Makita BHR240 Manual

Max. Output(W)
Battery
Voltage: V
Cell and Capacity
Capacity
: mm ( " )
Charging Time
330
0 - 1,100
0 - 4,000
18
Li-ion 3.0 Ah
Yes
Yes
Yes
Yes
Yes
Yes
Yes
10 (3/8)
13 (1/2)
26 (1-1/16)
18 (11/16)
3.0 (6.6) including Battery BL1830
approx. 22 min. with DC18RA
Models No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
P 1 / 14
BHR240
Cordless Rotary Hammer
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 410 (16-1/8)
78 (3-1/16)
206 (8-1/8)
W
H
L
Bit Shank
Chuck Capacity: mm ( " )
SDS plus
Steel
Wood
* Concrete * Concrete: 24 (7/8)
for North American Countries
Blows per min, :(bpm=min -1)
No load speed : (min -1= rpm)
Variable switch
Reverse switch
Clutch (Torque Limiter)
Electric Brake
Net Weight : kg (lbs)
* Grip Assembly ................................... 1 set * Depth Gauge (Stopper Pole) .............. 1 pc.
* SDS-Plus bits
* Taper shank T.C.T bits
* Taper shank adapter
* Cotter
* Drill chuck assembly
* Chuck adapter
* Drill chuck S13
* Bull points
* Dust Cup
* Grease Vessel 30g
* Blow out bulb
* Safety goggle
* Dust extractor attachment
* Joint 25
* Charger DC18RA
* Charger DC18SC
* Charger DC24SA
* Charger DC24SC
* Battery BL1830
Rotation
Hammering
Rotation + Hammering
Working
mode
These new products will be available in the following variations.
The cordless version of HR2453/HR2454 has been launched
with D-handle for operator's comfort.
The variations for USA, Canada, Mexico and Panama are as follows.
BHR240SFE
BHR240SF BL1830 DC18RA
Model No. Type Quantity Charger Plastic
carrying case
Yes
Yes
No No No
2
1
---
Battery
BHR240
BHR240Z
BHR240Z
BL1830 DC18RA
Model No. Type Quantity Charger Plastic
carrying case
Yes
No No No
2
---
Battery
* Chuck key S13
* Keyless drill chuck
* Grip assembly
* Scraper Assembly
* Cold chisels
* Grooving chisels
* Scaling chisels

P 2 /14
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the battery from the machine for safety before repair/ maintenance !
Item No. Description Purpose
1R003 Retaining ring S pliers ST-2N
1R004 Retaining ring S pliers ST-2
Removing/ installing Ring spring 19
Removing/ installing Ring spring 29
Removing Helical gear 251R022 Bearing plate
1R023 Pipe ring Removing Helical gear 25
1R032 Bearing Setting Plate 8.2 Installing Helical gear 25
1R033 Bearing Setting Plate 10.2 Installing Helical gear 25
1R034 Bearing Setting Plate 12.2 Installing Helical gear 25
1R281 Round bar arbor 7-50 Removing Ring 8
1R269 Bearing extractor Removing Ball bearing 608ZZ
1R038 Armature holder 32 Fixing Tool holder
Removing/ installing Ring spring 19 (for modular use with 1R003)1R212 Tip for retaining ring pliers
Installing Oil seal 251R232 Pipe 30
Removing Oil seal 251R252 Round bar for arbor
Installing Needle bearing complete1R164 Ring spring setting tool A
1R291 Retaining ring S and R pliers Removing Retaining ring S-7
1R306 Ring spring removing jig Removing Ring spring 29
Whole surface
50 Clutch cam
Whole surface
Groove
43 Flat washer 12 (2pcs)
Swash bearing 10 Pin portion that is inserted into 44 Piston joint
Item No. Description Portion to lubricate
Fig. 1
[2] LUBRICATION
Apply the following grease to the portions designated with the triangles to protect parts and product from unusual abrasion.
:Molybdenum disulfied grease
45
44 Piston joint
29 Tool holder complete Whole inside surface
52
52
50
29
Piston cylinder
44
43 45

P 3 /14
Repair
17 Gear housing comp. Gear room
Inner circumference of Oil seal
Swash bearing 10 Surface that contacts Helical gear 26 and the inside surface that
contacts Cam shaft
Crank room where Piston cylinder thrusts
Item No. Amount to applyDescription Portion to lubricate
65 Inner housing comp.
Fig. 2
[2] -2. Makita Grease RB No.00
:Makita grease RB No.00
about 17g
52
Cap 35 Inside surface that contacts hammer bit
Inner circumference that contacts Tool holder comp.
Needle bearing comp. Inside surface
Inner circumference27 Spur gear 51
appropriate amount
18
Steel ball 7.0 Whole surface
Face of cam and the surface that contacts Inner housing comp.
29 Tool holder comp.
28
X ring 9 Inner circumference
Surface that contacts Tool holder comp.32 Sleeve 9
31
Ring 10 Surface that contacts Cushion ring 13
Whole surface38 O ring 9
35
Whole surface41 O ring 16
Piston cylinder Inside surface that contacts Striker
Teeth portion and the inside surface that contacts Cam shaft49 Spur gear 10
42
Both faces of cam and the inside surface that contacts Cam shaft50 Clutch cam
Teeth portion53 Helical gear 26
Whole surface48 O ring 63
Inner circumference that contacts Armature shaft67 Oil seal 8
Whole surface66 O ring 24
Ring 21 appropriate amount
appropriate amount
Ball portion about 4g
about 5g
appropriate amount
appropriate amount
appropriate amount
4
1
Change lever comp. Two pins
Whole surfaceO ring 1716
13
52 53
66
Oil seal
1
4
17
13
16
18
28
Cushion ring 13
41
42
50
49
Cam shaft
54
65
67
27
29
31
32
35
38

P 4 /14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Chuck Section
Fig. 5
DISASSEMBLING
Fig. 4
Fig. 6
1) Slide Chuck cover in the direction of Gear housing.
Remove Cap 35 using hand and a slotted screwdriver (Fig. 3).
2) Remove Ring spring 19 from the groove on Tool holder complete
using 1R003 and 1R212. Remove Ring spring 19.
Chuck cover and Ring 21 can now be removed (Fig. 4).
3) Pushing Guide washer in the direction of Gear housing,
remove Steel ball 7.0 from the slot on Tool holder complete.
Remove Guide washer and Conical compression spring 21-29 (Fig. 5).
ASSEMBLING
Do the reverse of the disassembling steps.
Note: Conical compression spring 21-29 and Ring spring 19 are not reversible when assembled to Tool holder complete.
Be sure to assemble as illustrated in Fig. 6.
Ring spring 19
Chuck cover
Ring 21
Guide washer
Conical compression
spring 21-29
flat portion
Fig. 3
Cap 35
Chuck cover
Gear housing
Tool holder complete
Steel ball 7.0
Guide washer
Conical compression spring 21-29
Ring spring 19
Wrong
Cap 35 side
Gear housing side
Cap 35 side
Gear housing side
Conical compression
spring 21-29
Correct
Wrong
Correct
Tool holder complete
Ring spring 19
Tool holder complete
flat portion

P 5 /14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Change Lever
DISASSEMBLING
1) Lever up Cap from Change lever using two slotted screwdrivers (Fig. 7).
Note: Lock button and Compression spring 3 will fly away in this step.
Be careful not to lose them.
2) Rotate Change lever fully in the direction of the drill mode position until
the lever is located within the area B (Fig. 8). Change lever can now be
pulled off. Remove O ring 17 from Change lever (Fig. 9).
ASSEMBLING
1) Apply grease to O ring 17 and the pins of Change lever as described in page 3.
2) Put Compression spring 3 and Lock button in place on Change lever. Assemble Cap provisionally to Change lever
as illustrated in Fig. 10 in order to prevent the spring from popping out from Change lever.
Do not forget to assemble O ring 17 to Change lever in this step.
3) Place the provisionally assembled Change lever within the area A of Gear housing (Fig. 8), and insert into the Change
lever installation hole. Change lever cannot be inserted completely in this step.
4) Pushing Change lever against Gear housing, turn Change lever in the direction of the drill mode until it reaches the
area B where it can be completely inserted into the hole. If cannot be completely inserted, do this operation with
Lock button pressed.
5) Turn Change lever to the area C (Fig. 8). Assemble Cap completely to Change lever by pushing in the direction of
Gear housing (Fig. 11).
Change lever
O ring 17
Cap
Change lever
Change lever
Compression spring 3
Lock button
Cap
Lock button
Compression
spring 3
O ring 17
Fig. 8 Fig. 9
Fig. 10 Fig. 11
Fig. 7
Cap
Change lever
= Drill mode
= Rotary hammer mode
= Hammer mode
B
CA
Change lever
Cap provisionally
assembled to Change lever
not protruding
from the surface
of Change lever
Cap completely
assembled to Change lever
protruding
from the surface
of Change lever

P 6 /14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Armature
DISASSEMBLING
[3] -4. Tool Holder Complete and Spur Gear 51
DISASSEMBLING
1) Remove Brush holder cap and Carbon brush from Motor housing. (left in Fig. 12)
2) Separate the assembly of Gear housing armature from Motor housing by unscrewing four 4x40 Tapping screws.
(right in Fig. 12) The assembly of Gear housing is removed together with Armature in this step.
3) Remove Armature from Inner housing assembled to Gear housing by lightly tapping the end surface of Motor housing
with plastic hammer (Fig. 13).
ASSEMBLING
Do the reverse of the disassembling steps.
1) Remove Chuck section (Figs. 3, 4, 5 in page 4) and Change lever (Figs. 7, 8 ).
2) Separate Gear housing from Motor housing (Fig. 12). Remove Armature from Gear housing (Fig. 13).
3) Remove the assembly of Tool holder section and Inner housing from Gear housing as illustrated in Fig. 14.
Note: Ball bearing 606ZZ will remain fixed in Gear housing complete. See Fig. 28 for removal.
4) Remove Inner housing from Tool holder section as illustrated in Fig. 15.
Note: Be careful not to lose Flat washer 28.
Fig. 14 Fig. 15
Plastic hammer
Tool holder section
Inner housing
Tool holder section
Flat washer 28
Piston cylinder
Fig. 13Fig. 12
Inner housing
Armature
Carbon brush
Brush holder Cap
Motor housing
Tapping screw 4x40 (4 pcs)
Gear housing
Inner housing
Swash bearing section
Ball bearing 606ZZ
(will remain fixed
in Gear housing complete.)
Gear housing complete

P 7 / 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Tool Holder Complete and Spur Gear 51 (cont.)
DISASSEMBLING
5) Attach two 1R022 to 1R306.
Install them on arbor press as illustrated to left in Fig. 16.
6) Applying two 1R022 to Washer 31, press them down using arbor press in order to remove the force of
Compression spring 32 from Ring spring 29 (center of Fig. 16).
7) While pressing Washer 31, remove Ring spring 29 from Tool holder complete. (center of Fig. 16)
8) Remove Washer 31, Compression spring 32 and Spur gear 51 from Tool holder complete. (right in Fig. 16)
ASSEMBLING
Do the reverse of the disassembling steps.
Fig. 16
[3] -5. Impact Bolt Section
DISASSEMBLING
1) Take Tool holder complete out of the machine as
illustrated in Fig. 14 and Fig. 15.
2) Remove Striker from Tool holder complete using 1R281
for 1R281 as illustrated in Fig. 17.
3) Clamp Tool holder complete using Vise and 1R038 as
illustrated in Fig. 18.
4) Insert a slotted screwdriver between Ring spring 28 and
O ring case through the side hole of Tool holder.
Important: If you see the end of Ring spring 28 in the hole, push the spring using a slotted screwdriver until the end
is hidden (Fig. 19).
Strike the slotted screwdriver with plastic hammer to remove Ring spring 28 from the groove on the inside surface of
Tool holder complete. Applying slotted screwdriver through the other side hole, remove Ring spring 28 from the groove
in the same way (Fig. 18).
Fig. 17
Tool holder complete
Compression spring 32
Compression spring 32
Spur gear 51
Washer 31
Ring spring 29
1R022 1R022
Arbor press
1R306
Spur gear 51
Washer 31
Tool holder complete
Cap 35 side Inner housing side
Striker
Tool holder complete
1R281
Ring spring 28O ring case
Fig. 19Fig. 18
32mm
1R038
Vise
Ring spring 28
O ring case
Tool holder complete
Side hole of Tool
holder complete
Ring spring 28

P 8 /14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Impact Bolt Section (cont.)
DISASSEMBLING
ASSEMBLING
Do the reverse of the disassembling steps.
Note:
When assembling Ring spring 28 to
Tool holder complete;
*Be careful not to position the end of the
spring in either of the side holes on Tool
holder complete.
*Use Piston cylinder as a jig as illustrated
in Fig. 23.
Fig. 21 Fig. 22
5) Ring spring 28 can be pulled off from Tool holder complete when completely
removed from the groove (Fig. 20).
Note: Ring spring 28 will be damaged or deformed in the steps 4) and 5).
Be sure to replace damaged/deformed Ring spring 28 when
assembling Tool holder section.
6) Remove Impact bolt section from Tool holder complete by striking Tool holder
complete against workbench (Fig. 21).
7) Disassemble Impact bolt section as illustrated in Fig. 22.
[3] -6. Swash Bearing Section
DISASSEMBLING
Impact bolt section
X ring 9 O ring 16 Ring 10 O ring 9
Sleeve 9 Impact bolt Cushion ring 13 O ring case
Fig. 23
Piston cylinder as
an assembling jig
Note:
Never use the Piston cylinder built-in the
machine as the jig because it is scratched
when inserted in Tool holder complete.
Be sure to have an extra Piston cylinder
as a jig for the application.
Ring spring 28
Tool holder complete
1) Remove Inner housing from Gear housing (Fig. 14 in page 6). If Ball bearing 606ZZ remains fixed in Gear housing,
See page 9 for removal. Remove Inner housing from Tool holder section (Fig. 15 in page 6).
2) Remove Stop ring E-4, Flat washer 5 and Compression spring 6 from the pin of Inner housing (Fig. 24).
3) Remove two M4x12 Hex socket head bolts that fasten Bearing retainer to Inner housing (Fig. 25).
Fig. 24 Fig. 25
Inner housing
Ring spring 28
Fig. 20
Fat washer 5
Compression spring 6
Stop ring E-4
Pin of Inner housing
Piston cylinder
Change plate
Hex socket head bolts M4x12

P 9/14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Swash Bearing Section (cont.)
DISASSEMBLING
4) Move Piston cylinder to the rear dead center position (Fig. 26).
5) Remove Swash bearing section from Inner housing by pulling in the direction of the arrow (Fig. 27).
Fig. 27Fig. 26
7) Remove Ring 8 using 1R022, 1R023 and 1R281 as illustrated in Fig. 29.
8) Remove Ball bearing 608ZZ using 1R269. Flat washer 8 and Bearing retainer can now be removed by hand (Fig. 30).
Piston cylinder
Swash bearing section
Piston cylinder
in the rear dead center position Inner housing
Swash bearing section
Fig. 28
Fig. 29 Fig. 30
6) Remove Ball bearing 606ZZ from Gear housing complete using the removed Swash bearing section as a jig as follows;
Insert Cam shaft of Swash bearing section into the Ball bearing again. Tilt the Ball bearing a little bit by moving swash
bearing section as illustrated to left in Fig. 28. Ball bearing 606ZZ can now be removed by lightly tapping the edge of
Gear housing complete with plastic hammer as illustrated to right in Fig. 28.
Swash bearing section
used as a jig
Ball bearing 606ZZ
Gear housing
complete
1R023
Ring 8
1R022
Ball bearing
608ZZ
1R281
Ball bearing
608ZZ
Flat washer 8
Bearing
retainer
1R269

P 10/14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Swash Bearing Section (cont.)
DISASSEMBLING
9) Remove Helical gear 25 using 1R022, 1R023 and 1R281 as illustrated to left in Fig. 31. Swash bearing 10 and Clutch cam
can now be removed by hand (right in Fig. 31).
10) Remove retaining ring S-7 using No.1R291 (left in Fig. 27). Compression spring 7 and Spur gear 10 can now be removed
by hand. (right in Fig. 32).
Fig. 32Fig. 31
Fig. 33
Fig. 34 Fig. 35
Swash
bearing 10
Clutch cam
Retaining
ring S-7
Compression
spring 7
Spur gear 10
Cam shaft
Helical gear 25
1R023
1R281
1R022
1R291
ASSEMBLING
1) Assemble Swash bearing section using 1R034 as illustrated in Fig. 33.
Note: 1. Be sure to put Flat washer 8 in place or Bearing retainer will be clamped between Ball bearing 608ZZ and
Helical gear 25.
2. Assemble the following parts after Cam shaft is installed on Inner housing;
Clutch cam, Spur gear 11, Compression spring 7, Retaining ring S-7
2) Assemble Piston joint and two Flat washers 12 to Piston cylinder as illustrated in Fig. 34.
Note: Do not forget to apply molybdenum disulfied grease (Fig. 1).
3) Insert Piston cylinder into Inner housing (Fig. 35).
1R034
Swash
bearing 10 Helical
gear 25
Cam shaft
Flat washer 8
Ball bearing
608ZZ
Bearing retainer Ring 8
Flat washer 12
Flat washer 12
Piston jointPiston cylinder Inner housing
Correct Wrong

P 11 /14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Swash Bearing Section (cont.)
[3] -7. Needle Bearing Complete, Oil Seal 25
4) Move Piston cylinder to the rear dead center position. Tilt Swash bearing 10
to set at the same angle as in the rear dead position.
Insert the pin portion of Swash bearing 10 through Inner housing into the
hole of Piston joint. (Fig. 36)
5) Fasten Swash bearing section to Inner housing with two M4x12 Hex socket
head bolts (Fig. 37).
Note: M4x12 Hex socket bolt is a threadlocker coated fastener.
If you reuse the bolts removed from machine, be sure to apply such
threadlocker as Threebond 1321B/1342 or Loctite 242 before fastening.
6) Fitting the curved edge of Change plate in the groove on Clutch cam as
illustrated to top-left in Fig. 38, assemble Change plate to Inner housing and
Clutch cam to Cam shaft at the same time.
Put Spur gear 10 and Compression spring 7 through Cam shaft, and secure
them with Retaining ring S-7. Put Compression spring 6 and Flat washer 5
through the upper pin of Inner housing, and secure them with Stop ring E-4.
1) Set the disassembled inner housing to Gear housing complete. Press down 1R252 using arbor press.
Oil seal 25 and Needle bearing complete can now be removed from Gear housing complete. (Fig. 39)
Fig. 38Fig. 37
ASSEMBLING
Hex socket head bolts M4x12
Fig. 36
Inner housing
Piston cylinder in the rear
dead center position
Swash bearing 10
Clutch cam
groove
Change plate
Cam shaft
upper pin of Inner housing
Spur gear 10
Compression spring 7
Retaining ring S-7
Compression spring 6
Stop ring E-4
Flat washer 5
DISASSEMBLING
Fig. 39
Inner Housing
Neeld Bearing
Complete
Gear Housing
Complete 1R252
Round Bar for
Arbor 30-100 Oil Seal 25

P 12 / 14
Repair
[3] DISASSEMBLY/ASSEMBLY
Fig. 40
ASSEMBLING
[3] -7. Needle Bearing Complete, Oil Seal 25
[3] -8. F/R Change Lever
1) Applying 1R232 to Oil seal 25, press down 1R232 using arbor press in order to insert Oil seal 25 halfway into Gear
housing. (left in Fig. 40)
2) Applying 1R164 to Oil seal 25 inserted halfway into Gear housing complete, press down Gear housing complete
using arbor press until it stops. (right in Fig. 40)
3) Apply Makita grease RB No.00 to the inside surface of Needle bearing complete.
4) Applying 1R164 onto Needle bearing complete, set them to Gear housing complete.
5) Press down Gear housing complete using arbor press in order to insert Need bearing complete into Gear housing
complete.
1R232
Oil
Seal 25
Face 34mm side to
Oil seal 25 in Gear
housing complete.
1R164
Gear
Housing
Complete
1) Pass F/R change lever's tab through switch cover (left in Fig. 42)
2) Mount switch cover to switch by fitting the prong portion of F/R change lever to the boss of switch. (center of Fig. 42)
Gear Housing
Complete
1R164
Something to support 1R164
Fig. 41
Needle bearing
complete
Gear housing
complete
flat portion
bottom side
top
side top side
bottom side
34mm
34mm
Switch Cover
F/R Change
Lever
F/R Change
Lever
Switch Cover
Boss
Switch Switch
Prong portion
Completion
Fig. 42
Important: Needle bearing complete is not reversible when assembled to Gear housing complete. Be sure to place
the flat portion of Needle bearing complete on the bottom side of Gear housing complete.
1R164 is shorter in height than Gear housing complete. Be sure to add something to support it when
inserted into Gear housing complete.
Something to support 1R164

Circuit diagram
P 13 /14
Yoke Unit
Heat Sink
F E T
Terminal
End bell
Complete
Color index of lead wires' sheath
Black
Red
Blue
Fig. D-1
Yellow
Switch
Tape to bundle
the lead wires

Wiring diagram
P 14 / 14
Terminal M2
Route End bell's lead wires
(black) and (red) between
boss and rib A.
Fix the End bell's lead wires
(black and red) with lead
wire holder.
Connecting terminal of M2 side
can be inflected toward the direction
designated with arrow in order to
avoid pinching of lead wire,
if it is necessary.
Bundle the following lead wires
with band.
* FET's lead wires (black) (blue)
(yellow)
* Switch's lead wire (red)
Rib A
FET
Rib C
Route he following lead wire between rib B and rib C.
* Switch's lead wires (black and red)
* FET's lead wires (black, blue, yellow)
Rib B
Boss
Fix the FET's lead wires (black,
blue and yellow) with lead wire
holder.
Heat Sink
Terminal
Endbell Comp.
Switch
The flag connector has to be so connected,
that its wire connecting portion is located over
the mark of + - poles.
Flag Connector
Terminal
Wire Connecting Portion
Mark of Poles
Fig. D-2