Makita BHR200 User manual

INSTRUCTION MANUAL
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
www.makitatools.com
Cordless Rotary Hammer
Equipped with Electric Brake
20 mm (13/16”)
MODEL BHR200
003091

2
SPECIFICATIONS
• Manufacturer reserves the right to change specifications without notice.
• Specifications may differ from country to country.
GENERAL SAFETY RULES USA003-1
(FOR All BATTERY OPERATED TOOLS)
WARNING:
Read and understand all instructions. Failure to follow all
instructions listed below, may result in electric shock, fire and/or
serious personal injury.
Model BHR200
Capacities
Concrete 20 mm (3/4”)
Steel 13 mm (1/2”)
Wood 27 mm (1-1/16”)
No load speed (RPM) 0 - 1,100/min.
Blows per minute 0 - 4,700
Overall length 316 mm (12-7/16”)
Net weight 4.0 kg (8.8 lbs)
Battery Charger DC24SA DC24WA
Input A.C. only 50 Hz - 60 Hz
Output D.C. 7.2 V - 24 V
Battery Cartridge BH2420 BH2433 BH2420 BH2433
Voltage 24 V
Charging time 30 min. 60 min. 55 min. 90 min.

3
SAVE THESE INSTRUCTIONS
Work Area
1. Keep your work area clean and well lit.
Cluttered benches and dark areas invite acci-
dents.
2. Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases, or dust. Power
tools create sparks which may ignite the dust
or fumes.
3. Keep bystanders, children, and visitors
away while operating a power tool. Distrac-
tions can cause you to lose control.
Electrical Safety
4. A battery operated tool with integral bat-
teries or a separate battery pack must be
recharged only with the specified charger
for the battery. A charger that may be suit-
able for one type of battery may create a risk
of fire when used with another battery.
5. Use battery operated tool only with specif-
ically designated battery pack. Use of any
other batteries may create a risk of fire.
Personal Safety
6. Stay alert, watch what you are doing, and
use common sense when operating a
power tool. Do not use tool while tired or
under the influence of drugs, alcohol, or
medication. A moment of inattention while
operating power tools may result in serious
personal injury.
7. Dress properly. Do not wear loose cloth-
ing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long
hair can be caught in moving parts.
8. Avoid accidental starting. Be sure switch
is in the locked or off position before
inserting battery pack. Carrying tools with
your finger on the switch or inserting the bat-
tery pack into a tool with the switch on invites
accidents.
9. Remove adjusting keys or wrenches
before turning the tool on. A wrench or a
key that is left attached to a rotating part of
the tool may result in personal injury.
10. Do not overreach. Keep proper footing
and balance at all times. Proper footing and
balance enable better control of the tool in
unexpected situations.
11. Use safety equipment. Always wear eye
protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must
be used for appropriate conditions.
Tool Use and Care
12. Use clamps or other practical way to
secure and support the workpiece to a
stable platform. Holding the work by hand or
against your body is unstable and may lead
to loss of control.
13. Do not force tool. Use the correct tool for
your application. The correct tool will do the
job better and safer at the rate for which it is
designed.
14. Do not use tool if switch does not turn it
on or off. A tool that cannot be controlled
with the switch is dangerous and must be
repaired.
15. Disconnect battery pack from tool or
place the switch in the locked or off posi-
tion before making any adjustments,
changing accessories, or storing the tool.
Such preventive safety measures reduce the
risk of starting the tool accidentally.
16. Store idle tools out of reach of children
and other untrained persons. Tools are
dangerous in the hands of untrained users.
17. When battery pack is not in use, keep it
away from other metal objects like: paper
clips, coins, keys, nails, screws, or other
small metal objects that can make a con-
nection from one terminal to another.
Shorting the battery terminals together may
cause sparks, burns, or a fire.

4
18. Maintain tools with care. Keep cutting
tools sharp and clean. Properly maintained
tools with sharp cutting edge are less likely to
bind and are easier to control.
19. Check for misalignment or binding of
moving parts, breakage of parts, and any
other condition that may affect the tool’s
operation. If damaged, have the tool ser-
viced before using. Many accidents are
caused by poorly maintained tools.
20. Use only accessories that are recom-
mended by the manufacturer for your
model. Accessories that may be suitable for
one tool may create a risk of injury when
used on another tool.
SERVICE
21. Tool service must be performed only by
qualified repair personnel. Service or main-
tenance performed by unqualified personnel
may result in a risk of injury.
22. When servicing a tool, use only identical
replacement parts. Follow instructions in
the Maintenance section of this manual.
Use of unauthorized parts or failure to follow
Maintenance instructions may create a risk of
shock or injury.
SPECIFIC SAFETY RULES USB028-2
DO NOT let comfort or familiarity with product (gained from
repeated use) replace strict adherence to cordless rotary ham-
mer safety rules. If you use this tool unsafely or incorrectly, you
can suffer serious personal injury.
1. Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring.
Contact with a “live” wire will make exposed
metal parts of the tool “live” and shock the
operator.
2. Wear ear protectors when using the tool
for extended periods. Prolonged exposure
to high intensity noise can cause hearing
loss.
3. Be aware that this tool is always in an
operating condition, because it does not
have to be plugged into an electrical out-
let.
4. Wear a hard hat (safety helmet), safety
glasses and/or face shield. Ordinary eye
or sun glasses are NOT safety glasses. It
is also highly recommended that you wear
a dust mask and thickly padded gloves.
5. Be sure the bit is secured in place before
operation.
6. Under normal operation, the tool is
designed to produce vibration. The
screws can come loose easily, causing a
breakdown or accident. Check tightness
of screws carefully before operation.
7. In cold weather or when the tool has not
been used for a long time, let the tool
warm up for several minutes by operating
it under no load. This will loosen up the
lubrication. Without proper warm-up,
hammering operation is difficult.
8. Always be sure you have a firm footing.
9. Be sure no one is below when using the
tool in high locations.
10. Hold the tool firmly with both hands.
11. Keep hands away from moving parts.

5
12. Do not leave the tool running. Operate the
tool only when hand-held.
13. Do not point the tool at any one in the area
when operating. The bit could fly out and
injure someone seriously.
14. Do not touch the bit or parts close to the
bit immediately after operation; they may
be extremely hot and could burn your
skin.
15. Some material contains chemicals which
may be toxic. Take caution to prevent dust
inhalation and skin contact. Follow mate-
rial supplier safety data.
SAVE THESE INSTRUCTIONS
WARNING:
MISUSE or failure to follow the safety rules stated in this
instruction manual may cause serious personal injury.
SYMBOLS USD302-1
The followings show the symbols used for tool.
V....................... volts
................... direct current
................... no load speed
.../min................revolutions or reciprocation per
minute
................number of blow
IMPORTANT SAFETY INSTRUCTIONS FOR
CHARGER & BATTERY CARTRIDGE USC002-3
1. SAVE THESE INSTRUCTIONS- This man-
ual contains important safety and operat-
ing instructions for battery charger.
2. Before using battery charger, read all
instructions and cautionary markings on
(1) battery charger, (2) battery, and (3)
product using battery.
3. CAUTION - To reduce risk of injury, charge
only MAKITA rechargeable batteries
marked on the charger label. Other types
of batteries may burst causing personal
injury and damage.
4. Do not expose charger to rain or snow.
5. Use of an attachment not recommended
or sold by the battery charger manufac-
turer may result in a risk of fire, electric
shock, or injury to persons.
n˚

6
6. To reduce risk of damage to electric plug
and cord, pull by plug rather than cord
when disconnecting charger.
7. Make sure cord is located so that it will
not be stepped on, tripped over, or other-
wise subjected to damage or stress.
8. An extension cord should not be used
unless absolutely necessary. Use of
improper extension cord could result in a
risk of fire and electric shock. If extension
cord must be used, make sure:
a. That pins on plug of extension cord
are the same number, size, and shape
as those of plug on charger;
b. That extension cord is properly wired
and in good electrical condition; and
c. That wire size is at least as large as
the one specified in the table below.
9. Do not operate charger with damaged
cord or plug - replace them immediately.
10. Do not operate charger if it has received a
sharp blow, been dropped, or otherwise
damaged in any way; take it to a qualified
serviceman.
11. Do not disassemble charger or battery
cartridge; take it to a qualified serviceman
when service or repair is required. Incor-
rect reassembly may result in a risk of
electric shock or fire.
12. To reduce risk of electric shock, unplug
charger from outlet before attempting any
maintenance or cleaning. Turning off con-
trols will not reduce this risk.
13. The battery charger is not intended for
use by young children or infirm persons
without supervision.
14. Young children should be supervised to
ensure that they do not play with the bat-
tery charger.
15. If operating time has become excessively
shorter, stop operating immediately. It
may result in a risk of overheating, possi-
ble burns and even an explosion.
16. If electrolyte gets into your eyes, rinse
them out with clear water and seek medi-
cal attention right away. It may result in
loss of your eyesight.
ADDITIONAL SAFETY RULES FOR CHARGER &
BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when
temperature is BELOW 10°C (50°F) or
ABOVE 40°C (104°F).
2. Do not attempt to use a step-up trans-
former, an engine generator or DC power
receptacle.
3. Do not allow anything to cover or clog the
charger vents.
4. Do not short the battery cartridge:
(1) Do not touch the terminals with any
conductive material.
Table 1: RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION CORDS FOR BATTERY CHARGERS
Length of Cord (Feet) 25 50 100 150
AWG Size of Cord 18 18 18 16

7
(2) Avoid storing battery cartridge in a
container with other metal objects
such as nails, coins, etc.
(3) Do not expose battery cartridge to
water or rain.
A battery short can cause a large current
flow, overheating, possible burns and
even a breakdown.
5. Do not store the tool and Battery Car-
tridge in locations where the temperature
may reach or exceed 50°C (122°F).
6. Do not incinerate the Battery Cartridge
even if it is severely damaged or is com-
pletely worn out. The battery cartridge can
explode in a fire.
7. Be careful not to drop, shake or strike bat-
tery.
8. Do not charge inside a box or container of
any kind. The battery must be placed in a
well ventilated area during charging.
SAVE THESE INSTRUCTIONS
SYMBOLS
The following show the symbols used for the charger. Be sure that you understand their
meaning before use.
.......... Ready to charge
............. Charging
............. Charging complete
...........Delay charge (Cooling)
........Defective battery
....Conditioning
...........Cooling abnormality

8
FUNCTIONAL
DESCRIPTION CAUTION:
•Always be sure that the tool is switched off and the
battery cartridge is removed before adjusting or
checking function on the tool.
Installing or removing battery cartridge
•Always switch off the tool before insertion or removal of
the battery cartridge.
•To remove the battery cartridge, withdraw it from the tool
while sliding the button on the side of the cartridge.
•To insert the battery cartridge, align the tongue on the
battery cartridge with the groove in the housing and slip
it into place. Always insert it all the way until it locks in
place with a little click. If you can see the red part on the
upper side of the button, it is not locked completely.
Insert it fully until the red part cannot be seen. If not, it
may accidentally fall out of the tool, causing injury to you
or someone around you.
•Do not use force when inserting the battery cartridge. If
the cartridge does not slide in easily, it is not being
inserted correctly.
Charging
1. Plug the battery charger into the proper AC voltage
source. Two charging lights will flash in green color
repeatedly.
2. Insert the battery cartridge into charger until it stops
adjusting to the guide of charger. Terminal cover of
charger can be opened with inserting and closed with
pulling out the battery cartridge.
3. When the battery cartridge is inserted, the charging light
color will change from green to red and charging will
begin. The charging light will keep lighting up lit steadily
during charging. One red charging light indicates
charged condition in 0 - 80% and two red ones indicates
80 - 100%.
4. With finish of charge, the charging lights will change
from two red ones to two green ones.
5. If you leave the battery cartridge in the charger after the
charging cycle is complete, the charger will switch into
its “trickle charge (maintenance charge)”mode which
will last approximately 24 hours.
1. Battery cartridge
2. Red part
3. Button
13
2
003103
1. Terminal cover
2. Battery cartridge
3. Charging light
4. Battery charger
1
2
3
4
001336

9
6. After charging, unplug the charger from the power
source.
NOTE:
•The battery charger is for charging Makita battery
cartridge. Never use it for other purposes or for other
manufacturer’s batteries.
•When you charge a new battery cartridge or a battery
cartridge which has not been used for a long period of
time, it may not accept a full charge. This is a normal
condition and does not indicate a problem. You can
recharge the battery cartridge fully after discharging it
completely and recharging a couple of times.
•If you charge a battery cartridge from a just operated
tool or battery cartridge which has been left in a location
exposed to direct sunlight for a long time, the charging
light may flash in red color. If this occurs, wait for a while.
Charging will begin after the battery cartridge is cooled
by the cooling fan installed in the charger. (DC24SA
only) When the temperature on battery is more than
approx. 70°C, two charging lights may flash in red color,
and when approx. 50°C - 70°C, one charging light in red
color.
•If the charging light flashes alternately in green and red
color, charging is not possible. The terminals on the
charger or battery cartridge are clogged with dust or the
battery cartridge is worn out or damaged.
Cooling system (DC24SA only)
•This charger is equipped with cooling fan for heated
battery in order to enable the battery to prove its own
performance. Sound of cooling air comes out during
cooling, which means no trouble on the charger.
•Yellow light will flash for warning in the following cases.
- Trouble on cooling fan
- Incomplete cool down of battery, such as, being
clogged with dust
The battery can be charged in spite of the yellow
warning light. But the charging time will be longer than
usual in this case. Check the sound of cooling fan, vent
on the charger and battery, which can be sometime
clogged with dust.

10
•The cooling system is in order although no sound of
cooling fan comes out, if the yellow warning light will not
flash.
•Always keep clean the vent on charger and battery for
cooling.
•The products should be sent to repair or maintenance, if
the yellow warning light will frequently flash.
Conditioning charge (DC24SA only)
Conditioning charge can extend the life of battery by auto-
matically searching the optimum charging condition for the
batteries in every situations.
The battery employed in the following conditions repeatedly,
will be worn out shortly, and yellow warning light may flash.
1. Recharge of battery with its high temperature
2. Recharge of battery with its low temperature
3. Recharge of full charged battery
4. Over-discharge of battery (continue to discharge battery
in spite of down of power.)
The charging time of such battery is longer than usual.
Trickle charge (Maintenance charge)
If you leave the battery cartridge in the charger to prevent
spontaneous discharging after full charge, the charger will
switch into its “trickle charge (maintenance charge)”mode
and keep the battery cartridge fresh and fully charged.
Tips for maintaining maximum battery life
1. Charge the battery cartridge before completely dis-
charged.
Always stop tool operation and charge the battery car-
tridge when you notice less tool power.
2. Never recharge a fully charged battery cartridge.
Overcharging shortens the battery service life.
3. Charge the battery cartridge with room temperature at
10°C - 40°C (50°F - 104°F).
Let a hot battery cartridge cool down before charging it.
4. Charge the Nickel Metal Hydride battery cartridge when
you do not use it for more than six months.

11
Switch action
CAUTION:
•Before inserting the battery cartridge into the tool,
always check to see that the switch trigger actuates
properly and returns to the “OFF”position when
released.
To start the tool, simply pull the switch trigger. Tool speed is
increased by increasing pressure on the switch trigger.
Release the switch trigger to stop.
Electric brake
This tool is equipped with an electric brake. If the tool consis-
tently fails to quickly stop after switch trigger release, have
tool serviced at a Makita service center.
Reversing switch action
This tool has a reversing switch to change the direction of
rotation. Depress the reversing switch lever from the A side
for clockwise rotation or from the B side for counterclockwise
rotation.
When the reversing switch lever is in the neutral position, the
switch trigger cannot be pulled.
CAUTION:
•Always check the direction of rotation before operation.
•Use the reversing switch only after the tool comes to a
complete stop. Changing the direction of rotation before
the tool stops may damage the tool.
•When not operating the tool, always set the reversing
switch lever to the neutral position.
1. Switch trigger
1
003104
1. Reversing switch lever
AB
1
003113

12
Selecting the action mode
Rotation with hammering
For drilling in concrete, masonry, etc., depress the lock but-
ton and rotate the change lever so that the pointer points to
the symbol. Use a tungsten-carbide tipped bit.
Rotation only
For drilling in wood, metal or plastic materials, depress the
lock button and rotate the change lever so that the pointer
points to the symbol. Use a twist drill bit or wood bit.
Hammering only
For chipping, scaling or demolition operations, depress the
lock button and rotate the change lever so that the pointer
points to the symbol. Use a bull point, cold chisel, scaling
chisel, etc.
CAUTION:
•Do not rotate the change lever when the tool is running.
The tool will be damaged.
•To avoid rapid wear on the mode change mechanism, be
sure that the change lever is always positively located in
one of the three action mode positions.
Torque limiter
The torque limiter will actuate when a certain torque level is
reached. The motor will disengage from the output shaft.
When this happens, the bit will stop turning.
1. Rotation with hammering
2. Lock button
3. Pointer
4. Change lever
12
3
4
003128
1. Rotation only
2. Pointer
1
2
003131
1. Hammering only
2. Pointer
1
2
003133

13
CAUTION:
•As soon as the torque limiter actuates, switch off the tool
immediately. This will help prevent premature wear of the
tool.
ASSEMBLY CAUTION:
•Always be sure that the tool is switched off and the
battery cartridge is removed before carrying out any
work on the tool.
Side grip
The side grip swings around to either side, allowing easy
handling of the tool in any position. Loosen the side grip by
turning it counterclockwise, swing it to the desired position
and then tighten it by turning clockwise.
Bit grease (optional accessory)
Coat the bit shank head beforehand with a small amount of
bit grease (about 0.5 -1 g; 0.02 - 0.04 oz.). This chuck lubri-
cation assures smooth action and longer service life.
Installing or removing the bit
Clean the bit shank and apply bit grease before installing the
bit.
1. Side grip
1
003141
1. Bit shank
2. Bit grease
2
1
003150

14
Insert the bit into the tool. Turn the bit and push it in until it
engages.
If the bit cannot be pushed in, remove the bit. Pull the chuck
cover down a couple of times. Then insert the bit again. Turn
the bit and push it in until it engages.
After installing, always make sure that the bit is securely held
in place by trying to pull it out.
To remove the bit, pull the chuck cover down all the way and
pull the bit out.
Bit angle (when chipping, scaling or demolishing)
To change the bit angle, depress the lock button and rotate
the change lever so that the pointer points to the “O”symbol.
Turn the bit to the desired angle.
Depress the lock button and rotate the change lever so that
the pointer points to the symbol. Then make sure that the
bit is securely held in place by turning it slightly.
1. Bit
2. Chuck cover
1
2
003157
003166
1. Change lever
2. “O”symbol
12
003170
1. Change lever
1
003174

15
Depth gauge
The depth gauge is convenient for drilling holes of uniform
depth. Insert the depth gauge into the hole in the grip base.
Adjust the depth gauge to the desired depth and then tighten
the clamp screw to secure the depth gauge.
NOTE:
•The depth gauge cannot be used at the position where
the depth gauge strikes against the tool body.
Dust cup (optional accessory)
Use the dust cup to prevent dust from falling over the tool
and on yourself when performing overhead drilling opera-
tions. Attach the dust cup to the bit as shown in the figure.
The size of bits which the dust cup can be attached to is as
follows.
OPERATION CAUTION:
•Always insert the battery cartridge all the way until it
locks in place. If you can see the red part on the upper
side of the button, it is not locked completely. Insert it
fully until the red part cannot be seen. If not, it may
accidentally fall out of the tool, causing injury to you or
someone around you.
•When operating overhead, always make sure the battery
cartridge is locked securely so that it will not be fallen out
of the tool. If not, it may accidentally fall out of the tool,
causing injury to you or someone around you.
1. Depth gauge
2. Clamp screw
3. Grip base
12 3
003179
1. Dust cup
1
003186
Dust cup 5
Dust cup 9
Bit diameter
6 mm (1/4”) - 14.5 mm (9/16”)
12 mm (15/32”) - 16 mm (5/8”)

16
Hammer drilling operation
Set the change lever to the symbol.
Position the bit at the desired location for the hole, then pull
the switch trigger. Do not force the tool. Light pressure gives
best results. Keep the tool in position and prevent it from slip-
ping away from the hole.
Do not apply more pressure when the hole becomes clogged
with chips or particles. Instead, run the tool at an idle, then
remove the bit partially from the hole. By repeating this sev-
eral times, the hole will be cleaned out and normal drilling
may be resumed.
CAUTION:
•There is a tremendous and sudden twisting force
exerted on the tool/bit at the time of hole break-through,
when the hole becomes clogged with chips and
particles, or when striking reinforcing rods embedded in
the concrete. Always use the side grip (auxiliary handle)
and firmly hold the tool by both side grip and switch
handle during operations. Failure to do so may result in
the loss of control of the tool and potentially severe
injury.
Blow-out bulb (optional accessory)
After drilling the hole, use the blow-out bulb to clean the dust
out of the hole.
Chipping/Scaling/Demolition
Set the change lever to the symbol.
Hold the tool firmly with both hands. Turn the tool on and
apply slight pressure on the tool so that the tool will not
bounce around, uncontrolled. Pressing very hard on the tool
will not increase the efficiency.
003197
1. Blow-out bulb
1
002449
003203

17
Drilling in wood or metal
Use the optional drill chuck assembly. When installing it, refer
to “Installing or removing the bit”described on the previous
page.
Set the change lever so that the pointer points to the
symbol.
You can drill up to 13 mm (1/2”) diameter in metal and up to
27 mm (1-1/16”) diameter in wood.
CAUTION:
•Never use “rotation with hammering”when the drill
chuck assembly is installed on the tool. The drill chuck
assembly may be damaged. Also, the drill chuck will
come off when reversing the tool.
•Pressing excessively on the tool will not speed up the
drilling. In fact, this excessive pressure will only serve to
damage the tip of your bit, decrease the tool
performance and shorten the service life of the tool.
•There is a tremendous twisting force exerted on the tool/
bit at the time of hole breakthrough. Hold the tool firmly
and exert care when the bit begins to break through the
workpiece.
•A stuck bit can be removed simply by setting the
reversing switch to reverse rotation in order to back out.
However, the tool may back out abruptly if you do not
hold it firmly.
•Always secure small workpieces in a vise or similar hold-
down device.
MAINTENANCE CAUTION:
•Always be sure that the tool is switched off and the
battery cartridge is removed before attempting to
perform inspection or maintenance.
Replacing carbon brushes
Remove and check the carbon brushes regularly. Replace
when they wear down to the limit mark. Keep the carbon
brushes clean and free to slip in the holders. Both carbon
brushes should be replaced at the same time. Use only iden-
tical carbon brushes.
1. Drill chuck
2. Change lever
3. Pointer
1
2
3
003222
1. Limit mark
1
001145

18
Use a screwdriver to remove the brush holder caps. Take out
the worn carbon brushes, insert the new ones and secure
the brush holder caps.
After replacing brushes, insert the battery cartridge into the
tool and break in brushes by running tool with no load for
about 1 minute. Then check the tool while running and elec-
tric brake operation when releasing the switch trigger. If elec-
tric brake is not working well, ask your local Makita service
center for repair.
To maintain product SAFETY and RELIABILITY, repairs, any
other maintenance or adjustment should be performed by
Makita Authorized or Factory Service Centers, always using
Makita replacement parts.
1. Brush holder cap
2. Screwdriver
003228
1
2

19
ACCESSORIES CAUTION:
•These accessories or attachments are recommended for
use with your Makita tool specified in this manual. The
use of any other accessories or attachments might
present a risk of injury to persons. Only use accessory
or attachment for its stated purpose.
If you need any assistance for more details regarding these
accessories, ask your local Makita service center.
•SDS-Plus Carbide-tipped bits
•Bull point
•Cold chisel
•Drill chuck assembly
•Drill chuck S13
•Chuck adapter
•Chuck key S13
•Bit grease
•Grip assembly
•Depth gauge
•Blow-out bulb
•Dust cup
•Dust extractor attachment
•Safety goggles
•Plastic carrying case

Memo
20