Transcript
OFFICIAL USE for ASC & Sales Shop
T
ECHNICAL INFORMATION
Model No.
DHR263/ DHR264
Description
26mm (1") Cordless Combination Hammers
PRODUCT P 1/ 22
H W
CONCEPT AND MAIN APPLICATIONS
L Models DHR263/ DHR264 are 26mm cordless combination hammers based on Models BHR262 and BHR262T, and powered by The image above is model DHR263. two 18V Li-ion batteries in series. Their main features are: Dimensions: mm (") • Compact design Model No. DHR263 DHR264 • 3 operation modes (rotation only/ rotation with hammering/ hammering only) Length (L) 350 (13-3/4) 374 (14-3/4) • Battery capacity warning lamp Width (W) 116 (4-9/16) • XPT (eXtreme Protection Technology) Height (H) 232 (9-1/8) Models Chuck system DHR263 Normal chuck DHR264 Quick change chuck
Specification Specification Voltage: V Capacity: Ah Energy capacity: Wh Battery Cell
Model
DHR263
DHR264
36 (18x2) 1.5, 2.0, 3.0, 4.0, 5.0 27x2, 36x2, 54x2, 72x2, 90x2 Li-ion Charging time (approx.): min. 15x2, 24x2, 22x2, 36x2, 45x2 with DC18RC Max output: W 600 0 - 1,250 No load speed: min.ˉ¹= rpm Impacts per minute: min.ˉ¹ 0 - 5,000 Adapted for SDS-PLUS bits Chuck type Adapted for SDS-PLUS bits and Round shank bits*1 Capacity of Quick change chuck: mm (") N/A 1.5 (1/16) - 13 (1/2) 26 (1) TCT bit 54 (2-1/8) Concrete Core bit 65 (2-9/16) Diamond core bit Capacity: mm (") 13 (1/2) Steel 32 (1-1/4) Wood Operation mode 3 modes (Rotation only/ Rotation with hammering/ Hammering only) Yes Variable speed control Reversing switch Yes Yes Torque limiter Yes LED job light Weight according to 4.6 (10.1) 4.7 (10.3) EPTA-Procedure 01/2003*2: kg (lbs) *1 Round shank bits can also be used by replacing the factory-mounted chuck with Quick change drill chuck (keyless). *2 With side grip, two batteries BL1830, BL1840 or BL1850
Standard equipment
Grip assembly Depth gauge (Stopper pole) Quick change drill chuck (for DHR264) Battery*3 Battery cover*4 Charger*3 Dust cup*5 Bit grease*5 Waste cloth*5 Tool bag*5 Plastic carrying case*5 *3: Battery and charger are not supplied with “Z” model *4: Supplied with the same quantity of extra Battery *5: For some countries Note: The standard equipmen may vary by country or model variation.
Optional accessories
SDS-PLUS bits Taper shank TCT bits Taper shank adapter Cotter Chemical anchor adapter Diamond core bits Grip drills Grip drill holder Drill chuck assembly Grooving chisels Bull points Scaling chisels Cold chisels SDS-Plus hammer chuck set Scraper assembly Dust cup Dust cup 5 Dust cup 9 Dust extractor attachment Grease vessel 30g Bit grease Blow out bulb Hammer Service Kit Battery BL1815N Battery BL1820 Battery BL1830 Battery BL1840 Battery BL1850 Fast charger DC18RC Charger DC18SD Charger DC24SC Quad Port Charger DC18SF Automotive charger DC18SE
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Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”. [1] NECESSARY REPAIRING TOOLS Code No.
Description
1R003 Retaining ring pliers ST-2N
Use for removing Ring spring 19 from Tool holder complete/ Tool holder guide complete removing Retaining ring WR-12 from Armature shaft
1R017 1R032 1R033 1R045
1/4” Hex. Shank Bit M8 Bearing setting plate 8.2 Bearing setting plate 10.2 Gear extractor (large)
removing Ring spring 28, etc. assembling Spiral bevel gear 26
1R139 1R164 1R165 1R170 1R212 1R232 1R249 1R252 1R269 1R281
Drill chuck extractor Ring spring setting tool A Ring spring setting tool B T-type hex wrench 3-127 Tip for Retaining ring pliers Pipe 30 Round bar for arbor 24-100 Round bar for arbor 30-100 Bearing extractor Round bar for arbor 7-50
removing Spiral bevel gear 26 assembling Oil seal 25 to Gear housing complete assembling Needle bearing complete to Gear housing complete removing two M4x25 hex socket head bolts on Inner support complete attachment of 1R003 assembling Oil seal 25 to Gear housing complete removing Ring spring 29 removing Oil seal 25 from Gear housing complete removing Ball bearing 608ZZ from Inner support complete removing Ring 8
removing Ring spring 29
1R291 Retaining ring S and R pliers removing Retaining ring S-7 1R369 Jig for Spiro lock washer removing Ring spring 29 from Tool holder complete/ Tool holder guide complete 1R388 Ring spring extractor removing Ring spring 28
[2] LUBRICATION Apply the following grease to protect parts and product from unusual abrasion. * Makita grease RB No.00 to the portions indicated by the black triangle * Molybdenum disulfide lubricant to the portions indicated by the gray triangle Item No. Description Portion to lubricate Lubricant Amount Whole surface 40 O ring 16 Makita grease RB No.00 (a) Inside where Striker moves 41 Piston cylinder (b) Outside that contacts Tool holder (guide) complete Molybdenum disulfide 42 Guide plate Inside that contacts 43 Piston joint Grooves that contact 42 Guide plate 43 Piston joint 44 Compression spring 14 End to be fixed to the boss in Inner housing complete Makita grease RB No.00 Gear portion that engages with Spur gear 51 48 Spur gear 10 a little (c) Gear portion that engages with 50 Clutch cam 49 Cam shaft (d) Portion to be inserted into 51 Swash bearing 10 (e) Small diameter portion to be inserted into 48 Spur gear 10
50
Clutch cam
51
Swash bearing 10
53
Spiral bevel gear 26
(f) Groove for hooking Change plate (g) Gear portion that engages with 49 Cam shaft (h) Pole portion to be inserted into 43 Piston joint (i) Ball bearing portion (See Fig. 3.) (j) Inside of hole Gear portion that engages with Armature shaft gear Striker
Fig. 1
40
(b) (a) 41
42
43
Molybdenum disulfide
Makita grease RB No.00
a little 44
Transmission parts Compression spring 7
(h) (i)
(c) (d)
(j)
Ball bearing 606ZZ Retaining ring S-7
48
(e) 49
(f) 50 (g)
4g
51
53
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Repair [2] LUBRICATION (cont.)
Apply Makita grease RB No.00 to the following portions indicated by black triangle to protect parts and product from unusual abrasion. Item No. Description Portion to lubricate DHR263 DHR264
13 16
Cap 35 Ring 21 Stopper Steel ball 6 (2 pcs.) Steel ball 5 Change lever O ring 17
17
Gear housing complete
19 23
Needle bearing complete Lock plate complete
28
Spur gear 51
1 4
111 114 120 124
29 30
115 30 32 34 37
Lip portion where Bit is to be inserted Inner periphery Inner periphery Entire surface Entire surface Pins Entire surface (a) Oil seal 25 on the inside of Gear housing complete (b) Inside where Swash bearing section rotates Needle bearing portion in Cup washer Pins (c) Gear portion (d) Surface where Clutch portion of 30 Tool holder (guide) complete contacts
Steel ball 7 Tool holder complete
Entire surface
Inside where Piston cylinder reciprocates Tool holder guide complete Sleeve 9 Inside where Impact bolt reciprocates Ring 10 Portion that contacts Cushion ring 13 O ring 9 Entire surface 111
Fig. 2
114 115
(a) 17 (b)
DHR264
19
120
13
(c) 28
(d)
124
30
16
DHR264
1
Impact bolt
DHR263
23
4
29
32 30 DHR263
Cushion ring 13 37 Impact bolt
34
Fig. 3 Lubrication around
Swash bearing 10
[Cross section around Swash bearing 10]
Swash bearing section: 4g (See Fig. 1.)
[Inside view of Inner housing]
Crank section: 5g boss for fixing Compression spring 14
Gear section: 17g
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Repair
[3] DISASSEMBLY/ASSEMBLY [3] -1. Bit holder section for DHR263 Holder section for Drill chuck of DHR264 DISASSEMBLING for DHR263 Fig. 4 1. Remove Cap 35 with slotted screwdriver, then remove Ring spring 19 using 1R003 with 1R212. 1R003 1R212
2. Separate Chuck cover. Then remove Steel ball 7.0 while pressing down Ring 21.
3. Bit holder section can be disassembled as drawn above. Ring 21
Chuck cover
Guide washer
Cap 35 Steel ball 7.0
Ring spring 19
Conical compression spring 21-29
Ring 21
Fig. 4A ASSEMBLING for DHR263 Assemble by reversing the disassembly procedure. Note: Be sure to place the flat portion of Ring spring 19 on Steel ball 7.0. (Fig. 4A)
flat portion Steel ball 7.0
DISASSEMBLING of TOOL HOLDER SET for DHR264 Fig. 5 1. Separate Tool holder set from Tool holder guide complete.
2. Remove Cap 35 with slotted screwdriver, then remove Ring spring 19 using 1R003 with 1R212. Cap 35
4. Stopper, Guide washer, Conical compression spring 21-29, Flat washer 21 can be disassembled as drawn below. Stopper Guide washer Conical compression spring 21-29 Flat washer 21 Tool holder
Chuck cover 1R003 1R212
Tool holder set Tool holder guide
3. Separate Chuck cover. Then remove Steel ball 7.0 while pressing down Stopper.
Ring spring 19
Stopper Steel ball 7.0
5. Remove Ring spring 21 from Tool holder guide side using 1R004 . Flat washer 24, Leaf spring and Steel ball 5 can be disassembled.
6. Remove Tool holder together with Change ring from Change cover. And separate Change ring from Tool holder.
Ring spring 21
Tool holder
Flat washer 24
Torsion spring 31
Leaf spring
Change ring
Steel ball 5
Change cover
7. After removing Torsion spring 31, Steel balls 6 can be separated from Tool holder.
Torsion spring 31
Steel ball 6 (2 pcs.)
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Repair
[3] DISASSEMBLY/ASSEMBLY [3] -1. Bit holder section for DHR263 Holder section for Drill chuck of DHR264 (cont.) ASSEMBLING for DHR264 (1) Assemble Change ring to Change cover. (Fig. 6) (2) Assemble Torsion spring 31 to Tool holder, then mount Steel balls 6 to Tool holder. (Fig. 7) Note: Apply Makita Grease RB No.00 to Steel balls 6 to prevent them from falling off. Fig. 6 Fig. 7 Torsion spring 31 Note: Face the chamfered end of the hole upward.
Aligning the hole of Change ring with that of Change cover, assemble Change ring to Change cover.
[Section a - a']
Insert the short arm of Torsion spring 31 into the hole of Tool holder. Tool holder
a
a'
long arm Change ring
Steel ball 6 (2pcs.)
Change cover (3) Assemble Tool holder to Change cover. (Fig. 8) Fig. 8 1. Insert the long arm of Torsion spring 31 into the hole of Change cover through the hole of Change ring.
2. By turning Tool holder approx. 75° clockwise, Tool holder can be fastened to Change cover. 75°
Tool holder The long arm of Torsion spring 31 Change cover Change ring (4) Put Steel ball 5.0 in the groove surrounded by Change cover and Tool holder. (left in Fig. 9) (5) Set Leaf spring and Flat washer 24 in change cover, then secure them with Ring spring 21. (right in Fig. 9) (6) As for the assembling of Cap 35 side, do by reversing the disassembly procedure. (Refer to Fig. 4.) Fig. 9 Steel ball 5.0 Change cover Tool holder
Ring spring 21 Flat washer 24 Leaf spring
Change cover
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Repair
[3] DISASSEMBLY/ASSEMBLY [3] -2. Drill chuck assembly for DHR264 DISASSEMBLING Drill chuck assembly can be disassembled as drawn in Figs. 10 to 14. Fig. 10
Fig. 11
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.
Spacer
1R003
Chuck holder
1R212 Ring spring 21 Steel ball 5.0
Torsion spring 31 Change ring
Leaf spring
Change cover
Flat washer 24
Fig. 12
Fig. 13
Remove Spacer and two Steel balls 6 from Chuck holder.
Fig. 14
Clamp the flats of Chuck holder in vise, then unscrew M6x22 Flat head screw by turning it clockwise with Impact driver.
Hold Hex wrench 10 in Drill chuck firmly, then separate the chuck from Chuck holder by turning the wrench counterclockwise. Hex wrench 10
Spacer
M6x22 Flat head screw
Steel ball 6 (2 pcs.) Chuck holder Chuck holder Chuck holder
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Repair
[3] DISASSEMBLY/ASSEMBLY [3] -2. Drill chuck assembly for DHR264 (cont.) ASSEMBLING (1) Holding Chuck holder's flat portions in vise, assemble Drill chuck to Chuck holder by turning it clockwise using Hex wrench 10. (Refer to Fig. 14.) Then, mount two Steel balls 6. (Fig. 16) (2) Secure Drill chuck with M6x22 Flat head screw by turning it counterclockwise with Impact driver. (Refer to Fig. 13.) (3) Assemble Drill chuck to Spacer. (Fig. 15) (4) Mount Torsion spring 31. Then assemble Drill chuck to Change cover. (Fig. 17) (5) Mount Steel ball 5, Leaf spring and Flat washer 24 to Chuck holder, then secure them with Ring spring 21. (Fig. 18) Fig. 15
Fig. 16 Steel ball 6 (2 pcs.) Chuck holder
Fitting Chuck holder's flat portions to Spacer, mount Drill chuck to Spacer.
Chuck holder
Spacer
Spacer Note: Apply Makita grease RB No.00 to Steel balls 6 to protect them from falling off. Fig. 17 1. Insert the short arm of Torsion spring 31 into the hole of Chuck holder using pliers.
2. 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. By turning Drill chuck approx. 75°clockwise, Drill chuck can be fastened to Change cover. 75°
hole for Torsion spring 31 Spacer Chuck holder short arm of Torsion spring 31
Torsion spring 31
Drill chuck
long arm of Torsion spring 31 Change cover Change ring Change cover
Fig. 18 Leaf spring Flat washer 24 Ring spring 21
Steel ball 5
Repair
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[3] DISASSEMBLY/ASSEMBLY [3]-3. Change lever DISASSEMBLING Fig. 19 1. While pushing Lock button into Change lever, turn Change lever a little over Drill mode position to lock it in place.
2. Insert a slotted screwdriver between Change lever and Gear housing complete, then pry up Change lever.
Change lever
Drill mode slotted screwdriver
Lock button ASSEMBLING Fig. 20 Change plate can be seen through Change lever insertion hole of Gear housing complete. While hooking the thin pin of Change lever to Change plate from Hammer mode side, turn Change lever to Drill mode side. Note: Change lever is incompletely fit to Gear housing complete in the above step. Change plate Hammer mode
View from the upper side
thin pin of Change lever
Drill mode
(thick pin of Change lever)
Fig. 21 While pushing Lock button into Change lever, fit Change lever completely to Gear housing complete. Note: Be sure to check Change lever works properly after assembling. Change lever
Lock button
Drill mode
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Repair
[3] DISASSEMBLY/ASSEMBLY [3]-4. Motor section, Switch DISASSEMBLING of Motor section Note: Motor section and Switch can be replaced without removing Carbon brushes. (1) Disassemble Motor section as drawn in Fig. 22. Fig. 22 2. Remove Housing (R) from Housing (L). Note: No need to remove two 4x18 Tapping screws that fasten Handle (R) to Handle (L).
1. Before disassembling, support Housing (L) with the loop portion of Side grip for easy disassembling. Remove four 4x40 Tapping screws from Gear housing complete and ten 4x18 Tapping screws from Housing (R). 4x18 Tapping screw (10 pcs.)
4x18 Tapping screw (2 pcs.)
4x40 Tapping screw (4 pcs.)
Housing (R)
Loop portion of Side grip
3. Remove two Pins 6 and Handle section from Housing (L) to disassemble Motor section. Then, Remove Compression spring 10 from Handle section.
4. Remove Brush holder on the right side by unscrewing two 4x18 Tapping screws. Motor section and Gear section can now be removed as an assembly.
Handle section
4x18 Tapping screw (2 pcs.)
Gear section
[assembly of Handles (R) and (L)]
Pin 6 (2 pcs.)
Brush holder (on right side)
Compression spring 10 (2 pcs.) Motor section
5 Remove two M4x12 Hex socket head bolts with 1R170. 6 Remove Bearing retainer A. 7 Pull out Armature from Inner housing.
Inner housing
5 1R170
Armature
M4x12 Hex socket head bolt (2 pcs.) Bearing retainer A
7 6
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-4. Motor section, Switch (cont.) DISASSEMBLING of Motor section Fig. 23
When removing Ball bearing 6001DDW, remove Retaining ring WR12 from Armature shaft in advance. Then remove Ball bearing 6001DDW together with Sleeve 12 using 1R269. Note: Retaining ring WR12 is firmly seated in the groove of Armature shaft, and the groove is so small that the ring cannot be removed with a pair of commercial retaining ring pliers only. Therefore, slip the gap of the ring outside of the groove using 1R004 or 1R291, then remove the ring using commercial retaining ring pliers or 1R003 with 1R212. 1R004 or 1R291
1R003with 1R212
Retaining ring WR12
1R269
Ball bearing 6001DDW
Sleeve 12
groove of Armature shaft
ASSEMBLING of Motor section (1) Assemble Ball bearing 6001DDW and Sleeve 12 to Armature. Then, secure them with Retaining ring WR12. (Fig. 23) (2) Assemble Armature to Inner housing as drawn in Fig. 24. Fig. 24 1. When inserting Armature into Inner housing, do not fail to pass Armature through Yoke unit in advance. Note: Yoke unit is not directional when assembled with Armature.
M4x12 Hex socket head bolt with adhesive (2 pcs.)
2. Without enough care, Ball bearing 6001DDW on the drive-end of Armature may often be incompletely seated in the bearing room of Inner housing. Therefore, fit the bearing completely into the bearing room in Inner housing while carefully turning Armature by hand to engage the gear of Armature shaft with Spiral bevel gear 26 in Inner housing. Then fix the bearing with Bearing retainer and two M4x12 Hex socket head bolts. Note: Be sure to apply adhesive (ThreeBond 1321B/1342 or Loctite 242) to the threads when reusing M4x12 Hex socket head bolts removed from the machine because they are threadlocking bolts.
Bearing retainer A
Armature
(3) Before assembling Housing R. Be sure that the parts drawn in Fig. 25 are assembled to Housing L. Fig. 25 Be sure that the five parts shown below are set in place before mounting Housing (R) to Housing (L). 4x18 Tapping screw (4 pcs.) for fastening Handle (L), (R) Compression spring 10 (2 pcs.)
Terminal (2 pcs.)
Light circuit
Plate (4 pcs.)
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-4. Motor section, Switch (cont.) DISASSEMBLING of Switch section Fig. 26 1. Remove two 4x40 Tapping screws (tightening Gear housing complete to Housing (R)). And then, remove ten 4x18 Tapping screws to separate Housing (R). 4x18 Tapping screw (10 pcs.)
Housing (R) 4x40 Tapping screw (2 pcs.)
Housing (R)
Gear housing complete
2. Remove two Pins 6 and two 4x18 Tapping screws on Handle (R), then separate Handle (R) from Handle (L). Switch can now be replaced. 4x18 Tapping screw (2 pcs.)
Pin 6 (2pcs.)
Handle (R)
Handle (L) Switch
ASSEMBLING of Switch section Assemble Switch to Handle (L) by reversing the disassembly procedure. (Refer to Fig. 26)
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Repair
[3] DISASSEMBLY/ASSEMBLY [3]-5. Tool holder section of DHR263 Tool holder guide section of DHR264 DISASSEMBLING (1) Model DHR 263: Disassemble Bit holder section as drawn in Fig. 4. Model DHR 264: Disassemble Tool holder set (Quick change chuck) as drawn in Fig. 5. (2) Disassemble Change lever as drawn in Fig. 19. (3) Remove four 4x40 Tapping screws from Gear housing complete as drawn in Fig. 22. (4) Pull off Tool holder (guide) section from Inner housing complete as drawn in Fig. 27. Fig. 27 1. Tap the top of Tool holder ass’y with a plastic hammer. Gear housing complete can be removed. Note: Grease falls from Gear housing complete. Receive it with waste cloth.
2. Pull off Tool holder (guide) section from Inne housing. Note: Do not lose Flat washer 28 between Tool holder ass’y and Inner housing. Tool holder (guide) section
Flat washer 28
Piston Cylinder Inner housing 3. Set 1R369 onto Washer 31. Then, Insert 1R249 Tool holder (guide).
4. Press down 1R369 with 1R045 to reserve the space for screwdriver insertion. And remove Ring spring 29 with a small screwdriver.
5. Remove Washer 31, Compression spring 32 and Spur gear 51.
Washer 31 1R369
Ring spring 29 Compression spring 32
Ring spring 29 Washer 31
1R249
1R045
1R369
Spur gear 51
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Repair
[3] DISASSEMBLY/ASSEMBLY [3]-5. Tool holder section of DHR263 Tool holder guide section of DHR264 (cont.) ASSEMBLING (1) Assemble Spur gear 51, Compression spring 32 and Washer 31 to Tool holder (guide). (Fig. 27) (2) Using repairing jigs of 1R249 and 1R369, secure the parts with Ring spring 29. (Fig. 27)
[3]-6. Needle bearing complete and Oil seal 25 DISASSEMBLING Disassemble Needle bearing complete. (Fig. 28) Fig. 28 Put Gear housing complete on Arbor press table, and keep it upright. Then, by pressing down Oil seal 25 using 1R252, Oil seal 25 and Needle bearing complete can be removed from Gear housing complete with gentle pressure. Note: On Arbor press table, Gear housing complete can stand almost upright on its end edges. Although the end edges are rather thin, you need not worry about breakage because Oil seal 25 and Needle bearing complete are fitted to Gear housing complete with low press fit force.
1R252 Gear housing complete
Oil seal 25 Needle bearing complete ASSEMBLING (1) Assemble Oil seal 25 to Gear housing complete. (Figs. 29 and 30) Fig. 29 Fig. 30 With 1R232 and Arbor press, insert Oil seal 25 until it stops. In this step, Oil seal 25 is not yet inserted completely because the outer diameter of 1R232 is larger than that of Oil seal setting hole. 1R232
Oil seal 25
Using Arbor press and the 34mm outer diameter end of 1R164, press down Oil seal 25 until it stops at its original position. Outer diameter: 30mm 1R164
Outer diameter: 36mm
Outer Diameter: 34mm
The diameter of Oil seal 25 setting hole is smaller than 36mm.
original position of Oil seal 25
(2) Assemble Needle bearing complete. (Fig. 31) Fig. 31 With 1R165 and Arbor press, press down Needle bearing complete until it stops. 1R165
Outer diameter: 30mm Cup washer portion of Needle bearing complete Needle bearing portion of Needle bearing complete
bottom side of Gear housing complete
Note: 1) Do not use 1R164 in this step. 2) Do not press Needle bearing portion directly. 3) Too much pressure will deform Needle bearing complete. Do not press hard. 4) Be sure to press Cup washer portion with gentle pressure. Needle bearing complete [view from rear side]
Face the flat portion of Needle bearing complete towards the bottom side of Gear housing complete.
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-7. Impact bolt in Tool holder complete for DHR263 Tool holder guide complete for DHR264 DISASSEMBLING
(1) When Striker is left in Tool holder (guide) complete, push Striker out of Tool holder (guide) complete by inserting 1R281 from the top end and tapping 1R281 with a plastic hammer. (2) Remove Tool holder (guide) section as drawn in Fig. 27. (3) Remove Ring spring 28 from Tool holder (guide) complete and disassemble Impact bolt section. (Figs. 32 to 41) Fig. 32 Note: If the end gap of Ring spring 28 is in the hole of Tool holder (guide) complete, slide it with a slotted screwdriver until it is completely hidden. end gap of Ring spring 28
Ring spring 28
Slotted screwdriver
Tool holder (guide) complete
(4) 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. 33) O-ring case is moved toward the top of Tool holder (guide) complete, and therefore, Ring spring 28 can be relieved from O-ring case. (5) Using a slotted screwdriver, tap Ring spring 28 through the two access holes alternately to push them out of the inner groove of Tool holder (guide) complete. (Fig. 33) (6) The components are removed by tapping with 1R179 and a plastic hammer from the bit installation side of Tool holder (guide) complete. (Fig. 34) Fig. 33
Fig. 34 Ring spring 28
Slotted screwdriver
1R179 1R388 1R388
Sleeve 9
O-ring case Ring spring 28 Impact bolt Ring 10 Cushion ring 13 O ring case 1R388 Slotted screwdriver
Ring spring 28
Ring spring 28
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-7. Impact bolt in Tool holder complete for DHR263 Tool holder guide complete for DHR264 (cont.) ASSEMBLING (1) Assemble Impact bolt section to Tool holder (guide) complete as drawn in Fig. 35. Fig. 35 Note: The five components are directional, and must be mounted as shown below. Tool holder (guide) complete
Sleeve 9
O ring case with O ring 9 fit inside Ring 10 Impact bolt Cushion ring 13
Bit (chuck) installation side
Inner housing complete side long
short O ring 9
[cross-sectional view] (2) Push Ring spring 28 into the inner groove of Tool holder (guide) complete as drawn in Fig. 36. Fig. 36 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 positioned in either of the two holes of Tool holder (guide) complete. Note: 1) Piston cylinder as a jig
Inner groove of Tool holder (guide) complete
end gap
Piston cylinder as a jig
Ring spring 28
Tool holder (guide) complete
hole
Ring spring 28
hole
Note: 2)
[Correct] Tool holder (guide) complete Ring spring 28 end gap
[Wrong]
O ring case
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-8. Swash bearing 10, Gear section DISASSEMBLING
Fig. 37 Note: This step can be done without removing Motor section. (1) Remove Gear housing complete as per top left drawn in Fig. 27. Inner housing (2) Remove Inner support complete by loosening two M4x25 Hex socket M4x25 Hex socket head bolts with 1R170. (Fig. 37) head bolt (3) Remove two M4x12 Hex socket head bolts that is seated on Bearing retainer B on Inner support complete. (Fig. 38) (4) Remove Swash bearing 10 portion and Piston cylinder portion from Inner housing. (Fig. 39) (5) When Ball bearing 606ZZ is left in Gear housing complete after removing Swash bearing 10 section, insert Cam shaft into the hole of Inner support complete Ball bearing 606ZZ and tilt Cam shaft back and forth (Fig. 40), then 1R170 tap Gear housing complete with a plastic hammer as drawn in Fig. 41. Ball bearing 606ZZ can now be removed. (6) Put Spiral bevel gear 26 on a U-groove of 1R139 as shown in Fig. 42, then press down Cam shaft using 1R281 to loosen the press fit of Cam shaft to Spiral bevel gear 26, Ball bearing 608ZZ and Ring 8 at a time. (Fig. 42) Also Clutch cam, Swash bearing 10, Sleeve 9 and Bearing retainer B can be removed from Cam shaft in this step. (Fig. 43) (7) By removing Retaining ring S-7 from Cam shaft using 1R291, Compression spring 7 and Spur gear 10 can be removed from Cam shaft. (Fig. 43) Fig. 38 Fig. 39 M4x12 Hex socket head bolt (2 pcs.): threadlocking bolt
Inner housing
M4x12 Hex socket head bolt (2 pcs.): threadlocking bolt portion linder y c n o t Pis
ring sh bea
Bearing retainer B
Swa
Fig. 41
Fig. 40
rtion
10 po
Fig. 42
2
1R139 1R281
1 Cam shaft
Spiral bevel gear 26 Swash bearing 10 portion
Ball bearing 606ZZ in Gear housing complete
Cam shaft
Fig. 43 Ball bearing Compression 606ZZ spring 7
Retaining ring S-7
Swash bearing 10 Cam shaft
Clutch cam
Spiral bevel gear 26 Sleeve 9
Ball bearing 608ZZ
Ring 8 Spur gear 10
M4x12 Hex socket head bolt (2 pcs): threadlocking bolt
Bearing retainer B
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Repair [3] DISASSEMBLY/ASSEMBLY [3]-8. Swash bearing 10, Gear section (cont.) ASSEMBLING
Fig. 44 Note: Be sure to apply Makita grease RB No.00 and Molybdenum disulfide lubricant to the specific portions as shown in Figs. 1, 2 and 3. (1) Onto Cam shaft, slide Swash bearing 10, Sleeve 9, Spiral bevel gear 26 Guide plate in order, then press-fit them using 1R032 and1R033. 1 (2) Slide Bearing retainer B onto Cam shaft in advance, then press-fit Piston joint Ball bearing 608ZZ then Ring 8 onto the shaft; be careful not to fix 2 Bearing retainer B between the bearing and Spiral bevel gear26. (3) Onto Cam shaft, slide Super gear 10 and Compression spring 7 in order, then secure them with Retaining ring S-7 using 1R291. (4) Mount Guide plate then Piston joint to Piston cylinder. (Fig. 44) Piston cylinder (5) Fit Compression spring 14 over the boss of Inner housing. (Fig. 45) (6) Insert the pole of Swash bearing 10 through the hole of Piston joint, Fig. 45 then mount Swash bearing portion into Inner housing. Secure Swash bearing portion by fixing Bearing retainer B to Inner Compression spring 14 housing with two M4x12 Hex socket head bolts. (Fig. 46) Note: Be sure to apply adhesive (ThreeBond 1321B/1342 or Loctite 242) to the threads of the two M4x12 Hex socket head bolts. Inner housing (7) Insert Change plate into the groove of Clutch cam, then secure Inner support complete with two M4x25 Hex socket head bolts. (Fig. 47)
Fig. 46
M4x12 Hex socket head bolts (2pcs.): Threadlocking bolt
Swash bearing portion
Bearing retainer B Inner housing
pole of Swash bearing 10
hole of Piston joint
Fig. 47
Change plate groove of Clutch cam Clutch cam
Inner support complete
P 19/ 22
Repair
[4] Maintenance program It is recommended to replace the following parts at the same time when replacing Carbon brushes. (Fig. 48) Note: Be sure to put Makita grease RB No. 00 and Molybdenum disulfide lubricant to the specific portions. (Refer to Figs. 1, 2 and 3.) Fig. 48
DHR263
1 Cap 35 (286263-4)
29 Steel ball 7.0 (216022-2) 40 O ring 16 (213227-5)
35 Cushion ring 13 (421955-0) 37 O ring 9 (213073-6)
38 Ring spring 28 (233917-4)
DHR264 111 Cap 35 (286263-4)
115 Steel ball 7.0 (216022-2)
40 O ring 16 (213227-5)
35 Cushion ring 13 (421955-0) 37 O ring 9 (213073-6)
38 Ring spring 28 (233917-4)
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Circuit diagram Fig. D-1 Color index of lead wires' sheath White Orange Yellow Blue
Black Red
Switch Line filter (ø10-30) Line filter (2 holes type) These Line filters are not used for some countries. Line filter (the component of Controller) This Line filter is used for all countries.
Housing set (L) side Brush holder Housingset (R) side
Controller
Printed wiring board A
Terminal A
Printed wiring board B
Terminal B
LED light circuit
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Wiring diagram Fig. D-2 Wiring to Switch 1. Connect Brush holder’s lead wire (red) to M1 terminal of Switch and the black one to M2 terminal while keeping their connectors in 90 degrees as shown below.
M1 terminal
2. Bent Connector of Brush holder’s lead wire (black) toward the red one side.
M2 terminal
90 degrees
Handle set (L) side
Handle set (R) side
Fig. D-3 Wiring in Housing set (L) Brush holder’s Lead wires have to be tightened between Switch and Lead wire holder by Compression spring 10. Route Switch’s lead wires and Controller’s lead wires between Ribs A and B. Note: Put Black lead wire of Switch on the other lead wires.
Switch Lead wire holders
Route Switch’s lead wires and Controller’s lead wires between Ribs B and D, Ribs B and C.
Groove Put Closed end splices in here.
Rib A
RibCC Rib Rib D
Rib B Line filter Put Line filter in here.
Fix Brush holder’s lead wires with these Lead wire holders and the groove.
Rib F
Rib E
Compression spring 10 Lead wire holder
To Controller Put Lead wires of Controller between Ribs E and F.
Put Line filters to the place here, if they are used.
Fig. D-4 Wiring of Brush holder First, pass Brush holder’s lead wires through Line filter (2 holes type), then pass the wires through Line filter (single hole type), if Line filters are used.
Fix Brush holder’s lead wires with this Lead wire holder.
Housing set (L) side
Fix Brush holder’s lead wires with these lead wire holders.
Housing set (R) side Line filter Line filter (single hole type) (2 holes type)
Brush holder
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Wiring diagram Fig. D-5 Wiring of Controller and Terminals 1. Put Controller to Housing set (L) while facing its Lead wire connected portion to the housing.
2. Connect Flag connectors to Terminals while facing the wire connected portions to the housing as shown below. Then, set Terminals to Housing set (L) while facing the wire connected side of Receptacles to the housing.
Lead wire connected portion
Lead wire of Controller
Controller
Housing set (L) 3. Put the bundling portion of Lead wires into Housing set (L) at the deeper position than the wire connected portion of Printed wiring boards. 4. And then, set Printed wiring board to Housing set (L). Bundling portion of Lead wires Housing set (L)
Wire connected portion Printed wiring boards
Controller
Terminal
Fig. D-6 Wiring of LED light circuit
Rib J Connectors Put Connectors in this space.
LED Light circuit Put LED Light circuit between Ribs I and J. Rib I
