between right and left, therefore, it is not directional. (Fig. 47)
protrusion of
Switch
Maintenance program
It is recommended to replace the following parts shown below and apply lubricant to the specific parts designated in Figs.
2 and 3 when replacing Carbon brushes.
1
Cap 35
29 Steel
ball 7.0
40 O ring 16
35 Cushion
ring 13
37 O ring 9
38 Ring spring
28
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P 13 / 13
Circuit diagram
Fig. D-1
FET
Color index of lead wires' sheath
Black
White
Blue
Heat dissipation plate
Orange
Yellow
Red
(Housing
R side)
(Housing
L side)
Switch
Tape
Yoke unit
LED
Brush holder
Terminal
Connector
Light
circuit
Wiring diagram
Fig. D-2
Note: Route Lead wires for switch to each lead wire holders and
guide them between insulated terminal and two Ribs.
Insulated terminal
Ribs
Lead wire holder
for blue lead wire
Lead wire holder
for black lead
wire
Lead wire holder
for yellow lead
wire
Install Light circuit so that
Light circuit lead wire (orange)
is located to Terminal side.
Fix Lead wire
for connector
with these Lead
wire holders.
Lead wires for connecting Carbon
brushes
LED
Lead wire holders
Fix LED lead wires with
these Lead wire holders.
Terminal
Fix Lead wires with Lead wire holders on Brush holders.
Brush holders
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