Makita LXRH02 1 Series Manual

Models No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
P 1/ 25
BHR242 (LXRH01*1), BHR243 (LXRH02*1)
Cordless Combination Hammer 24mm (15/16")
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 328(12-7/8)
353(13-7/8)
85 (3-3/8)
213 (8-3/8)
The subject models are 24mm (15/16") Cordless Combination Hammers
powered by 18V Li-ion Battery, featuring:
• Efficient Brushless DC motor provides higher productivity than that of
18V Cordless Combination Hammer model BHR202.
• Able to drill in concrete as fast or faster than 24V Cordless Combination
Hammer model BHR200.
•3 operation modes (rotation only/ rotation with hammering/ hammering only)
• Quick change drill chuck for models BHR243 (LXRH02*1) only
• Makita’s first Cordless Combination Hammers with Dust extraction system.
Note: • These products are not compatible with 1.3Ah battery BL1815.
BHR242 (LXRH01*1)
BHR243 (LXRH02*1)
Normal chuck
For Model and its Chuck systemDust extraction system
DX01
Quick change chuckDX02
Battery
Voltage: V
Cell
Capacity: mm (")
Charging time: min.
18
3.0
Yes
Yes
10 (3/8)
13 (1/2)
27 (1-1/16)
24 (15/16)
3.4 (7.6)3.3 (7.2)
1.3 (3.0) for DX01,
1.4 (3.0) for DX02
22 with DC18RC (DC18RA*2)
Note: The standard equipment for the tool
shown above may vary by country.
Bit shank
Chuck capacity: mm (")
Adapted for SDS-PLUS
Steel
Wood
Concrete
Reverse switch
Yes
Variable speed control
by switch trigger
YesConstant speed control
Clutch (Torque limiter)
Weight of Dust
extracting system: kg (lbs)
Weight according to EPTA-
Procedure 01/2003: kg (lbs)
*2: for North and Central American countries only
Side grip assembly ............................ 1
Depth gauge (Stopper pole) .............. 1
Plastic carrying case ......................... 1
Quick change drill chuck set
for BHR243 (LXRH02*1) only ....... 1
0 - 950
0 - 4,700Blows per min.: (bpm=min-1)
No load speed: (min-1= rpm)
Quick change drill chuck No Yes
Operation mode
3 modes
(Rotation only/ Rotation with Hammering/
Hammering only)
*1 Model number for North and Central American countries.
H
L
W
BHR242
BHR243
Dimensions: mm (")
Height (H)
Length (L) 372(14-5/8)
397(15-5/8)
287 (11-1/4)
Width (W) 88 (3-1/2)
DX01
DX02
DX01, DX02
These are the accessories as Makita’s first Dust extracting system exclusively
for model BHR242 (LXRH01*1), BHR243 (LXRH02*1).
This system is designed to collect dust effectively with on-off operation
of the tool’s on-off trigger switch interlocked with this system.
Note: • This system can be applied for concrete drilling only and comes with
Dust case, Filter and 5 pcs. of extra Sealing caps.
• The following parts are available optionally:
Dust case set, Filter set, Plastic carrying case (can be stored with BHR242
or BHR243)
Model BHR242
(LXRH01*1)
BHR243
(LXRH02*1)
Capacity: Ah
54
Energy capacity: W
Li-ion
SDS-PLUS bits, Taper shank T.C.T bits,
Taper shank adapter, Cotter, Center bit,
Core bit adapter, Drill chuck assembly,
Chuck adapter, Drill chuck S13,
Chuck key S13, Keyless drill chuck,
Tool holder set, Dust cup 5 & 9,
Dust cup set, Bull point, Cold chisel,
Grooving chisel, Scaling chisel,
Scraper assembly, Grease vessel 30g,
Blow out bulb, Safety goggles,
Bit grease, Plastic carrying case,
Battery BL1830,
Fast charger; DC18RA*2, DC18RC,
Charger; DC18SC, DC24SC,
Automotive charger DC18SE,
Dust extraction system (DX01, DX02)
L
H
W

[1] NECESSARY REPAIRING TOOLS
DescriptionCode No. Use for
Retaining ring pliers ST-2N1R003 removing Ring spring 19 from Tool holder complete/ Tool holder guide complete
Retaining ring pliers ST-21R004
assembling Cam shaftBearing setting plate 15.21R035
removing / assembling Spiro lock washer 30Gear extractor (large)1R045
assembling Ring 8Bearing setting plate 10.21R033
Tip for Retaining ring pliers1R212 attachment of 1R003
1/4" hex shank bit for M41R228 removing M4 hex socket head bolts (if the bolt head damages.)
T-type hex wrench 3-1271R170 removing M4 hex socket head bolts
Ring spring setting tool A1R164 assembling Oil seal 25 to Gear housing complete
Drill chuck extractor1R139 removing Spiral bevel gear 32
Pipe 301R232 assembling Oil seal 25 to Gear housing complete
Round bar for arbor 30-1001R252 removing Oil seal 25 from Gear housing complete
V block1R258 assembling Oil seal 25 to Gear housing complete
Bearing extractor1R269 removing Ball bearing 626DDW
Round bar for arbor 7-501R281 removing Spiral bevel gear 32
Ring spring 26 setting tool B1R273 assembling Cup sleeve / Ball bearing 6806LLU to Gear housing complete
1R356 removing Ball bearings from Rotor
Jig for Spiro lock washer for
spring type models
1R369 removing / assembling Spiro lock washer 30
Ring spring extractor1R388 removing Ring spring 28
Bearing plate 10mm for
arbor press
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
removing Retaining ring 21 for BHR243 from Armature shaft
Repair
P 2/ 25

[2] LUBRICATION
Apply the following grease to protect parts and product from unusual abrasion.
Fig. 1
Item No. Description Portion to lubricate Lubricant
See
Fig. 3.
Amount
3g
a little
a little
a little
3g
Compression spring
14
End to be fixed to the boss in Inner housing complete
(See Fig. 3.)
Makita grease RB No.00
Makita grease RB No.00
49
51
Piston joint Grooves that contact 49 Guide plate
50
57
59
46
46
48
Clutch cam A
Swash bearing 10
Striker
Piston cylinder
Guide plate Inside that contacts 50 Piston joint
56 Spur gear 10 Gear portion that engages with Spur gear 51
Whole surface of projection
47 O ring 17.5 Whole surface
(f) Pole portion to be inserted into 50 Piston joint
(h) Inside of hole
60
73
Spiral bevel gear 32
Flat fillister HD pin 6
Portion that contacts the hinge of Inner housing complete
74 76 Weight holder guide
75 Counter weight
80 Spiral bevel gear 11
complete
Makita Grease FA No. 2
Gear portion that engages with Armature shaft gear
(a) Inside where Striker moves
(b) Outside that contacts Tool holder (guide) complete
58 Cam shaft
(e) Cylindrical portion to be inserted into 56 Spur gear 10
(g) Ball bearing portion
(c) Gear portion that engages with 57 Clutch cam A
(d) Portion to be inserted into 59 Swash bearing 10
Gear portion that engages with 60 Spiral bevel gear 32
[in the room of Inner housing complete for Spiral bevel gear 32]
Gear portion that engages with 58 Cam shaft
47 48
57
59 60
58
49 50 51
75
74
73
76
80
(a)
(c) (d)
(b)
Transmission parts
Counterweight
section
and
Makita grease RB No.00
Molybdenum disulfide
Repair
P 3/ 25
(g)
hinge of Inner
housing complete
(h)
(f)
(e)
56

Put 16g Makita grease RB No 00 by using the space
(designated by the black dot) to lubricate
Swash bearing section and Cam shaft section.
boss for fixing
Compression
spring 14
Inside view of
Inner housing
Fig. 2
Fig. 3
BHR242 BHR243
Item No. Description Portion to lubricate Lubricant Amount
a little
a little
2g
Cross section around
Swash bearing 10
Cap 35
O ring 21
1
22
Gear housing complete
Spur gear 51
15
32
Steel ball 7.0
28
Tool holder complete
Tool holderguide complete
30
Lip portion where Bit is to be inserted
Entire surface
(b) Inside where Swash bearing section rotates
(See Fig. 3.)
(c) Gear portion
(a) Oil seal 25 in Gear housing complete
Entire surface
Inside where 48 Piston cylinder reciprocates
Push corn25 Outer surface
6
8
105
109
30
Ring 21 Inner periphery
Sleeve 9B
39 Inside where Impact bolt A/ B reciprocates
Washer 1041
Entire surface
O ring 944
(d) Surface where Clutch portion of 30 Tool
holder (guide) complete contacts
114 Steel ball 6 Entire surface
118 Steel ball 5.0 Entire surface
[2] LUBRICATION (cont.)
Apply the following grease/ oil to protect parts and product from unusual abrasion.
P 4/ 25
Repair
Makita lubricating oil
VG100
Makita grease
RB No.00
Makita grease
RB No.00
BHR242
BHR243
8
1
Impact bolt A
Impact bolt B
32
39
40
(c)
15
25
(b)
(a)
44
41
(d)
30
108
118
114
105
109
22
Quick change drill chuck: Apply Makita grease RB No. 00 to
two Steel balls 6 and one Steel ball 5.
Steel ball 6
(2 pcs.)
Steel ball 5
Rubber washer 16 Inner periphery
108 Stopper Inner periphery
6
28

[3] DISASSEMBLY/ASSEMBLY
[3] -1A. Bit holder section for BHR242
DISASSEMBLING for BHR242
Repair
P 5/ 25
Chuck cover
Chuck cover
Chuck coverCap 35
Groove of
Tool holder
complete
Tool holder
complete
(1) Remove Cap 35.
(2) Separate Ring spring 14 from the groove of Tool holder complete using
1R003 with 1R212. (Fig. 4)
Washer 16 on Ring spring 15 is removed.
(3) Remove Ring spring 15 in the same way while pressing down Chuck cover.
(Fig. 5) Then pick up Flat washer 17 and Rubber washer 16
from the space between Chuck cover and Tool holder complete.
Chuck cover is removed.
(4) Remove two Steel balls 7.0 while pressing down Ring 21. (Fig. 6)
Ring 21, Guide washer and Conical compression spring 21-29 are removed.
Fig. 4
Fig. 5
Fig. 7
Fig. 6
ASSEMBLING
Assemble by reversing the disassembly procedure. Refer to Fig. 7 for the directions of the components.
Cap 35
Ring spring 14
(black)
Ring spring 14
(black)
Ring spring 15
(silver)
Ring spring 15
(silver)
Flat washer 17
1R003
1R212
Ring 21
Ring 21
Guide washer
Guide washerWasher 16
chamfered
portion
Conical compression
spring 21-29
Conical compression
spring 21-29
Steel ball 7.0
(2 pcs.)
chamfered
portion
concave
side
Steel ball
7.0 (2 pcs.)
Flat washer 17 Rubber
washer 16
convex
side
flat side

[3] DISASSEMBLY/ASSEMBLY
[3] -1B. Holder section for BHR243
DISASSEMBLING
Repair
P 6/ 25
(1) Remove Tool holder set from Tool holder guide complete. (Fig. 8)
(2) Remove Cap 35, then separate Ring spring 19 from the groove of Tool holder using 1R003 with 1R212. (Fig. 9)
(3) Remove Chuck cover, then remove Steel ball 7.0 while pressing down Stopper. (Fig. 10)
Stopper, Guide washer, Conical compression spring 21-29 and Flat washer 21 are removed. (Fig. 11)
(4) Remove Ring spring 21 with 1R004 from Tool holder guide complete side.
Flat washer 24, Leaf spring and Steel ball 5 are removed. (Fig. 12)
(5) Remove two Steel balls 6, Torsion spring 31 and Change ring from Tool holder. (Fig. 13)
Fig. 8
Chuck cover
Steel ball 7.0
Stopper
Chuck cover Groove of
Tool holder
Cap 35
Ring spring 19
1R003
1R212
Change ring
Torsion spring 31
Steel ball 6
(2 pcs.)
Tool holder
Change cover
Fig. 11 Fig. 13Fig. 12
Fig. 9 Fig. 10
Tool holder
Tool holder
guide
complete
side
Stopper
Guide washer
Tool holder
Flat washer 21
Conical
compression
spring 21-29
Ring spring 21
Flat washer 24
Leaf spring
Steel ball 5
Tool holder guide
complete
Tool holder set
Tool holder set

P 7/ 25
[3] DISASSEMBLY/ASSEMBLY
[3]-1B. Holder section for BHR243 (cont.)
ASSEMBLING
Repair
(1) Assemble Torsion spring 31 to Tool holder as follows:
• Set two Steel balls 6 on the holes of Tool holder.
• Insert the short arm of Torsion spring 31 into the hole of Tool holder.
Note: Apply Makita grease No. RB No. 00 to two Steel balls 6 to prevent
them from falling. (Fig. 14)
(2) Assemble Change ring to Change cover. (Fig. 15)
(3) Assemble Tool holder to Change cover. (Fig. 16)
Fig. 14
a
Note:
Face the chamfered end
of the hole upward.
Align the hole of
Change ring with
that of Change cover.
a'
[Section a - a']
(4) Put Steel ball 5.0 in the groove surrounded by Change cover and Tool holder. (left in Fig. 17)
(5) Set Leaf spring and Flat washer 24 in change cover, then secure them with Ring spring 21. (right in Fig. 17)
(6) As for Cap 35 side, assemble the components by reversing disassembly procedure. Refer to the previous page.
Fig. 15 Fig. 16
Change ring
Change cover
Change cover
Change ring
By turning Tool holder
approx. 75
° clockwise,
Tool holder can be fastened
to Change cover.
Tool holder
75
°
Insert the long arm of
Torsion spring 31 into
the hole of Change cover
through the hole of
Change ring.
Flat washer 24
Leaf spring
Fig. 17
long arm of
Torsion spring 31
Change cover
Steel ball 6 (2pcs.)
Tool holder
long arm
Torsion spring 31
short arm
Steel ball 5.0
Tool holder
Change cover
Ring spring 21

P 8/ 25
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Drill chuck assembly for BHR243
Repair
DISASSEMBLING
Fig. 18 Fig. 19
Fig. 22Fig. 21Fig. 20
Steel ball 5.0
Leaf spring
Flat washer 24
Drill chuck assembly can be disassembled as drawn in Figs. 18 to 22.
Change cover
Change ring
After Removing Ring spring 21, strike Drill chuck assembly against
workbench which is covered with a cloth as a cushion.
Flat washer 24, Leaf spring and Steel ball 5.0 can be removed.
Pull off Change cover.
Change ring and Torsion spring 31
can be removed.
Torsion spring 31
Chuck holder
Spacer
Chuck holder
Chuck holder
Chuck holder
Spacer
Remove Spacer and
two Steel balls 6 from
Chuck holder.
Clamp the flats of Chuck holder in vise,
then unscrew M6x22 Flat head screw
by turning it clockwise using Impact
driver.
Clamp the flats of Chuck holder in vise,
then separate Drill chuck from Chuck
holder by turning it counterclockwise
using Hex wrench 10.
Steel ball 6 (2 pcs.)
M6x22
Flat head screw
Hex wrench 10
Ring
spring 21
1R003
1R212

Change cover
Change ring
ASSEMBLING
Chuck holder
short arm of
Torsion spring 31
long arm of
Torsion spring 31
hole for
Torsion spring 31
(1) Holding the flat portions of Chuck holder in vise, assemble Drill chuck to Chuck holder by turning it clockwise
using Hex wrench 10.
(2) Secure Drill chuck with M6x22 Flat head screw by turning it counterclockwise using Impact driver.
(3) Assemble Drill chuck to Spacer. (Fig. 23) Then mount two Steel balls 6. (Fig. 24)
(4) Mount Torsion spring 31. Then assemble Drill chuck to Change cover. (Fig. 25)
(5) Mount Steel ball 5, Leaf spring and Flat washer 24 to Chuck holder, then secure them with Ring spring 21. (Fig. 26)
Spacer
Spacer
Spacer
Insert the short arm of Torsion
spring 31 into the hole of
Chuck holder using small pliers.
While fitting the flat portions
of Chuck holder to Spacer,
mount Drill chuck to Spacer.
Fig. 23 Fig. 24
Chuck holder
Steel ball 6 (2 pcs.)
Note: Apply Makita grease RB No.00 to Steel balls 6
to protect them from falling.
Fig. 26
Fig. 25
By turning Drill chuck
approx. 75
° clockwise,
Drill chuck can be fastened
to Change cover.
Drill
chuck
75
°
Ring spring 21
Steel ball 5
Flat washer 24
Leaf spring
Change
cover
Torsion spring 31
Insert the long arm of Torsion spring 31
into the hole of Change cover through
the hole of Change ring, then assemble
Change ring to Change cover. (See Fig. 6.)
[3] DISASSEMBLY/ ASSEMBLY
[3] -2. Drill chuck assembly for BHR243 (cont.)
Chuck holder
Repair
P 9/ 25

[3] DISASSEMBLY/ASSEMBLY
[3]-3. Change lever
(1) Remove dust and dirt from Change lever and the grooved area on Motor housing.
(2) Set Change lever to Hammer mode. (Fig. 27)
Note: If it is hard to set Change lever to Hammer mode because of getting stuck in the halfway,
turn the bit holder section / holder section of the machine by hand and then try again.
(3) While pushing Lock button into Change lever, turn Change lever to the right fully over the position of Hammer mode.
(Fig. 28)
(4) Pull out Change lever from the position drawn in Fig. 29. If it is impossible to remove Change lever by hand, lever it up
with slotted screwdriver.
Note: Be careful not to remove Change lever without placing as drawn in Fig. 29.
The exact positioning prevents Change lever from breakage.
(5) Disassemble Change lever section as drawn in Fig. 2.
(1) Assemble the following parts to Change lever.
▪ Lock button ▪ Compression spring 3 ▪ Change lever cover ▪ O ring 21 (Apply Makita lubricating oil VG100.)
▪ Thin washer 16 ▪ Compression spring 5 ▪ Push corn
(2) Apply Makita grease RB No. 00 to Push corn.
(3) Fit the top of Push corn into the groove of Clutch cam A, and insert the hinge of Change lever into the hole of
Motor housing while keeping the exact position drawn in Fig. 29. (Refer to Fig. 30.)
(4) While pushing Lock button, turn Change lever to the left.
Note: Make sure that Change lever works properly by setting it to Drill mode/ Rotary hammer mode/ Hammer mode.
If it is hard to set Change lever to each mode because of getting stuck in the halfway; try 1 or 2 as follows:
1. Turn the bit holder section / holder section of the machine by hand and then try again.
2. Install battery and pull Switch very slightly a second to run the machine.
DISASSEMBLING
Fig. 27 Fig. 28 Fig. 29
Fig. 30
ASSEMBLING
Change lever Lock button
Hammer mode
Repair
P 10/ 25
Change lever section

[3] DISASSEMBLY/ASSEMBLY
[3]-4. Rotor
(1) Loosen four 4x35 Tapping screws, and then remove Battery housing R and Housing R in order from their housings L.
(Fig. 31)
(2) Remove Gear housing section as drawn in Fig. 32.
Inner housing in Gear housing section comes with Rotor.
(3) Loosen two M4x12 Hex socket head bolts with 1R170, and then remove Bearing retainer A. (Fig. 33)
(4) Pull Rotor section out straight from Inner housing by hand.
Note: Due to the effect of O ring 22.4 in the groove in Bearing room, pulling is preferable to tapping for removing Rotor
section.
(5) Insert a set of 1R356 under Ball bearing 608LLU, and press the shaft of Rotor in the center of Spiral bevel gear 11
complete with 1R281. (Fig. 34)
Ball bearing 608LLU, Flat washer 8 and Spiral bevel gear 11 complete are removed.
Remove 626DDW from Rotor with 1R269.
Battery
housing R
Gear housing section
4x18 Tapping
screw (10 pcs.)
4x35 Tapping
screw (4 pcs.)
DISASSEMBLING
ASSEMBLING
Fig. 31 Fig. 32
Fig. 33 Fig. 34
Repair
P 11/ 25
Housing R
Rotor section
Arbor press
Spiral bevel gear
11 complete
Shaft of Rotor
Ball bearing 626DDW
1R170
Bearing retainer A
M4x12 Hex
socket head bolt
Rotor section
Two holes of Inner housing
for inserting two bosses of
Housing L
Stator
1R281
1R356 Ball bearing 608LLU
on Flat washer 8
Assemble by reversing the disassembly procedure.
Note: Be sure to set Flat washer 8 in place between Fan and Ball bearing 608LLU.

Fig. 35
[3] DISASSEMBLY/ASSEMBLY
[3]-5. Torsion spring 6 for Connector, Battery housing
ASSEMBLING
Repair
P 12/ 25
A
B
C
Cushion
rubber (R)
Cushion rubber (L)
(behind Terminal)
Rubber pin 5
Pin 1.5
See Fig. 35.
Set Torsion spring 6 into Housing L, and then assemble Connector to Compression spring 6. Refer to A .
Set Opener in place. Refer to B .
When Battery housing L and R are matched, do not fail to assemble the parts shown in C .
Hold one end of Torsion spring 6
with the inner wall of Housing L.
Align the chamfered side
of Opener with the walls
of Housing L.
Insert the hinge of Connector
into the coil of Torsion spring 6.
Hook the opposite end
of Torsion spring with
the step of Housing L.
Battery housing set
(Housing set)
Cushion
Opener

[3] DISASSEMBLY/ASSEMBLY
[3]-6. Torque limiter section
DISASSEMBLING
ASSEMBLING
Repair
P 13/ 25
(1) Disassemble Tool holder section. (Figs. 4 to 6 for BHR242/ Figs. 8 to 13 for BHR243.)
(2) Disassemble Change lever. (Figs. 27 to 29)
(3) Remove Gear housing section from Motor housing, and then remove Rotor section from Gear housing section.
(Figs. 31 to 33)
(4) While holding Gear housing section by hand, tap the top of Tool holder (guide) complete with plastic hammer. (Fig. 36)
Note: 1. Grease falls from Gear housing section. Receive the grease with cloths.
2. Do not lose Flat washer 30 between Tool holder section and Inner housing.
(5) Remove Stop ring EXT U-6 from Cam shaft. (Fig. 37)
The ring tends to be caught by Spur gear 51, and therefore, it interferes in the disassembling step.
(6) Remove Tool holder section. (Fig. 37)
(7) Set 1R045 and 1R369 to Tool holder section. (Fig. 38)
(8) Compress Compression spring 31 of Tool holder section by turning the handle of 1R045 clockwise. (Fig. 39)
(9) Remove Spiro lock washer 30 from Tool holder (guide) complete by gradually sliding it on Tool holder (guide) complete
with Thin-slotted screwdriver. (Fig. 40) Tool holder (guide) section are disassembled as drawn in Fig. 41.
Fig. 36
Swash bearing section
Tool holder section Tool holder section
1R369
1R045
Stop ring
EXT U-6
Flat washer 7
Tool
holder
section
Fig. 37 Fig. 38
Fig. 39 Fig. 40
Magnified view of Fig. 39
Thin-slotted
screwdriver
Ends of Spiro lock
washer 30
Tool holder (guide) complete
Fig. 41
1R045 1R045
1R369
(Compression
spring 31)
Spiro lock washer 30
Spiro lock washer 30Compression spring 31
Pin 6 (6 pcs.)Driving flangeTool holder (guide)
complete
Spur gear 51Steel ball 3 (4 pcs.)
Flat washer 30
(thin shape 2 pcs.)
Flat washer 30
(thick shape)
Assemble by reversing the disassembly procedure.
Note: 1. Set Spiro lock washer 30 in place with 1R369 and 1R045.
2. After assembling the components of Tool holder section, set Flat washer 7 and Stop ring EXT U-6 to Cam shaft.
(Refer to Fig. 37)
1R369
Super gear 51

[3] DISASSEMBLY/ASSEMBLY
[3]-6. Impact bolt in Torque limiter section
Repair
P 14/ 25
DISASSEMBLING
(1) Put 1R388 into Tool holder (guide) complete, then push 1R388 in vise with the access holes on Tool holder (guide)
complete parallel to Vise. (Fig. 42)
O-ring case B is moved toward the top of Tool holder (guide) complete, and therefore, Ring spring 28 can be relieved
from O-ring case B.
(2) When the end gap of Ring spring 28 is in the access hole, slide it with slotted screwdriver until it is completely hidden.
(3) Using slotted screwdriver, tap Ring spring 28 through the two access holes alternately to push it out of the inner groove
of Tool holder (guide) complete.
Note: As soon as a part of Ring spring 28 is removed from the inner groove of Tool holder (guide) complete, insert another
slotted screwdriver in between Ring spring 28 and the inner groove of Tool holder (guide) complete to prevent
returning the removed portion back to the inner groove.
(4) The components are removed by tapping with Phillips screwdriver and Plastic hammer from bit installation side of
Tool holder (guide) complete. (Fig. 43)
Fig. 42
Fig. 43
Inner housing
side
Ring spring 28
Compression spring 20
Washer 10
Sleeve 9B
Bit installation side
O ring 9O ring case B
slotted
screwdriver
Ring spring 28
90
°
1R388
Vise Vise
1R388 O-ring case B
The directions of two access holes on Tool holder (guide) complete
have to be parallel to Vise.
holes on both side of Tool holder (guide)
complete to access inside
inner groove of Tool holder (guide) complete
BHR243: Impact bolt B
BHR242: Impact bolt A

[3] DISASSEMBLY/ASSEMBLY
[3]-6. Impact bolt in Torque limiter section (cont.)
Repair
P 15/ 25
ASSEMBLING
Note: 2
Fig. 44A
Fig. 44B
Impact bolt A
(1) Assemble Impact bolt section to Tool holder (guide) complete as drawn in Fig. 44A/ 44B.
Impact bolt section in Tool holder complete for BHR242
Impact bolt section in Tool holder guide complete for BHR243
Sleeve 9B
Bit installation side Inner housing side
O ring case B with
O ring 9 fit inside
ø9mm
long short
ø9.5mm
Inner housing side
Fig. 45
Note: 1. Use an extra Piston cylinder as a jig. Never use Piston cylinder that is
to be assembled to the machine.
2. The end gap of Ring spring 28 must not be placed at the two holes of
Tool holder (guide) complete.
(2) Push Ring spring 28 into the inner groove of Tool holder (guide) complete as drawn in Fig. 45.
Note: Do not reuse the removed Ring spring 28 if it is deformed or damaged.
Piston cylinder
as a jig
Tool holder (guide)
complete
end gap
hole
hole
[cross-sectional view]
Ring spring 28
Tool holder Guide)
complete
end gap
Ring spring 28
[Correct] [Wrong]
Note: 1
Impact bolt B
Tool holder guide complete (140266-1)
Tool holder complete (140265-3)
Bit installation
side
Note: These components
are directional.
Note: These components
are directional.
Piston cylinder as a jig
Inner groove of
Tool holder (guide)
complete
Ring spring 28 O ring case B
Sleeve 9B Washer 10 Compression
spring 20
O ring case B with
O ring 9 fit inside
Washer 10 Compression
spring 20
[cross-sectional view]

P 16/ 25
Repair
DISASSEMBLING
Fig. 47
Fig. 49
Fig. 48
Fig. 50
Fig. 51
(1) Disassemble Motor housing section, Gear housing section and Inner housing section.
(2) Remove Flat fillister HD pin 6, two Weight holder guides, Flat washer 6, Stop ring E-5, Inner support complete and
two M4x25 Hex socket head bolts from Inner housing. (Fig. 47)
(3) While pushing Piston cylinder, remove Counter weight from Swash bearing section as drawn in Fig. 48.
(4) Remove two M4x12 Hex socket head bolts with 1R170 or 1R228. (Fig. 49)
- Then pull Swash bearing section and Piston cylinder section out of Inner housing. (Fig. 49)
- Swash bearing section can be removed from Piston cylinder section with Inner housing attached as drawn in Fig. 50.
(5) Remove Ball bearing 606ZZ from Gear housing complete using the removed Swash bearing section. (Fig. 51)
Push Piston cylinder into Inner housing
to tilt Swash bearing 10.
Pull Swash bearing section horizontally
with Swash bearing 10 kept tilted, and
remove the pole of Swash bearing 10
toward the tilted direction.
Swash bearing section
Swash bearing 10
[3] DISASSEMBLY/ASSEMBLY
[3]-7. Swash bearing section, Piston cylinder section
M4x25 Hex socket
head bolt (2 pcs.)
Inner support complete
Inner housing
Flat fillister HD pin 6 Weight holder guide
(2 pcs.) Piston cylinder
Counter
weight
Swash bearing
section
Flat washer 6
Piston cylinder section
Swash bearing section
Stop ring E-5
M4x12 Hex socket head bolt (2 pcs.)
Note: These are thread locking screws.
Do not reuse them without applying
ThreeBond 1321B/ 1342 or
Loctite 242.
Inner housing
Insert the shaft of Swash bearing section to the hole
of Ball bearing 606ZZ, and tilt it back and forth.
Tap Gear housing complete with plastic hammer.
Ball bearing 606ZZ is removed together with
Swash bearing section.
Piston
cylinder
Ball bearing 606ZZ
in Gear housing complete Ball bearing 606ZZ

P 17/ 25
Repair
DISASSEMBLING
ASSEMBLING
Fig. 52
Fig. 53
(6) Remove Stop ring EXT U-6 from Can shaft, then separate Flat washer 7, Spur gear 10 and Clutch cam A from Can shaft.
(7) Receive Spiral bevel gear 32 on 1R139 put on U-groove of Arbor press table and press out Cam shaft with 1R281
(ø7mm round bar) as drawn in Fig. 52.
The swash bearing section can be removed as drawn in Fig. 53.
Assemble the Swash bearing section carefully to the directions of each part and the order shown in Fig. 53.
(1) Pass Cam shaft through Clutch cam A, and then receive Clutch cam A on 1R035.
(2) Pass Cam shaft through Swash bearing 10 and press-fit Spiral bevel gear 32 to Cam shaft until Spiral bevel gear stops.
(3) Pass Cam shaft through Ring 8 and Bearing retainer B, and then press-fit Ball bearing 608ZZ and Ring 8 to Cam shaft
with 1R033 carefully. Do not pinch Bearing retainer B by Ball bearing 608ZZ and Spiral bevel gear 32.
Note: When 1mm height of Cam shaft is projected out over Ring 8, the assembling work is successful. (Fig. 54) Check
the height at this time.
(4) Set Spur gear 10 and Flat washer 7 in place on Cam shaft, and secure them with Stop ring EXT U-6.
[3] DISASSEMBLY/ASSEMBLY
[3]-7. Swash bearing section (cont.)
Stop ring
EXT U-6
Flat washer 7 Bearing retainer BSpur gear 10
Arbor press
1R139
Clutch cam A Swash bearing 10 Spiral bevel gear 32
Cam shaft Ring 8
(Flat shape) Ring 8
(stepped)
Ball bearing 608ZZ
Spiral bevel gear 32
Arbor press table
1R281
1mm height
Cam shaft
Arbor press
Top of Ring 8
Fig. 54
Bearing retainer B Spiral bevel gear 32
1R033
1R035
Clutch cam A

P 18/ 25
Repair
ASSEMBLING
Fig. 55
(5) Set Compression spring 14 and Flat washer 14 to the projection of Inner housing as drawn in Fig. 55.
Insert Guide plate and Piston joint into Piston cylinder, and then pass the pole of Swash bearing 10 through Piston joint.
(Fig. 56)
(6) Assemble Inner support complete to Inner housing with two M4x25 Hex socket head bolts. (Refer to Fig. 47)
(7) Make sure that the gear teeth of Clutch cam A engage those of Swash bearing 10. (Fig. 57)
(8) Assemble Compression spring 4 and Lock plate to Gear housing. (Fig. 58)
Note: Apply Makita grease RB No. 00 to the end of Compression spring 4 on Lock plate mating side in order to do
the next step smoothly.
(9) While holding Lock plate by a finger so as not to drop from the guides of Gear housing, assemble Gear housing to
Inner housing. (Figs. 58 and 59)
[3] DISASSEMBLY/ASSEMBLY
[3]-7. Swash bearing section, Piston cylinder section (cont.)
Fig. 57
Fig. 59
Fig. 58
Fig. 56
Compression spring 14 Guide plate Inner housingPiston cylinder
It is not necessary
to position this hole.
Flat washer 14
Projection of
Inner housing
Clutch cam A
Gear housing complete Compression spring 4 Lock plate
Correct assembling
Swash bearing 10
Note: Apply Makita grease RB No. 00
to the specific portions of Piston joint
designated by .
Pole of
Swash bearing 10
Piston joint
Apply Makita grease RB No. 00 to the portion
of Compression spring 4 designated by .
Guides of Gear housing

1R258
P 19/ 25
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-8. Oil seal 25, Cup sleeve, Ball bearing 6806LLU
Fig. 60
Ball bearing
6806LLU
Cup sleeve
Fig. 61 Fig. 62
1R258
Fig. 63 Fig. 64
(1) Assemble Inner housing complete to Gear housing complete.
(2) Put Inner housing complete on U-groove table portion of arbor press, then press Oil seal 25, Cup sleeve and Ball
bearing 6806LLU out of Gear housing complete using 1R252.
DISASSEMBLING
(1) Press-fit Ball bearing 6806LLU into Cup sleeve. (Fig. 60)
(2) While receiving the stepped collar of Gear housing complete on 1R258 as drawn in Fig. 61,
press-fit Oil seal 25 with 1R232 until it stops. (Fig. 62)
Oil seal 25 is not yet inserted completely because the outer diameter of 1R232 is larger than
that of Oil seal setting hole.
(3) Press-fit Oil seal 25 to the original position with 1R164 until it stops. (Fig. 63)
(4) Press-fit Cup sleeve with Ball bearing 6806LLU into the place using 1R273. (Fig. 64)
Note: Too much pressure will deform Oil seal 25 and Cup sleeve. Press-fit them with gentle
pressure.
ASSEMBLING
1R164
30mm
34mm
1R232
36mm
37mm
37mm
the stepped collar
(gray color portion)
to be put on 1R258
Gear housing
complete
Cup sleeve with Ball bearing 6806LLU
at the bottom
Note: Be careful to the direction.
1R273 100mm
Oil seal 25
Oil seal 25

P 20/ 25
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-9. Motor of Dust extraction system DX01, DX02
Fig. 65
Fig. 66
Note: Special repairing tool and Lubricant are not required.
(1) Separate Housing R and eight 4x18 Tapping screws from Housing L.
(2) Remove Baffle plate, Filter plate, Sponge sheet C and Motor complete as an assembled part. (Fig. 65)
Assemble the components by reversing the disassembly procedure.
Guide plate, Cushion and four Rubber pins 4 are on not only Housing R but also Housing L, and therefore, be careful not
to drop their parts.
DISASSEMBLING
ASSEMBLING
Guide plate
Motor complete
Note: Replacing Fan separately is not allowed.
Baffle plate
Baffle plate
Sponge sheet C
Cushion
Rack B
Earth rubber
Rubber pin 4 (4 pcs. on this side)