Makita DHR165 Manual

CONCEPT AND MAIN APPLICATIONS
Specification
PRODUCT
P 1/ 17
Models DHR165/DHR164 are 18V/14.4V LXT cordless rotary hammers
and have been developed based on the current 14.4V LXT model DHR162.
The two models feature XPT (eXtreme Protection Technology)
in addition to the benefits of the compact and lightweight DHR162.
18V model DHR165 has been developed to expand our lineup of
18V LXT cordless rotary hammers, while 14.4V model DHR164
has been developed as an upgraded model of DHR162.
Note: DHR165 is not compatible with BL1815.
DHR164 is not compatible with BL1415.
Battery
Specification Model
Shank type
Capacity: mm (")
Concrete
Operation mode
Steel
Wood
No load speed: minˉ¹= rpm
Energy capacity: Wh
Voltage: V
Capacity: Ah
Cell Li-ion
Charging time (approx): min 15, 24, 22, 36, 45
with DC18RC
18
DHR165 DHR164
13 (1/2)
24 (15/16)
2 modes (Rotation only/ Rotation with hammering)
0 - 1,600
0 - 5,300
Adapted for SDS-PLUS bits
Chuck type One-touch sliding chuck
16 (5/8)
Max output: W 400
0 - 1,600
0 - 5,300
400
1.5, 2.0, 3.0, 4.0, 5.0
27, 36, 54, 72, 90
Li-ion
15, 22, 36, 45
with DC18RC
14.4
1.5, 3.0, 4.0, 5.0
22, 44, 58, 5.0
Impacts per minute: minˉ¹
Torque limiter
Variable speed control by trigger
Reverse switch
Weight according to
EPTA-Procedure 01/2003*
3 : kg (lbs)
Yes
Yes
Yes
Yes
2.2 (4.9)*
4
2.5 (5.5)* 5
2.2 (4.8)* 6
2.4 (5.3)* 7
LED job light
*3 With Side grip
*4 With BL1815N or BL1820
*5 With BL1830, BL1840 or BL1850
*6 With BL1415N
*7 With BL1430, BL1430A, BL1440 or BL1450
Model No. DHR165/ DHR164
Description 16mm (5/8") Cordless Rotary Hammer
*1 DHR165: With BL1815N or BL1820
DHR164: With BL1415N or BL1415NA
*2 DHR165: With BL1830, BL1840 or BL1850
DHR164: With BL1430, BL1430A, BL1440
or BL1450
297 (11-3/4)
Width (W)
Height (H)
Length (L)
79 (3-1/8)
236 (9-1/4)*1
253 (10)*2
Dimensions: mm (")
DHR165 DHR164
235 (9-1/4)*1
250 (9-7/8)*2
H
W
L
T
ECHNICAL INFORMATION
Electric brake
Yes
Shank diameter: mm (") 10 (3/8)
OFFICIAL USE
for ASC & Sales Shop

Optional accessories
Battery BL1815N (for DHR165)
Battery BL1820 (for DHR165)
Battery BL1830 (for DHR165)
Battery BL1840 (for DHR165)
Battery BL1850 (for DHR165)
Battery BL1415N (for DHR164)
Battery BL1415NA (for DHR164)
Battery BL1430 (for DHR164)
Battery BL1430A (for DHR164)
Battery BL1440 (for DHR164)
Battery BL1450 (for DHR164)
Fast charger DC18RC
Charger DC18SD/DC24SC
Automotive charger DC18SE
Four port multi charger DC18SF
Two port multi fast charger DC18RD
Note: The standard equipment may vary by country or model variation.
*8 Battery and charger are not supplied with “Z” model
*9 Supplied with the same quantity of extra battery
*10 For some countries
Side grip
Depth gauge (Stopper pole)
Battery*8
Battery cover*9
Charger*8
Plastic carrying case*10
Standard equipment
P 2/ 17
SDS-PLUS shank TCT hammer drill bits
Taper shank TCT hammer drill bits
Taper shank adapter
Cotter
Drill chuck assembly
Chuck adapter
Chuck key S13
Drill chuck S13
Dust cup 5.9
SDS-PLUS hammer chuck set
Anchor setting rod
Safety goggle
Holder driver
Bit grease
Blow out bulb
Grip drills
Grip drill holder
Dust collector set
Dust cup set

P 3/ 17
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R003 Retaining ring pliers ST-2N Removing Retaining ring WR-25
1R022 Bearing plate Removing Helical gear 22
Assembling Helical gear 22
Assembling Helical gear 22
1R032
1R033
1R212
1R225
1R232
1R235
1R252
1R268
1R306
*331708-8 Piston cylinder
*Use Piston cylinder of DHR162, DHR164, DHR165 and HR1830 (Part No. 331708-8) as a repairing tool.
Assembling Ring spring 22 into Tool holder
Bearing setting plate 8.2
Bearing setting plate 10.2
Tip for Retaining ring pliers
Bearing extractor Removing Armature
Pipe 30 Assembling Oil seal 25
Round bar for Arbor 6-100 Removing Armature
Round bar for Arbor 30-100 Assembling Ball bearing 6805LLB
Spring pin extractor M3 Removing Pin 4 from Inner housing
Ring spring removing jig Removing Retaining ring WR-25
Attaching to 1R003 for removing Retaining ring WR-25
Maintenance program
When you replace Carbon brushes, it is recommended to replace the following parts with new ones at the same time.
Hammer service kit is available.
Note: Be sure to remove the old grease in the machine, apply the specified grease in accordance with Fig. 1 of page 4.
Item No.
< Hammer service kit >
Description
31 Ring spring 22
Hammer service
kit includes these
parts.
1 Cap 35
Makita grease FA No. 2
35 O ring 14
28 X ring 13
44 Seal ring
Makita grease RA No. 1

1
26
29
35
36
40
42
43
41
38
5g: Inner housing and
the components
Apply any of grease/lubricant to the outer periphery
of Oil seal 25 because it should be pressfit in place
without twisting/ deforming.
20g: Makita grease RA No.1
(except grease FA No. 2
and Molybdenum disulfide)
3g: Gear teeth and Flat washer
on gear teeth side
52
54
Cross section of 1
Makita grease RA No.1
Makita grease FA No.2
Molybdenum disulfide
15
16
27
32 33
22
21
[2] LUBRICATION
Apply the following grease/ lubricant to protect parts and product from unusual abrasion.
Fig. 1
Item No. Description Amount
See below
for approx.
amount
for each
section.
Portion to lubricate
1 Cap 35 Lip portion
1 g
1 g
15 Oil seal 25 Outer periphery
1 g
1 g
1 g
1 g
16 Ball bearing 6805LLB Inner periphery
21 Compression spring 25 Portion where 22 Spur gear 46 contacts
22 Spur gear 46
a. Gear teeth
e. Cylindrical surface to which Inner housing complete is joined
b. Cam portion
1 g
1 g
1 g
1 g
c. Inner periphery
27 Steel ball 7 Whole portion
Cylindrical surface
1 g 29 Impact bolt
Whole portion
1 g
35 O ring 14
f. Inside 1 g
g. Outside 1 g
36 Piston cylinder
Whole portion
Hole for the pole of Swash bearing 9
Gear teeth to engage 41 Clutch cam
1 g 38 Piston joint
h. Pole 1 g
42 Swash bearing 9
Gear teeth to engage 22 Spur gear 46
1 g
Gear teeth where 22 Spur gear 46 engages
1 g
1 g
40 Spur gear 10
Groove for fit 33 Joint plate
i. Surface where 43 Helical gear 22 contacts
1 g
1 g Clutch cam41
Helical gear 2243
Space where Armature's drive end and 43 Helical gear 22 engage
5 g
Inner housing complete52
Armature's gear teeth and Flat washer on gear teeth side
3 g
Armature54
1 g
32 Flat washer 24
Inner periphery 1 g 33 Joint plate
26 Tool holder complete d. Curved surface where 22 Spur gear 46 contacts
Grease
P 4/ 17
Repair

[3] DISASSEMBLY/ASSEMBLY
[3]-1. Tool holder
ASSEMBLING
Assemble by reversing the disassembly procedure.
Note: Be careful about the directions of Ring spring 19 and Conical compression spring 21-29. (Fig. 3)
Be sure to place the flat portion
of Ring spring 19 on Steel ball
7.0.
Ring spring 19
flat portion
Steel ball 7.0
Fig. 3
Fig. 4
Fig. 5
[3]-2. Armature
DISASSEMBLING
(1) Remove Carbon brushes. (Fig. 4)
(2) Armature can be removed from
Gear housing complete as drawn in Fig. 5.
1.Remove four 4x35 Tapping screws, and then separate
Gear housing complete from Housing set.
Armature comes with Gear housing complete.
2. Pull out Armature from Inner housing complete.
If it is difficult to remove, tap Inner housing portion
carefully with a plastic hammer as drawn below.
Armature is removed from Gear housing complete.
Note: Do not tap Gear housing complete and Armature fan
near Inner housing complete.
Holder cap cover Groove
Remove Holder cap covers with
a thin slotted screwdriver.
And then, remove Holder caps
and Carbon brushes.
Slotted
screwdriver
Armature
Gear housing
complete
Armature
P 5/ 17
Repair
DISASSEMBLING
Ring 21
Ring 21
Guide washer
Conical
compression
spring 21-29
Cap 35
Tool holder section can be disassembled as drawn in Fig. 2.
Steel ball 7.0
Chuck cover
Ring spring 19
flat portion
Chuck
cover
1R003
1R212
Ring 21
Remove Cap 35 with slotted screwdriver, then
remove Ring spring 19 using 1R003 with 1R212.
Separate Chuck cover.
Then remove Steel ball 7.0 while
pressing down Ring 21.
Bit holder section can be
disassembled as drawn below.
Fig. 2
flat portion
Wrong
Cap 35
side
Gear
housing
side
Gear
housing
side
Cap 35
side
Conical compression
spring 21-29
Right
Tool holder complete
Ring spring 19
Tool holder complete
flat portion

[3] DISASSEMBLY/ASSEMBLY
[3]-2. Armature (cont.)
Fig. 6
DISASSEMBLING
Lock button must be pushed into Change lever
deeper than the usual operation.
(2) In case Armature cannot be removed by the steps mentioned in the previous page, disassemble the machine as drawn
in the following and the next page.
(3) Remove Change lever complete, and separate Inner housing section from Gear housing.
Then separate Tool holder section and Joint plate from the Inner housing section as drawn in Fig. 6.
5. Remove Tool holder section. 6. Detach Joint plate from the groove of Clutch cam and remove
Joint plate from Piston cylinder.
3. Change lever complete is removed from
Gear housing complete.
Change lever
complete
Change lever
complete
Tool holder section
Joint plate Groove of Clutch cam
Piston cylinder
Inner housingTool holder complete
Workbench
Gear housing complete
Tool holder complete
Armature
4. Remove Inner housing complete and Armature section from Gear
housing complete by attaching the top of Tool holder complete
on workbench and sliding down Gear housing complete.
2. Turn Change lever to the left further than hammer drill mode position
while pushing Lock button deeper than the surface level of Change lever.
1. Set Change lever complete to hammer
drill mode while pushing Lock button.
Lock button
P 6/ 17
Repair

[3] DISASSEMBLY/ASSEMBLY
[3]-2. Armature (cont.)
Fig. 7
Fig. 8
DISASSEMBLING
Note: Separating Spur gear 10 with Swash bearing section
from Piston cylinder is impossible when Piston cylinder
stays in the furthest position from Armature side as
drawn below.
(4) Disassemble Spur gear 10 and Swash bearing section as drawn in Fig. 7.
(5) Armature can be removed from Inner housing complete as drawn in Fig. 8.
1. Move Piston cylinder to the closest position
to Armature side by turning Armature carefully.
Note: Do not scratch and stain Armature.
Put Inner housing complete on 60 mm width U-grooved table of Arbor press,
and then press down Armature shaft with 1R225.
Spur gear 10 Swash bearing section
Armature
Armature
Pole of Swash bearing Pole
Piston cylinder
Piston cylinder
3. Remove Piston cylinder from
Inner housing complete.
60 mm
Armature
Inner cylindrical portion of
Inner housing
complete
Inner cylindrical
portion of Inner
housing complete
2. Pull out Spur gear 10 and Swash bearing section from Piston cylinder
in direction of the black arrows.
1R225
Armature
shaft Inner housing
complete
Inner housing
complete
1R225
Arbor press
Armature
Inner housing
complete
P 7/ 17
Repair

[3] DISASSEMBLY/ASSEMBLY
[3]-2. Armature (cont.)
Fig. 9
ASSEMBLING
(1) Armature can be assembled to Inner housing complete as drawn in Fig. 9.
(2) Assemble the rest of the parts by reversing the disassembly procedure. (Refer to Figs. 7 and 6.)
1. Assemble Armature to Inner housing complete
by hand until Ball bearing on Armature fan side
reaches O ring 24.
2. Tap Armature shaft carefully with a plastic hammer
to set Ball bearing of Armature in place in Inner
housing complete
O ring 24 Armature
Inner housing
complete
P 8/ 17
Repair

[3] DISASSEMBLY/ASSEMBLY
[3]-3. Gear section
DISASSEMBLING
1R022
Set 1R022 and 1R306 to
Arbor press in advance.
Set Tool holder section
on Arbor press.
Press down Flat washer 25
with 1R022 to reserve the
space for inserting 1R004
to Retaining ring WR-25.
While pressing down Flat washer 25 with 1R022,
remove Retaining ring WR-25 with 1R212.
Washer 25, Compression spring 25 and Spur
gear 46 are removed.
1R306
1R022
Tool holder section Flat washer 25
1R022 for pressing
down Flat washer 25 Flat washer 25
Compression spring 25
Spur gear 46
Spur gear 46 on Tool holder
Note: Ball bearings 606ZZ on the both ends of Spur gear 10 are still
left in Gear housing complete and Inner housing complete.
Spur gear 10
and
Swash bearing section
(1) Disassemble Tool holder section, Joint plate from Piston cylinder. (Fig. 6 in page 6)
(2) Remove Spur gear 10 and Swash bearing section from Piston cylinder and Inner housing complete. (Fig. 7 in page 7)
(3) Spur gear 46 can be removed as the upper drawing in Fig. 10.
Meanwhile, Spur gear 10 and Helical gear 22 can be removed as the lower drawing in Fig. 10.
Fig. 10
1R022
1R022 1R022
Hold Helical gear 22 with 1R022, and press down the shaft portion.
Helical gear 22, Swash bearing 9, clutch cam are removed from Spur gear 10.
1R022
Helical gear 22
Clutch cam
Swash bearing 9
Spur gear 10
P 9/ 17
Repair
1R0221R022
Flat washer 25
1R212
Retaining
ring WR-25
Helical gear 22

[3] DISASSEMBLY/ASSEMBLY
[3]-3. Gear section (cont.)
DISASSEMBLING
(3) Ball bearings 606ZZ on the both ends of Spur gear 10 are still left when Spur gear 10 and Swash bearing section are
removed from Gear housing complete and Inner housing complete.
These Ball bearings can be removed as drawn in Fig. 11.
Ball bearing 606ZZ in Inner housing complete can be also removed as drawn in Fig. 11S.
Fig. 11
Fig. 11S
Spur gear 10
1. Insert Spur gear 10 temporarily
into Ball bearing 606ZZ
in Gear housing complete.
1. Insert Spur gear 10 temporarily
into Ball bearing 606ZZ
on Inner housing complete.
2. Tilt the inserted Spur gear 10 toward
either direction, tap the edge of
Inner housing complete.
2. Tilt the inserted Spur gear 10 toward
either direction, tap the edge of
Gear housing complete.
3. Ball bearing 606ZZ is removed
from Inner housing complete
with Spur gear 10.
3. Ball bearing 606ZZ is removed
from Gear housing complete
with Spur gear 10.
Ball bearing 606ZZ can be removed from Gear housing complete/ Inner housing complete by using Spur gear 10
as a Repairing tool.
Ball bearing 606ZZ
Gear housing
complete
Inner housing
complete
Ball bearing
606ZZ
Ball bearing 606ZZ
Spur gear 10
Ball bearing
606ZZ
Spur gear 10
Spur gear 10
Ball bearing 606ZZ
Inner housing complete view from Armature insertion side
Ball bearing
606ZZ Push out Ball bearing 606ZZ with
a thin slotted screwdriver from
Inner housing complete.
P 10/ 17
Repair