TECHNICAL INFORMATION

TECHNICAL INFORMATION Models No. Description BHR202 Cordless Combination Hammer 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. These new products are available in the following variations. Model No. BHR202RFE BHR202RF BHR202Z Battery Type Quantity Charger Plastic carrying case 2 BL1830 DC18RA 1 No --- No No W L PRODUCT P 1 / 13 Dimensions: mm (") Length (L) 358 (14-1/8) Width (W) Height (H) H 84 (3-5/16) 259 (10-1/4) The variations for USA, Canada, Mexico and Panama are as follows. Model No. BHR202 BHR202Z Specification No load speed: (min-1= rpm) Blows per min: (bpm=min-1) Max. Output(W) Voltage: V Battery Cell and Capacity Charging Time Chuck Capacity: mm ( " ) Bit Shank Variable switch Reverse switch Clutch (Torque Limiter) Electric Brake LED Light Net Weight: kg (lbs) Standard equipment Battery Type Quantity Charger Plastic carrying case BL1830 2 DC18RA No --- No No 0-1,100 0-4,000 330 18 Li-ion 3.0 Ah approx. 22 min. with DC18RA 10 (3/8) SDS plus Capacity : mm ( " ) Steel Wood 13 (1/2) 26 (1) * Concrete 20 (13/16) * Concrete: 24 (15/16) for North Operation mode 3 modes America (Rotation only/ Rotation with Hammering/ Hammering only) 3.2 (7.0) including Battery BL1830 * 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 * Taper shank T.C.T bits * Taper shank adapter * Cotter * Drill chuck assembly * Drill chuck S13 * Chuck key S13 * Keyless drill chuck * Grip assembly * Scraper Assembly * Cold chisels * Grooving chisels * Scaling chisels * Bull points * Dust cup set * Dust cups * Grease Vessel 30g * Bit grease * Blow out bulb * Safety goggle * Dust extractor attachment * Joint 25 * Hose * Hammer service kit * Charger DC18RA * Charger DC18SC * Charger DC24SA * Charger DC24SC

CAUTION: Remove the bit and the battery from the machine for safety before repair/ maintenance in accordance with the instruction manual! [1] NECESSARY REPAIRING TOOLS Code No. Description 1R003 Retaining ring S pliers ST-2N Removing Ring spring 19 1R004 Retaining ring S pliers ST-2 Removing Ring spring 29 [2] LUBRICATION Use for 1R022 Bearing plate(for arbor press) Attachment of 1R306 / Removing and Helical gear 25 1R023 Pipe ring (for arbor press) Removing Helical gear 25 1R032 Bearing setting plate 8.2 Assembling Swash bearing 10 1R033 1R038 1R164 1R165 1R212 1R232 1R252 1R269 1R281 1R291 1R306 Bearing setting plate 10.2 Assembling Helical gear 25 Armature holder 32 set for use Holding Tool holder when removing Ring spring 28 from Tool holder with vise Ring spring setting tool A Assembling Oil seal 25 and Needle bearing to Gear housing Ring spring setting tool B Assembling Needle bearing into Gear housing Tip for Retaining ring pliers Pipe 30 Round bar for arbor 30-100 Bearing extractor Round bar for arbor 7-50 Retaining ring S and R pliers Ring spring removing jig Attachment of 1R003 Assembling Oil seal 25 to Gear housing Removing Oil seal 25 from Gear housing Removing Ball bearing 608ZZ from Swash bearing section Removing Ring 8 from Cam shaft Removing Retaining Ring S-7 from Cam shaft Removing Ring spring 29 from Tool holder 318132-2 Piston cylinder Assembling Ring spring 28 to Tool holder Apply the following grease to protect parts and product from unusual abrasion. * Makita grease R No.00 to the portions marked with black triangle * Molybdenum disulfide lubricant to the portions marked with gray triangle Fig. 1 P 2 / 13 Item No. Description Portion to lubricate Lubricant Amount 1 Cap 35 Lip portion where Bit is inserted 13 16 17 28 29 30 34 37 1 Change lever O ring 17 Gear housing Spur gear 51 Steel ball 7 Tool holder Ring 10 O ring 9 Pin portion Whole portion Inside where Swash bearing section rotates (a) Teeth portion, (b) Surface where Clutch portion of 30 Tool holder contacts Whole portion (c) Surface where Needle bearing contacts (d) Surface where Plane bearing 28 of 63 Inner housing contacts (e) Inside where 41 Piston cylinder reciprocates Surface where Cushion ring 13 contacts Whole portion Tool Holder Section Needle bearing (a) (c) (d) 17 28 29 30 Makita grease R No. 00 Cushion ring 13 34 37 a little Makita grease R No. 00 16 (b) (e) Sleeve 9 Impact bolt 13

P 3 / 13 [2] LUBRICATION (cont.) Item No. Description Portion to lubricate Lubricant Amount 40 O ring 16 Whole portion (f) Inside where Striker moves Makita grease R No. 00 (g) Hole for accepting Piston joint 41 Piston cylinder (h) Surface where 30 Tool holder contacts. Molybdenum disulfide (Refer to Fig. 1.) lubricant 49 Spur gear 10 Gear teeth where 28 Spur gear 51 engages (Refer to Fig. 1.) Makita grease R No. 00 a little 50 Cam shaft Surface where 51 Clutch cam and 49 Spur gear 10 contact (i) Outside groove Molybdenum disulfide 51 Clutch cam lubricant (j) Side where 52 Swash bearing 10 engages 52 53 63 17 Swash bearing 10 Helical gear 25 Inner housing Gear housing Pole portion which is inserted into Piston joint Bearing portion Teeth portion Space where Armature's drive end and 53 Helical gear 25 engages (k) Crank room Makita grease R No. 00 4g 17g a little 5g Fig. 2 Compression spring 7 Ball bearing 606ZZ Swash Bearing Section 40 41 Flat washer 12 Striker (f) (h) (g) Piston joint (k) Crank room (g) Makita grease R No. 00 Molybdenum disulfide lubricant Armature Retaining ring S-7 49 50 (i) (j) 51 52 53 63 [3] -1. Tool Holder Section DIS Disassemble Tool holder section as illustrated in Fig. 3. Fig. 3 1R003 1R212 Ring 21 Chuck cover Cap 35 Ring spring 19 Chuck cover Ring 21 Steel ball 7.0 Ring 21 Guide washer Conical compression spring 21-29 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. 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.

P 4 / 13 [3] -2. Change Lever DIS 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 and Change lever. 1) Assemble Change lever to Gear housing 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, 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.

[3] -4. Armature DIS Holder cap cover Gear housing Motor housing P 5 / 13 1) Remove Holder cap cover by inserting Slotted screwdriver between Holder cap cover and Motor housing. (Fig. 8) Then remove Holder cap and Carbon brushes. 2) Seperate Gear housing from Motor housing by loosening 4x40 Tapping screws (4 pcs.). Armature is left on Gear housing in this step. (Fig. 9) 3) Pull Armature out from Gear housing 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 using O ring 26. ) Fig. 8 Fig. 9 Fig. 10 Ball bearing 6000DDW of Armature (behind the Fan) 4x40 Tapping screws (4 pcs.) bearing room of Gear housing Do the reverse of the disassembling step. [3] -5. Torque Limiter Section DIS 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 from Motor housing. Then remove Armature from Gear housing. (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. 11 Fig. 12 Gear housing Torque limiter section Remove Torque limiter section from Gear housing by striking Chuck assembling portion with Plastic hammer. Ball bearing 606ZZ remains fixed in Gear housing. 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. 1R036 ram of arbor press Flat washer 28 Torque limiter section Piston cylinder Inner housing Remove Torque limiter section from Piston cylinder and Inner housing. 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. 1R022 (2 pcs.) Ring spring 29 Washer 31 1R004 Ring spring 29 Table of arbor press Spur gear 51 Washer 31 Compression spring 32

[3] -5. Torque Limiter Section (cont.) P 6 / 13 Do the reverse of disassembling steps. Note: Do not forget to assemble Flat washer 28 between Torque limiter section and Inner housing. Refer to Fig. 12. [3] -6. Needle Bearing Complete and Oil Seal 25 DIS 1) Disassemble Torque limiter section and Inner housing from Gear housing. See Disassembly of [3] -5. Torque Limiter Section. 2) Insert Inner housing into Gear housing. (Fig. 15) 3) Remove Needle bearing and Oil seal 25. (Fig. 16) Fig. 15 1R252 As the side for joining to Motor housing is not flat, Gear housing can not stand vertically without support. Therefore, insert Inner housing into Gear housing as a support. Gear housing Inner housing Fig. 16 1R252 Oil seal 25 Needle bearing Applying 1R252, press it with Arbor press. Needle bearing is removed together with Oil seal 25 from Gear housing. 1) Assemble Oil seal 25 to Gear housing in the order of Figs. 17 and 18. 2) Assemble Needle bearing 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 ly in this step, because the outer diameter of 1R232 is bigger than that of Oil seal setting hole. 1R232 Press Oil seal 25 to the initial position with arbor press and the outer diameter 34mm end surface of 1R164. outer diameter: 30mm 1R164 outer diameter: 36mm 1R164 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. 19 Fig. 20 Face the flat portion of Needle bearing to the belly side of Gear housing. Needle bearing back side Gear housing flat portion belly side 1R164 Needle bearing Oil seal 25 Press Needle bearing with arbor press and the outer diameter 34mm end surface of 1R164 until Needle bearing stops.

[3] -7. Impact Bolt Section P 7 / 13 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. Refer to Figs. 11 to 14. 2) Holding Gear housing in vise and 1R038, Tap Ring spring 28 in Tool holder as illustrated in Figs. 21 and 22. 3) Remove Ring spring 28 from Tool holder and disassemble Impact bolt section. (Figs. 23 to 24) Fig. 21 end of Ring spring 28 Ring spring 28 Fig. 23 Ring spring 28 When the end of Ring spring 28 is in the hole of Tool holder, slide the end to the blind side using a slotted screwdriver. Ring spring 28 can be pulled off from Tool holder when ly removed from the groove. Note: Be sure to replace Ring spring 28 when assembling Tool holder section. Fig. 22 Tap Ring spring 28 from the two holes alternately to push downward. Fig. 24 Tool holder Tool holder 1R038 Impact bolt section Sleeve 9 Impact bolt Ring spring 28 Vise Disassemble Impact bolt section by striking Tool holder against workbench. Ring 10 Cushion ring 13 O ring case 1) Referring to Figs. 25, 26 and 27 assemble the Impact bolt section to Tool holder as illustrated in Fig. 28. Fig. 25 Fig. 26 Fig. 27 Note: Make sure O ring 9 is mounted to O ring case in advance. O ring case Note: This end has to be inserted into Sleeve 9. Incorrect assembling causes trouble in hammering. Impact bolt Note: Do not put the end of the ring spring 28 into the two holes on Tool holder. Correct hole end of Ring spring 28 O Ring 9 20mm 15.5mm Wrong Fig. 28 Tool holder Sleeve 9 Impact bolt Ring 10 Cushion ring 13 O ring case Ring spring 28 Impact Bolt Section assembled in Tool holder O ring 9

P 8 / 13 [3] -7. Impact Bolt Section (cont.) 2) Push Ring spring 28 with Piston cylinder until it fits to the inner groove of Tool holder. (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 Ring spring 28 Inner groove of Tool holder Piston cylinder as a repairing jig Tool holder Ring spring 28 O ring case [3] -8. Swash Bearing Section DIS 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 from Motor housing. And then, remove Armature from Gear housing. (Refer to Figs. 8 to 10.) 4) Remove Stop ring E-4, Flat washer 5 and Compression spring 6 from pin of Inner housing. (Fig. 30) 5) Remove two M4x12 Hex socket bolts that fasten Bearing retainer to Inner housing. (Fig. 31) Fig. 30 Fig. 31 Stop ring E-4 Flat washer 5 Pin of Inner housing M4x12 Hex socket head bolt (2 pcs.) Compression spring 6 Change plate

P 9 / 13 [3] -8. Swash Bearing Section (cont.) DIS 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 Piston cylinder Swash bearing section Change plate Inner housing Swash bearing section Change plate Clutch cam 8) Remove Ball bearing 606ZZ from Gear housing 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 with plastic hammer as illustrated to right in Fig. 34. Fig. 34 Gear housing 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 Fig. 36 Ring 8 Ball bearing 608ZZ 1R022 1R281 Ring 8 1R269 Bearing retainer 1R022 Ball bearing 608ZZ Flat washer 8 1R023

P 10 / 13 [3] -8. Swash Bearing Section (cont.) DIS 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 1R022 1R281 Helical gear 26 Swash bearing 10 Clutch cam Retaining ring S-7 Cam shaft Spur gear 10 1R023 1R291 Compression spring 7 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 Cam shaft Swash bearing 10 Helical gear 26 Clutch cam 1R032 1R033 Retaining ring S-7 Compression spring 7 Spur gear 10 Flat washer 8 Cam shaft Bearing retainer Ball bearing 608ZZ Ring 8

P 11 / 13 [ [3] -8. Swash Bearing Section (cont.) 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. (Fig. 41). Fig. 40 Fig. 41 Piston cylinder Correct Flat washer 12 Piston joint Wrong Inner housing 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 at rear dead center position hole for the pole of Swash bearing 10 Piston cylinder hole of Piston joint Front Piston joint Flat washer 12 Flat washer 12 Rear pole of Swash bearing 10 Ring 8 Tilt Swash bearing 10 to insert the pole. 6) Insert Ring 8 (the end of Swash bearing section) into Inner housing. (Fig. 44) 7) Fitting the tip of Change plate in the groove on Clutch cam, insert Change plate over the pins of Inner housing. (Fig. 45) Note: Ball bearing 608ZZ of Swash bearing section is not yet inserted into Inner housing in this step. Fig. 44 Fig. 45 Inner housing Ball bearing 608ZZ pins of Inner housing Change plate Ball bearing 608ZZ Swash bearing section Ring 8 tip of Clutch cam groove Clutch cam 8) Insert Ball bearing 608ZZ of Swash bearing section into Inner housing, and fasten Swash bearing section to Inner housing with two M4x12 hex socket head bolts. Then, put Compression spring 6 and Flat washer 5 through the upper pin of Inner housing, and secure them with Stop ring E-4 (Fig. 46) Fig. 46 Flat washer 5 Compression spring 5 Stop ring E-4 Note: If reusing M4x12 hex. socket head bolts, be sure to apply ThreeBond 1321B or 1342, or Loctite 242 to the threads before fastening. Ball bearing 608ZZ Ring 8 Upper pin of Inner housing M4x12 Hex socket head bolt ( 2 pcs.) (with threadlocker coated)

P 12 / 13 [3]-9. 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) Fig. 47 oval hole of F/R change lever 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

P 13 / 13 Circuit diagram Fig. D-1 FET Color index of lead wires' sheath Black White Blue Orange Heat dissipation plate Yellow Red Switch (Housing R side) Brush holder (Housing L side) Yoke unit Tape Terminal LED 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 Lead wire holder for blue lead wire Ribs Lead wire holder for black lead wire Fix Lead wire for connector with these Lead wire holders. Lead wire holder for yellow lead wire LED Install Light circuit so that Light circuit lead wire (orange) is located to Terminal side. Lead wires for connecting Carbon brushes Lead wire holders Terminal Fix LED lead wires with these Lead wire holders. Fix Lead wires with Lead wire holders on Brush holders. Brush holders