Makita DHR165 Technical Information

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 TECHNICAL INFORMATION Electric brake Yes Shank diameter: mm (") 10 (3/8) OFFICIAL USE for ASC & Sales Shop

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

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

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 cam 41 Helical gear 22 43 Space where Armature's drive end and 43 Helical gear 22 engage 5 g Inner housing complete 52 Armature's gear teeth and Flat washer on gear teeth side 3 g Armature 54 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

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

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 housing Tool 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

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

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

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 1R022 1R022 Flat washer 25 1R212 Retaining ring WR-25 Helical gear 22

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

DISASSEMBLING ASSEMBLING P 11/ 17 Repair Fig. 12 (4) As for Oil seal 25 and Ball bearing 6805LLB, remove them from Gear housing complete by tapping the four notches on the top of Gear housing complete in a crisscross manner using a slotted screwdriver and plastic hammer. (Fig. 12) Note: Apply a little amount of Grease or Lubricanting oil to the outer periphery of Oil seal 25 to prevent the improper setting such as twisting. four notches Ball bearing 6805LLB Oil seal 25 (1) Assemble Oil seal 25, Ball bearing 6805LLB and Ball bearing 606ZZ as illustrated in Fig. 13. (2) Assemble Swash bearing and Spur gear 10 section as drawn in Fig. 14. Fig. 13 Fig. 14 Ball bearing 6805LLB 1. Assemble Oil seal 25 with 1R232. 2. Assemble Ball bearing 6805LLB with 1R252. 3. Assemble Ball bearing 606ZZ with Spur gear 10. 4. Assemble Ball bearing 606ZZ with Spur gear 10 to Inner housing complete. Oil seal 25 Ball bearing 6805LLB Oil seal 25 1R232 1R252 Spur gear 10 Ball bearing 606ZZ Ball bearing 606ZZ Spur gear 10 1R033 Spur gear 10 Clutch cam Swash bearing 1. Stand Spur gear 10 on 1R033 and set Clutch cam and Swash bearing in place. 2. Put Helical gear 22 on Swash bearing with facing the stepped side to Swash bearing. 3. Put 1R032 onto Helical gear 22, and press it down to Spur gear 10 as drawn below. 1R033 Helical gear 22 Helical gear 22 1R032 Stepped side

[3]-4. Inner housing section ASSEMBLING DISASSEMBLING Note: Do not forget to mount Flat washer 24 in place before insertion of Tool holder section on Piston cylinder. Fig. 16 Fig. 15 1. Compression spring 3 connects Change plate with Stopper plate. Remove this Compression spring. 3. Remove Stopper plate. 5. Remove Compression spring 32. 4. Pressing down Compression spring 32 with Change plate, separate Compression spring 32 from the hooks of Change plate. Change plate is removed. 2. Put Inner housing complete on Arbor press table, facing its Armature assembling side toward upward. Applying 1R268 to Inner housing complete at the position drawn below, press down Pin 4 and Felt 4x3. (3) Assemble Tool holder section. Refer to the upper drawings in Fig. 10. (4) Assemble the rest parts by reversing the disassembly procedure. Be careful about the matter as drawn in Fig. 15. (1) Disassemble Tool holder section. (Fig. 2 of page 5) And remove Carbon brushes. (Fig. 4 of page 5) (2) Remove Inner housing section from Gear housing complete, and separate Tool holder complete and Joint plate from Piston cylinder. (Fig. 6 of page 6) (3) Remove Spur gear 10 and Swash bearing section. (Fig. 7 of page 7) And then, remove Armature from Inner housing complete. (Fig. 8 of page 7) Armature can also be disassembled as drawn in Fig. 5 of page 5. Ball bearing 606ZZ can be removed from Inner housing complete. (Fig. 11 or 11S) (4) Disassemble Inner housing section is started as drawn in Fig. 16. Flat washer 24 Piston cylinder Flat washer 24 Compression spring 3 Change plate Pin 4 Stopper plate Pin 4 Pin 4 Felt 4x3 Note: Felt 4x3 is damaged in this step. Do not re-use it. 1R268 Stopper plate hook hook Change plate Compression spring 32 P 12/ 17 Repair

ASSEMBLING Compression spring 32 claw claw Change plate 2. While aligning the holes of Change plate and Inner housing complete, hitching claws of Change plate to Compression spring 32. 3. While aligning passing holes of Stopper plate to the sames of Change plate, set Stopper plate to Inner housing complete. 4. Insert Pin 4 to Inner housing complete through the passing holes of Change plate and Stopper plate. Note in Assembling: Do not re-use the removed Felt 4x3. Because this part has been damaged when disassembling. 1. Put a new Felt 4x3 into the hole of Inner housing complete, and then mount Compression sprint 32 to Inner housing complete. Stopper plate Felt 4x3 Assemble Inner housing complete as drawn in Fig. 17. Pin 4 Pin 4 Pin 4 Rib Rib 5. Pin 4 has to be stepped at the same level of Inner housing’s Rib when pressing it with Arbor press. Fig. 17 P 13/ 17 Repair

DISASSEMBLING (1) Disassemble the parts on the top of Tool holder section. (Fig. 2 of page 5) Remove Carbon brushes. (Fig. 4 of page 5) (2) Remove Inner housing section from Gear housing complete, and separate Tool holder complete from Piston cylinder (Fig. 6 of page 6) (3) Remove Retaining ring WR-25, Flat washer 25, Compression spring 25 and Spur gear 46 from Tool holder. (Fig. 10 of of page 9) (4) Remove Ring spring 22 from Inner housing complete installation side of Tool holder complete. (Fig. 18) Note: Fitting of Ring spring 22 into the groove on inner surface of Tool holder complete is weaker than that of AC tool, and therefore, holding Ring spring 22 in a vise is not necessary. (5) Remove Ring 11, Impact bolt and X ring 13 from Cap 35 installation side of Tool holder complete. (Fig. 19) Fig. 18 Fig. 19 2. Tap Ring spring 22 through the other hole of Tool holder complete with a slotted screwdriver in the same way of the step 1. 3. Repeat 1 and 2 alternately. 1. Tap Ring spring 22 through the hole of Tool holder complete with a slotted screwdriver in direction of the gray arrow. Cap 35 installation side Inner housing complete installation side Inner housing complete installation side X ring 13 Ring 11 Impact bolt Cap 35 installation side Inner groove of Tool holder Ring spring 22 off from inner groove 4. Pull off Ring spring 22 with pliers. Strike the inner housing complete installation side of Tool holder complete against workbench to remove Ring 11, X ring 13 and Impact bolt. Ring spring 22 P 14/ 17 Repair

[3]-6. Assembling of F/R change lever ASSEMBLING Assemble Impact bolt as drawn in Fig. 20. Fig. 20 Fig. 21 1. Mount X ring 13 to Ring 11. 2. Mount X ring 13 and Ring 11 to Impact bolt. 3. Put X ring 13, Ring 11 and Impact bolt into Tool holder. 4. Mount Ring spring 22 by pressing it with Piston cylinder into Tool holder. 5. Put Striker into Tool holder while facing the cylindrical hole to Impact bolt side. Note: Do not forget to assemble O ring 14 to Striker in advance. Set Ring spring 22 in place so that the gap of Ring spring 22 does not come to the side holes of Tool holder complete. * Piston cylinder as a repairing tool (Refer to [1] NECESSARY REPAIRING TOOLS of page 3.) X ring 13 Ring 11 Impact bolt Striker Cylindrical hole Ring spring 22 side holes of Tool holder complete Tool holder complete Pronged portion Assemble F/R change lever to Switch as drawn below. Pin portion F/R change lever O ring 14 P 15/ 17 Repair

Black Red Terminal Flag terminal (#250, t=0.8mm) Flag terminal (#250, t=0.8mm) Straight terminal (#187, t=0.8mm) Connector Switch Endbell complete Endbell Line filter** Line filter** Tape * AWG: American wire gauge ** Line filter is not used for some countries. LED Job light Lead wire (26AWG*) Light circuit Insulated connector (M3.5) AS P 16/ 17 Red Lead wire is used for some countries instead of white. Lead wire (16AWG*) Lead wire (20AWG*) Lead wire (16AWG*) Lead wire (16AWG*) Lead wire (16AWG*) Lead wire (20AWG*) Lead wire (24AWG*)

Put Heat sink with FET to the place illustrated. Lead wire holder (B) Lead wire holder (A) Lead wire holder Line filter (if used.) If Line filters are used, put them respectively into the places on left side and right side of Lead wire holder (A) as follows: 1. Put one Line filter near Lead wire holder (A). 2. Put the other Line filter near Lead wire holder (B). Line filter (if used.)r Switch Boss Connector Wiring of Light circuit Wiring in Housing set L Terminal Switch LED Job light Line filter (if used.) Bend Connecting terminals so that they do not touch Heat sink. Fix Lead wire (yellow) of Heat sink with Lead wire holder nearest to Switch trigger. Fix Lead wire (blue) of Heat sink in center Lead wire holder. Rib Put Lead wires (orange, blue, black) of Light circuit between Boss and Rib. Fix Lead wire (black) of Heat sink in Lead wire holder farthest from Switch trigger. Light circuit Light circuit has to be put so that its Lead wire (orange) connected side comes to Terminal side. Lead wire (orange) Terminal Fig. D-2 Wiring diagram P 17/ 17 If Line filters are used, fix Lead wires (black, red) of Endbell complete in Lead wire holders (A) and (B). If not, no need to fix Lead wires in Lead wire holders (A) and (B). Fix lead wires of LED job light with Lead wire holder