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[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 28

O ring case

Fig. 19

Fig. 18

32mm

1R038

Vise

Ring spring 28

O ring case

Tool holder complete

Side hole of Tool 
holder complete

Ring spring 28

Summary of Contents for BHR240Z

Page 1: ...ke 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...

Page 2: ...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 25 1R232 Pipe 30 Removing Oil seal 25 1R252 Round bar for arbor Installing Needle bearing complete 1R164 Ring spring setting tool A 1R291 Retaining ring S and R pliers Removing Retaining ring S 7 1R306 Ring spring removing jig Removing Ring spr...

Page 3: ...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 surface 38 O ring 9 35 Whole surface 41 O ring 16 Piston cylinder Inside surface that contacts Striker Teeth portion and the inside surface that contacts Cam shaft 49 Spur gear 10 42 Both faces of cam and the inside surface that contacts Cam shaft 50...

Page 4: ...e 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...

Page 5: ...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 inserte...

Page 6: ...ection 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 illustra...

Page 7: ...strated 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 ...

Page 8: ...ig 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 s...

Page 9: ...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 b...

Page 10: ...1 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 ...

Page 11: ...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 p...

Page 12: ...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 s...

Page 13: ...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 ...

Page 14: ...e 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 w...

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