Makita BFR540 Manual

Model No.

Description

PRODUCT

CONCEPT AND MAIN APPLICATIONS

P 1/16

Specification

BFR540, BFR550, BFR750

Cordless Auto Feed Screwdriver

Models BFR540, BFR550 and BFR750 have been developed

as the advanced models of Model BFR440, featuring higher durability.

These models feature more reliable casing attachment

with the following benefits:

Rigid aluminum casing

Stopper base with anti-tilt device for preventing screws from swaying

Rubber cap securely fixed to stopper base

Dust-proof construction for smooth sliding action

These products are available in the following variations.

Dimensions: mm (")

Width (W)

Height (H)

Length (L) 424 (16-3/4) 464 (18-1/4)

BFR540/BFR550 BFR750

80 (3-1/8)

238 (9-3/8)

Specification

Net weight**: kg (lbs) 2.1 (4.6) 2.3 (5.0)

Model BFR550 BFR750BFR540

4 (5/32)

25 to 55

(1 to 2-3/16)

45 to 75

(1-3/4 to 2-15/16)

Diameter

Overall length

4,000No load speed: min.-1 = rpm

Driver bit: mm (")

Capacities: mm (")

[collated drywall screw]

Reverse switch

6.35 (1/4) Hex

162 (6-3/8) or 157 (6-3/16)

Shank

Overall length*

Yes

*Overall length of driver bit may differ by country.

**BFR540: includes battery BL1430; BFR550/ BFR750: includes battery BL1830

Battery

Cell

Voltage: V

Capacity: Ah

Li-ion

14.4 18

3.0

Li-ion

3.0

Max output: W 235 235

(The image above is BFR540.)

182 (7-1/8) or 177 (7)

All models also include the accessories listed in "Standard equipment".

BFR540

BFR540RFE

BFR540Z

BFR540 BL1430

(Li-ion 3.0Ah) DC18RA

No No No

Model No. type quantity Charger

Yes

Plastic

carrying case Offered to

All countries

North America

All countries except North America

BFR540RFE3 3

Battery

BFR550

BFR750

See next page for "Standard equipment" and "Optional accessories".

TECHNICAL INFORMATION

Battery

cover

BFR550RFE

BFR550Z

BFR550 BL1830

(Li-ion 3.0Ah) DC18RA

No No No

Yes

No All countries

North America

All countries except North America

BFR550RFE3 3

BFR750RFE

BFR750Z

BFR750 BL1830

(Li-ion 3.0Ah) DC18RA

No No No

Yes

No All countries

North America

All countries except North America

BFR750RFE3 3

P 2/16

Standard equipment

Optional accessories

Note: The standard equipment for the tool shown above may differ by country.

BFR540/ BFR550

Phillips bit 2-162 or 2-157 (for BFR540/ BFR550)

Square bit 2-162 or 2-157 (for BFR540/ BFR550)

Phillips bit 2-182 or 2-177 (for BFR750)

Square bit 2-182 or 2-177 (for BFR750)

Extension handle

Casing attachment

Plastic carrying case

BFR750

Phillips bit 2-162 or 2-157 ...................... 3

Belt clip ................................................... 1

Phillips bit 2-182 or 2-177 ...................... 3

Belt clip ................................................... 1

Battery BL1430 (for BFR540)

Battery BL1830 (for BFR550/ BFR750)

Fast charger DC18RA

Charger DC24SA (for North America only)

Charger DC24SC (for all countries except North America)

P 3/16

[2] LUBRICATION

Apply Makita grease FA.No.2 to the following portions designated with the black triangle to protect

parts and product from unusual abrasion.

[1] NECESSARY REPAIRING TOOLS

CAUTION: Remove the battery from the machine for safety before repair/ maintenance

in accordance with the instruction manual!

Fig. 1

Repair

Description

Bearing setting plate 8.2

Spring pin extractor 2 Removing Pin 2 from Guide box complete

Removing Casing cover and Insulation sleeveRetaining ring S and R pliers

Code No.

1R032

1R266

1R291

Use for

Item No. Description Portion to lubricate

Apply approx. 4g.

Apply approx. 1g.

Apply approx. 4g.

Plane bearing 14

Steel ball 3.5 Whole surface

Each depressed portion for Steel ball 4

Steel ball 4 (3 pcs)

Spindle B

Clutch cam C

Gear complete 18-44

Compression spring 25

Helical gear 48

Armature

(a)

(a) The Drum portion that contacts Plane bearing 14

(d) Teeth of the large Gear that engages Armature's gear

(b) The Cam portion that contacts 57 Clutch cam C

(b)

(c)

(d)

P 4/16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly

Repair

DISASSEMBLING

Clamper Clamper

Casing complete

4) Clamper and Compression spring 23 can now be

removed from Casing complete.

Fig. 2 Fig. 3

Fig. 4

Disassemble by taking the steps described in Fig. 2 to Fig 17.

2) Then pull off Casing

assembly from Housing.

Casing assembly

3) While pressing Clamper, remove three M4x12 Countersunk

head screws from Casing complete.

1) Loosen Thumb screw M4x28

by turning counterclockwise.

Countersunk head screw M4x12:

one on Thumb screw M4x28 side, two on the opposite side

No.1 Phillips

screwdriver

(+) Shoulder flat head screw M3x5

Fig. 6Fig. 5

Compression spring 23

Clamper

Removing Insulation sleeve from Clamper

While pressing two of the three locking tabs of Insulation

sleeve inward using 1R291, push it off from Clamper.

Clamper

Insulation sleeve

1R291

5) Stopper on either side of Casing complete can be

removed by sliding it in the direction of the gray

arrow while lifting up its rear end with a slotted

screwdriver.

6) Remove (+) Shoulder flat head screw M3x5

together with Sleeve 4 using No.1 Phillips screwdriver.

rear end

of Stopper

rear end of Stopper

Sleeve 4

P 5/16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

DISASSEMBLING

Fig. 7

7) While pressing the locking claws of Casing cover inward

using 1R291, pull off Feeder box section from Casing cover.

8) Remove Plate from Stopper base as follows:

while pressing down two Levers at the same time,

push Stopper base towards Feeder box fully until

it stops.

9) While pressing down two Levers

at the same time, separate Feeder box

from Stopper base.

10) Remove Lever and Compression Spring 2 (2 pcs each)

from Feeder box.

Fig. 8

1R291

Feeder box section locking claw

of Casing cover

Casing complete

Feeder box

Plate

Stopper base

Plate

Lever

Countersunk head

screw M4x12

Dial 42 can now be removed from

Casing complete by unscrewing

Countersunk head screw M4x12.

Flat washer 6

O Ring 12

Shifter pin

Dial 42

Lever

Compression spring 2

Feeder box

Stopper base

Fig. 9 Fig. 10

Feeder box

P 6/16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

DISASSEMBLING

Fig. 11

11) Remove Box cover complete from Feeder box

by unscrewing Tapping screw 4x18.

13) Remove Stopper, Pin 3 and Torsion spring 4

from Feeder box.

Fig. 12 Fig. 13

Ratchet arm complete

Compression spring 6

Spur gear 16

Torsion spring 4

Stopper

Pin 3

Feeder box

Box cover complete

Tapping screw 4x18 Feeder box

Side view of Feeder box

after removing Box cover complete

Dust cover Ratchet arm complete

Compression spring 6

Torsion spring 4Stopper

Pin 3

Fig. 14

12) Remove Ratchet arm complete and

Compression spring 6 from Spur gear 16.

14) Remove Dust cover from Feeder box.

Note: Because the bow portion of Dust cover

is easily damaged, be sure to remove carefully

together with Wheel as illustrated to right.

Insert a screwdriver through the hole of

Dust cover into Wheel, then lever up Dust cover

together with Wheel.

Dust cover

Wheel

bow portion of Dust cover

Dust cover Wheel

P 7/16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

DISASSEMBLING

Fig. 17

17) Remove Sleeve 5 from Feeder box.

If cannot remove by hand, lever it off

using Phillips screwdriver or the like

as illustrated below.

16) Remove Spur gear 16 from Feeder box.

Fig. 15 Fig. 16

15) Remove Shoulder pin 6 from Feeder box.

Spur gear 16

Sleeve 5Phillips screwdriver

Feeder box

Spur gear 16

Sleeve 5

Shoulder pin 6

P 8 /16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

ASSEMBLING

1) Assemble Sleeve 5, Spur gear 16 and Shoulder pin 6 to Feeder box. (See Fig. 17 to Fig. 15 on page 7.)

2) Assemble Wheel together with Dust cover to Feeder box. (See Fig. 14.)

Important 1: Dust cover must be fixed securely to Feeder box as described in Fig. 18.

Important 2: Make sure that Wheel and Spur gear 16 are correctly engaged. (Fig. 19)

3) Assemble Pin 3 and Torsion spring 4 to Stopper (Fig. 20), then assemble them to Feeder box as described in Fig. 21.

Fig. 20

Stopper

Torsion spring 4

Note: Be sure to assemble Torsion spring 4

and Pin 3 to Stopper as illustrated below

before assembling them to Stopper.

Fig. 19

View from Box cover complete side

Top view

Box cover complete side

Feeder box side

Wheel Spur gear 16

Fig. 18

Push the metal plate of Dust cover in the three portions designated by gray star;

especially, be sure to push it securely into the hole designated by "A" until Dust cover stops.

metal plate

of Dust cover

Feeder box

Engaging Wheel with Spur gear 16

1) Engage with .

2) and can be engaged by doing 1).

Pin 3

Hook the bent end on

the groove of Stopper.

Gear portion

Inner sprocket

Outer sprocket

Inner gear

Outer gear

Stopper catching portion

Wheel Spur gear 16

Note: As illustrated to right:

must be engaged with .

Fig. 21

Torsion spring 4

Stopper

Pin 3Spur gear 16

The straight end of Torsion

spring 4 must be placed on

the rear wall of the concave

portion.

Wheel

Engage Stopper with so that

the backward movement of Spur gear 16

can be prevented by Stopper.

concave portion

of Feeder box

P 9 /16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

ASSEMBLING

4) Assemble Ratchet arm complete and Compression spring 6 to Spur gear 16. (See Fig. 12 on page 6.)

5) Assemble Box cover complete to Feeder box. (See Fig. 11 on page 6.)

6) Make sure that Wheel moves correctly as described in Fig. 22 by pushing Ratchet arm complete up and down .

7) Make sure that Wheel can be stopped by pushing in Shoulder pin 6. (Fig. 23)

Note:

Do not apply any lubricant oil/grease or anticorrosive oil to the parts illustrated in Fig. 24.

because smooth feeding can be prevented by dirt and dust sticking to such oily/greasy parts.

Fig. 23 Fig. 24

Fig. 22

Wheel

Ratchet arm complete

Wheel moves when Ratchet arm complete is pushed up.

Wheel does not move when Ratchet arm complete is pushed down. (Also refer to Fig. 21 on page 8.)

Wheel

Ratchet arm complete

Shoulder pin 6

Wheel

Compression spring 6

Ratchet arm complete

Spur gear 16

Pin 3

Torsion spring 4

Stopper

Shoulder pin 6

Dust cover

Feeder box

Push in.

P 10/16

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Casing Assembly and Feeder Box Assembly (cont.)

Repair

ASSEMBLING

8) Casing complete can be assembled by doing the reverse of the disassembling steps. (Fig. 7 to Fig.2on pages 5 to 4)

Note: Be sure to follow the instructions described in Fig. 25 to Fig. 27.

Fig. 25

Fig. 26

Fig. 27

U-groove

Spring pin 4-12

of Casing complete

Steel ball 3.5

Dial 42

Assembling Dial 42 to Shifter pin

Assembling Plate to Stopper base

Assembling Sleeve 4 to Casing complete

Shifter pin

Thumb screw M4x28

By placing Shifter pin so that the pin's flat faces towards

the side where Thumb screw M4x28 is mounted,

Spring pin 4-12 of Casing complete fits in the U-groove

of Dial 42 when Dial 42 is assembled to Shifter pin.

Important:

Click stop of Dial 42 does not work without Steel ball 3.5.

Therefore, before assembling Dial 42 to Shifter pin,

make sure that Steel ball 3.5 is mounted in place on

Casing complete.

Plate

Stopper base

Feeder box

Lever Lever

While pressing down two Levers at the same time,

push Stopper base towards Feeder box until it stops,

then hitch Plate to Stopper base.

Sleeve 4 is not reversible when assembled to Casing complete.

Be sure to do as illustrated in "Correct".

While pressing down two Levers at the same time,

pull Stopper base slowly back to the initial position.

Plate is now assembled in place.

Shoulder flat head

screw M3x5

Casing complete

[cross section

of Sleeve 4]

Sleeve 4

Casing complete

Sleeve 4

Correct

Wrong

Shoulder flat head

screw M3x5

outside of

Casing complete

Shoulder flat head

screw M3x5 cannot

be fastened in place.

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