Makita BFR540 Manual

Model No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
P 1/16
Specification
BFR540, BFR550, BFR750
Cordless Auto Feed Screwdriver
Models BFR540, BFR550 and BFR750 have been developed
as the advanced models of Model BFR440, featuring higher durability.
These models feature more reliable casing attachment
with the following benefits:
Rigid aluminum casing
Stopper base with anti-tilt device for preventing screws from swaying
Rubber cap securely fixed to stopper base
Dust-proof construction for smooth sliding action
These products are available in the following variations.
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 424 (16-3/4) 464 (18-1/4)
BFR540/BFR550 BFR750
80 (3-1/8)
238 (9-3/8)
L
H
W
Specification
Net weight**: kg (lbs) 2.1 (4.6) 2.3 (5.0)
Model BFR550 BFR750BFR540
4 (5/32)
25 to 55
(1 to 2-3/16)
45 to 75
(1-3/4 to 2-15/16)
Diameter
Overall length
4,000No load speed: min.-1 = rpm
Driver bit: mm (")
Capacities: mm (")
[collated drywall screw]
Reverse switch
6.35 (1/4) Hex
162 (6-3/8) or 157 (6-3/16)
Shank
Overall length*
Yes
*Overall length of driver bit may differ by country.
**BFR540: includes battery BL1430; BFR550/ BFR750: includes battery BL1830
Battery
Cell
Voltage: V
Capacity: Ah
Li-ion
14.4 18
3.0
Li-ion
3.0
Max output: W 235 235
(The image above is BFR540.)
182 (7-1/8) or 177 (7)
All models also include the accessories listed in "Standard equipment".
BFR540
BFR540RFE
BFR540Z
BFR540 BL1430
(Li-ion 3.0Ah) DC18RA
No No No
Model No. type quantity Charger
Yes
No
Plastic
carrying case Offered to
All countries
North America
All countries except North America
2
BFR540RFE3 3
1
2
Battery
BFR550
BFR750
See next page for "Standard equipment" and "Optional accessories".
TECHNICAL INFORMATION
Battery
cover
BFR550RFE
BFR550Z
BFR550 BL1830
(Li-ion 3.0Ah) DC18RA
No No No
Yes
No All countries
North America
All countries except North America
2
BFR550RFE3 3
1
2
BFR750RFE
BFR750Z
BFR750 BL1830
(Li-ion 3.0Ah) DC18RA
No No No
Yes
No All countries
North America
All countries except North America
2
BFR750RFE3 3
1
2

P 2/16
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
BFR540/ BFR550
Phillips bit 2-162 or 2-157 (for BFR540/ BFR550)
Square bit 2-162 or 2-157 (for BFR540/ BFR550)
Phillips bit 2-182 or 2-177 (for BFR750)
Square bit 2-182 or 2-177 (for BFR750)
Extension handle
Casing attachment
Plastic carrying case
BFR750
Phillips bit 2-162 or 2-157 ...................... 3
Belt clip ................................................... 1
Phillips bit 2-182 or 2-177 ...................... 3
Belt clip ................................................... 1
Battery BL1430 (for BFR540)
Battery BL1830 (for BFR550/ BFR750)
Fast charger DC18RA
Charger DC24SA (for North America only)
Charger DC24SC (for all countries except North America)

P 3/16
[2] LUBRICATION
Apply Makita grease FA.No.2 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion.
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the battery from the machine for safety before repair/ maintenance
in accordance with the instruction manual!
Fig. 1
Repair
Description
Bearing setting plate 8.2
Spring pin extractor 2 Removing Pin 2 from Guide box complete
Removing Casing cover and Insulation sleeveRetaining ring S and R pliers
Code No.
1R032
1R266
1R291
Use for
Item No. Description Portion to lubricate
Apply approx. 4g.
Apply approx. 1g.
Apply approx. 4g.
Plane bearing 14
Steel ball 3.5 Whole surface
Each depressed portion for Steel ball 4
Steel ball 4 (3 pcs)
Spindle B
Clutch cam C
Gear complete 18-44
Compression spring 25
Helical gear 48
Armature
50
49
57
64
49
50
57
64
(a)
(a) The Drum portion that contacts Plane bearing 14
(c) Teeth of the small gear that engages Helical gear 48
(d) Teeth of the large Gear that engages Armature's gear
(b) The Cam portion that contacts 57 Clutch cam C
(b)
(c)
(d)

P 4/16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly
Repair
DISASSEMBLING
Clamper Clamper
Casing complete
Casing complete
4) Clamper and Compression spring 23 can now be
removed from Casing complete.
Fig. 2 Fig. 3
Fig. 4
Disassemble by taking the steps described in Fig. 2 to Fig 17.
2) Then pull off Casing
assembly from Housing.
Casing assembly
3) While pressing Clamper, remove three M4x12 Countersunk
head screws from Casing complete.
1) Loosen Thumb screw M4x28
by turning counterclockwise.
Countersunk head screw M4x12:
one on Thumb screw M4x28 side, two on the opposite side
No.1 Phillips
screwdriver
(+) Shoulder flat head screw M3x5
Fig. 6Fig. 5
Compression spring 23
Clamper
Removing Insulation sleeve from Clamper
While pressing two of the three locking tabs of Insulation
sleeve inward using 1R291, push it off from Clamper.
Clamper
Insulation sleeve
1R291
5) Stopper on either side of Casing complete can be
removed by sliding it in the direction of the gray
arrow while lifting up its rear end with a slotted
screwdriver.
6) Remove (+) Shoulder flat head screw M3x5
together with Sleeve 4 using No.1 Phillips screwdriver.
rear end
of Stopper
rear end of Stopper
Sleeve 4

P 5/16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
DISASSEMBLING
Fig. 7
7) While pressing the locking claws of Casing cover inward
using 1R291, pull off Feeder box section from Casing cover.
8) Remove Plate from Stopper base as follows:
while pressing down two Levers at the same time,
push Stopper base towards Feeder box fully until
it stops.
9) While pressing down two Levers
at the same time, separate Feeder box
from Stopper base.
10) Remove Lever and Compression Spring 2 (2 pcs each)
from Feeder box.
Fig. 8
1R291
Feeder box section locking claw
of Casing cover
Casing complete
Feeder box
Plate
Stopper base
Plate
Lever
Countersunk head
screw M4x12
Dial 42 can now be removed from
Casing complete by unscrewing
Countersunk head screw M4x12.
Flat washer 6
O Ring 12
Shifter pin
Dial 42
Dial 42
Lever
Compression spring 2
Feeder box
Stopper base
Fig. 9 Fig. 10
Feeder box

P 6/16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
DISASSEMBLING
Fig. 11
11) Remove Box cover complete from Feeder box
by unscrewing Tapping screw 4x18.
13) Remove Stopper, Pin 3 and Torsion spring 4
from Feeder box.
Fig. 12 Fig. 13
Ratchet arm complete
Compression spring 6
Spur gear 16
Torsion spring 4
Stopper
Pin 3
Feeder box
Box cover complete
Tapping screw 4x18 Feeder box
Side view of Feeder box
after removing Box cover complete
Dust cover Ratchet arm complete
Compression spring 6
Torsion spring 4Stopper
Pin 3
Fig. 14
12) Remove Ratchet arm complete and
Compression spring 6 from Spur gear 16.
14) Remove Dust cover from Feeder box.
Note: Because the bow portion of Dust cover
is easily damaged, be sure to remove carefully
together with Wheel as illustrated to right.
Insert a screwdriver through the hole of
Dust cover into Wheel, then lever up Dust cover
together with Wheel.
Dust cover
Wheel
bow portion of Dust cover
Dust cover Wheel

P 7/16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
DISASSEMBLING
Fig. 17
17) Remove Sleeve 5 from Feeder box.
If cannot remove by hand, lever it off
using Phillips screwdriver or the like
as illustrated below.
16) Remove Spur gear 16 from Feeder box.
Fig. 15 Fig. 16
15) Remove Shoulder pin 6 from Feeder box.
Spur gear 16
Sleeve 5Phillips screwdriver
Feeder box
Spur gear 16
Sleeve 5
Shoulder pin 6

P 8 /16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
ASSEMBLING
1) Assemble Sleeve 5, Spur gear 16 and Shoulder pin 6 to Feeder box. (See Fig. 17 to Fig. 15 on page 7.)
2) Assemble Wheel together with Dust cover to Feeder box. (See Fig. 14.)
Important 1: Dust cover must be fixed securely to Feeder box as described in Fig. 18.
Important 2: Make sure that Wheel and Spur gear 16 are correctly engaged. (Fig. 19)
3) Assemble Pin 3 and Torsion spring 4 to Stopper (Fig. 20), then assemble them to Feeder box as described in Fig. 21.
Fig. 20
Stopper
Torsion spring 4
Note: Be sure to assemble Torsion spring 4
and Pin 3 to Stopper as illustrated below
before assembling them to Stopper.
Fig. 19
View from Box cover complete side
Top view
Box cover complete side
Feeder box side
Wheel Spur gear 16
Fig. 18
Push the metal plate of Dust cover in the three portions designated by gray star;
especially, be sure to push it securely into the hole designated by "A" until Dust cover stops.
metal plate
of Dust cover
Feeder box
Engaging Wheel with Spur gear 16
1) Engage with .
2) and can be engaged by doing 1).
Pin 3
Hook the bent end on
the groove of Stopper.
Gear portion
Inner sprocket
Outer sprocket
Inner gear
Outer gear
Stopper catching portion
Wheel Spur gear 16
Note: As illustrated to right:
must be engaged with .
must be engaged with .
Fig. 21
Torsion spring 4
Stopper
Pin 3Spur gear 16
The straight end of Torsion
spring 4 must be placed on
the rear wall of the concave
portion.
Wheel
Engage Stopper with so that
the backward movement of Spur gear 16
can be prevented by Stopper.
concave portion
of Feeder box

P 9 /16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
ASSEMBLING
4) Assemble Ratchet arm complete and Compression spring 6 to Spur gear 16. (See Fig. 12 on page 6.)
5) Assemble Box cover complete to Feeder box. (See Fig. 11 on page 6.)
6) Make sure that Wheel moves correctly as described in Fig. 22 by pushing Ratchet arm complete up and down .
7) Make sure that Wheel can be stopped by pushing in Shoulder pin 6. (Fig. 23)
Note:
Do not apply any lubricant oil/grease or anticorrosive oil to the parts illustrated in Fig. 24.
because smooth feeding can be prevented by dirt and dust sticking to such oily/greasy parts.
Fig. 23 Fig. 24
Fig. 22
Wheel
Ratchet arm complete
Wheel moves when Ratchet arm complete is pushed up.
Wheel does not move when Ratchet arm complete is pushed down. (Also refer to Fig. 21 on page 8.)
Wheel
Ratchet arm complete
Shoulder pin 6
Wheel
Wheel
Compression spring 6
Ratchet arm complete
Spur gear 16
Pin 3
Torsion spring 4
Stopper
Shoulder pin 6
Dust cover
Feeder box
Push in.

P 10/16
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Casing Assembly and Feeder Box Assembly (cont.)
Repair
ASSEMBLING
8) Casing complete can be assembled by doing the reverse of the disassembling steps. (Fig. 7 to Fig.2on pages 5 to 4)
Note: Be sure to follow the instructions described in Fig. 25 to Fig. 27.
Fig. 25
Fig. 26
Fig. 27
U-groove
Spring pin 4-12
of Casing complete
Steel ball 3.5
Dial 42
Assembling Dial 42 to Shifter pin
Assembling Plate to Stopper base
Assembling Sleeve 4 to Casing complete
Shifter pin
Thumb screw M4x28
By placing Shifter pin so that the pin's flat faces towards
the side where Thumb screw M4x28 is mounted,
Spring pin 4-12 of Casing complete fits in the U-groove
of Dial 42 when Dial 42 is assembled to Shifter pin.
Important:
Click stop of Dial 42 does not work without Steel ball 3.5.
Therefore, before assembling Dial 42 to Shifter pin,
make sure that Steel ball 3.5 is mounted in place on
Casing complete.
Plate
Stopper base
Feeder box
Lever Lever
While pressing down two Levers at the same time,
push Stopper base towards Feeder box until it stops,
then hitch Plate to Stopper base.
Sleeve 4 is not reversible when assembled to Casing complete.
Be sure to do as illustrated in "Correct".
While pressing down two Levers at the same time,
pull Stopper base slowly back to the initial position.
Plate is now assembled in place.
Shoulder flat head
screw M3x5
Casing complete
[cross section
of Sleeve 4]
Sleeve 4
Casing complete
Sleeve 4
Correct
Wrong
Shoulder flat head
screw M3x5
outside of
Casing complete
Shoulder flat head
screw M3x5 cannot
be fastened in place.

P 11/16
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Stopper Base Section
Repair
DISASSEMBLING
Disassemble by taking the steps described in Fig. 28 to Fig. 31.
Fig. 28 Fig. 29
Fig. 30 Fig. 31
Guide box complete
Guard
Stopper base
slotted screwdriver
1) Remove Guide box complete from Stopper base together with
Guard first by inserting slotted screwdriver into the rectangular
hole of Stopper base, then by pushing Guide box complete
with the screwdriver.
rectangular hole
Guard
Guide box complete
2) Separate Guard from Guide box complete.
1R266
1R032
3) Guide box complete can be disassembled as illustrated below
using 1R032, 1R266 and arbor press.
(The parts with asterisk: one each on left and right side)
4) Cap can be removed from Stopper base
using slotted screwdriver.
Pin 2*
Guide*
Torsion spring 4*
Guide box
Stopper base
Cap
[3] -3. Clutch Section
DISASSEMBLING
Disassemble by taking the steps described in Fig. 32 to Fig. 36.
Fig. 32
1) After removing Casing assembly (Fig.2on page 4),
disassemble Front cover from Housing together with
Guide attachment.
2) Remove Belt clip from Housing by pulling
in the direction of the gray arrow while opening
the ends in the directions of the black arrows.
Tapping screw 4x18
(2 pcs)
Front cover
Guide attachment
Housing Belt clip

P 12/16
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Clutch Section
Repair
DISASSEMBLING
ASSEMBLING
Disassemble by taking the steps described in Fig. 32 to Fig. 36.
Fig. 33 Fig. 34
Fig. 35 Fig. 36
3) Remove Housing (R) from Housing (L)
by unscrewing nine 4x18 Tapping screws.
4) Remove Clutch section from Housing (L).
Gear complete 18-44 can be
also removed in this step.
Flat washer 26
Compression spring 25
Clutch cam C
Steel ball 4 (3 pcs)
Helical gear 48
Spindle B
Steel ball 3.5
Sleeve 20
O Ring 18
Dust cover
6) Assembly of Helical gear 48 can be disassembled
by hand as illustrated below.
Plane bearing 14
Flat washer 25 (2 pcs)
Housing (R)
Tapping screw 4x18 (9 pcs) From the removed Clutch section,
Ball bearing 608 and Assembly of
Helical gear 48 will be separated by
the force of Compression spring 25.
Ball bearing 608
Gear complete 18-44
Housing (L)
Clutch section
Assembly of Helical gear 48
consisting of:
Helical gear 48, Clutch cam C
Steel ball 4 (3 pcs), Flat washer 26
Compression spring 25
5) The rest of Clutch section can be disassembled
by hand as illustrated below.
Fig. 37
1) Put Flat washer 26 on the flanged portion of
Clutch cam C.
Note: Make sure that there is no space between
Flat washer 26 and the flanged portion.
2) While turning Compression spring 25
in the direction of the arrow, push it down
until it touches Flat washer 26.
Compression spring 25
Flat washer 26
Clutch cam C
Assemble by taking the steps described in Fig. 37 to Fig. 40.

P 13/16
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Clutch Section (cont.)
Repair
ASSEMBLING
Fig. 38
Fig. 39
Fig. 40
Ball bearing 608
Steel ball 4
(3 pcs)
Steel ball 3.5
Clutch cam C Helical gear 48
Assembly of Helical gear 48
Spindle B
Flat washer 25 (2 pcs)
Sleeve 20
O Ring 18
Dust cover
Plane bearing 14
Gear complete 18-44
Plane bearing 5
(front)
Plane bearing 5
(rear)
Flat washer 5
3) Apply Makita grease FA.No.2 to
the inside wall of Clutch cam C
to prevent Steel balls from falling
off from Clutch cam C.
5) Assemble the parts illustrated below into Clutch section.
6) Assemble Gear complete 18-44 to Housing (L).
Note: Do not forget to put Flat washer 5 between
Gear complete 18-44 and Plane bearing 5 (front).
4) Put each Steel ball 4 in the concave portion on the inside wall
of Clutch cam C.
Then assemble Clutch cam C to Helical gear 48.
Note:
Apply Makita grease FA.No.2 to the cam portion
of Spindle B to prevent Flat washer 25 (2 pcs)
from falling off from Spindle B.

P 14/16
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Motor Section
DISASSEMBLING
1) Remove Casing assembly. (Fig.2on page 4)
Then disassemble Front cover, Guide attachment and Belt clip. (Fig. 32 on page 11)
2) Remove Housing (R) from Housing (L) by unscrewing nine 4x18 Tapping screws. (Fig. 33 on page 12)
3) Disassemble Armature from the machine as illustrated in Figs. 41, 42.
ASSEMBLING
Fig. 44Fig. 43
Your fingers can be pinched
and injured.
[Wrong][Correct]
Fig. 41 Fig. 42
12
Carbon
brush
Carbon
brush
Torsion
spring
1. Move the tail of Torsion spring
onto the notch of Brush holder.
2. Then pull off Receptacle from
Brush holder, then remove
Carbon brush.
Brush holder
complete
Yoke unit
Armature
1) Insert Armature into Yoke unit as described in Figs. 43, 44.
2) Assemble Brush holder complete to the commutator end of Armature. (Fig. 41)
Because Yoke unit is a strong magnet, when assembling Armature
to Yoke unit, be sure to hold the commutator portion as illustrated
to left. Do not hold the Armature core as illustrated to right
or your fingers will be pinched between Yoke unit and the fan of
Armature that is pulled strongly by the magnet force.
Yoke unit is not reversible when assembled
to Armature.
Be sure to assemble so that the notch in
Yoke unit is positioned on the drive-end
of Armature.
If assembled wrong, the Motor section
cannot be assembled to Housing (L).
[Wrong][Correct]
notch
Gear

P 15/16
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Motor Section (cont.)
Fig. 45
ASSEMBLING
[3] -5. Switch
3) Assemble the Motor section to Housing (L) as illustrated in Fig. 45.
Put the projection on Switch between the prongs of F/R change lever,
then assemble the Switch to Housing L. (Fig. 46)
notch in Yoke unit Brush holder complete
groove
Housing L
rib
ASSEMBLING
With the projection on Housing (L) fitting in the notch on Yoke,
put Yoke unit inside the four ribs on Housing (L).
Fig. 46
F/R change lever
Switch projection
prong
1) Fit Brush holder complete in the groove
of Housing (L).
2) The flat portion of Brush holder complete
must be at 90 degrees to the edge surface
of Housing L.
flat portion of Brush holder complete
edge surface of
Housing L
Housing L
Brush holder complete,
viewed from the Case assembly installation side.
90 degrees
Assembling Brush Holder to Housing (L)
projection
Assembling Yoke Unit to Housing (L)

P 16/16
Circuit diagram
Wiring diagram
Color index of lead wires' sheath
Black
Red
Switch Brush Holder
Complete
Terminal
Fig. D-1
Fig. D-2
Switch
Brush holder
complete
rib A
rib B
Lead wire holder
Switch lead wires (red, black)
must be passed between rib A and rib B.
Terminal
The flag connector must be so connected that
the wire connecting portion is positioned on
the side of pole marks of Terminal.
Flag connector
Terminal
Connecting Flag Connector to Terminal
Wire connecting portion
Pole mark
Lead wires (red, black)
of Brush holder complete
must be fixed with
these lead wire holders.
Do not put any
Lead wire on
this rib to protect
from pinching.
Lead wire holder
Switch lead wires (red, black)
must be fixed with
these Lead wire holders.