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HR2440-TE


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T    ECHNICAL INFORMATION
   Model No.                HR2440, HR2441, HR2442
                                                                                                               PRODUCT
                                                                                                                 P 1 / 18

   Description              Rotary Hammer 24mm (15/16")                                                  L

CONCEPT AND MAIN APPLICATIONS
   The above models are the advanced version of MAKITA's
   famous 2-modes 2Kg rotary hammer HR2410                                                                                   H
   Each new model features ;
   HR2440 : with variable switch and reverse switch                                                     W
   HR2441 : with variable switch, without reverse switch
                                                                          Dimensions : mm ( " )
   HR2442 : with single speed switch, without reverse switch
                                                                     Length ( L ) 352 (13-7/8)
                                                                     Width ( W )   72 (2-13/16)
 Specification                                                       Height ( H ) 204 (8)
                                                                       Continuous Rating (W)
      Voltage (V)         Current (A)          Cycle (Hz)                                               Max. Output(W)
                                                                      Input           Output
          110                  7.5                50 / 60               780               370                 650
          120                  6.7                50 / 60               780               370                 650
          220                  3.7                50 / 60               780               370                 650
          230                  3.6                50 / 60               780               370                 650
          240                  3.4                50 / 60               780               370                 650

    Model No.                                                HR2440                      HR2441                     HR2442
    No load speed : (min -1= rpm)                                           0 - 1,100                               1,100
    Blows per min : (min -1= bpm).                                          0 - 4,500                               4,500
    Type of bit shank                                                                  SDS - plus
    Chuck ability                                                                      10 (3/8)
                       Steel                                                      13 (1/2
   Drilling            Wood                                                       32 (1-1/4)
   capacity : mm ( " )            TCT. hammer bit                                 24 (15/16)     25 (1) for North America
                       Concrete Core bit                                          54 (2-1/8)
                                 Diamond Wet                                      65 (2-9/16)
                                   core    Dry                                    65 (2-9/16)
    Single blow energy ( J )                                                              2.7
                                                                                           rotation
    Working mode                                                            2 modes rotation+percussion
    Variable switch                                    Yes                      Yes                       No
    Clutch for protecting user from lock of bit        Yes                      Yes                       Yes
    Reverse switch                                     Yes                      No                        No
    Protection from electric shock                                    by double insulation
    Cord length : m (ft)                                4(13.1)        2.5(8.2) for Asia   2.0(6.6) for Australia
    Net weight : kg (lbs)                                              2.3 (5.1)
    < Note > When using wet type dia. core, employ HR2440 series models connecting with residual current device.

 Standard equipment
   * Side grip .................................. 1 pc. * Plastic carrying case ............... 1 pc.
   * Stopper pole (Depth gauge) .... 1 pc.
   < Note > The standard equipment for the tool shown may differ from country to country.

 Optional       accessories
    * SDS plus TCT. bits 5.5mm(7/32") - 24mm)15/16")      * Safety goggle  * Dust extractor attachment
    * Drill chuck assembly                                * Bit grease     * Diamond core bits (wet and dry)
    * Chuck adapter                                       * Blow out bulb       32mm, 38mm, 54mm, 65mm
    * Chuck key S-13                          * Core bits 32mm, 45mm, 54mm * Water protection collar
    * Drill chuck S-13                        * Core bit                   * Various taper shank TCT. bits
    * Holder driver                           * Core bit adapter           * Taper shank adapter
    * Dust cups 5 and 9                       * Rod                        * Cotter
Features   and benefits                                                                            P 2 / 18


                                     HR2440, HR2441, HR2442




                                                                           In-line and ergonomical
                                                                           designed palm fitting soft grip
  Accepts SDS-plus shank bit
  Slide lock type chuck for                       Lock on button
  rapid changing bits




                                                                                               Palm fitting
                                                                                               soft grip




                                              Built-in torque limiter



                                                       Equipped with
                                                       reverse switch
                                                       (only HR2440)
           With 2-modes settings,
           rotation   rotation + percussion
                                                       Cord guard is not only
                                                       tough but also excellent
                                                       in flexibility to protect
                                                       cable from disconnection.
Comparison                        of products                                                                          P 3 / 18

                                    Model No.                          MAKITA            Competitor A   Competitor B
                                Variable speed+Reverse   * HR2440          *HR2410        * A-VR         * B-VR
  Specifi-                      Variable peed            * HR2441          *HR2413        * A-V
  cations      Single peed                                 HR2442           HR2412            A              B
  Power input : W                                            780              680            620             620
  No load                                                * 0 - 1,100      * 0 - 1,050    * 0 - 1,050     * 0 - 1,050
        speed: min-1=rpm.                                      1,100            1,050          1,050           1,050
   Blows per                                             * 0 - 4,500      * 0 - 4,900    * 0 - 4,850     * 0 - 4,400
         min. : min-1=bpm.                                     4,500            4,900          4,850           4,400
   Bit type                                               SDS-plus           SDS-plus      SDS-plus       SDS-plus
           TCT.hammer bit : mm                                24                 24            24             24
                            (")                            (15/16)             (15/16)       (15/16)       (15/16)
                 Concrete




           Core bit : mm                                      54                 54            65            50
                      (")                                   (2-1/8)            (2-1/8)      (2-9/16)         (2)
  Capacity




                            Diamond                         **65                 65                         120
                            core : mm       Wet           (2-9/16)            (2-9/16)                    (4-3/4)
                                  (")                         65                                            120
                                            Dry
                                                           (2-9/16)                                       (4-3/4)
                            Steel : mm                        13                13             10            13
                                    (")                      (1/2)             (1/2)          (3/8)         (1/2)
                            Wood : mm                         32                32             30            32
                                    (")                     (1-1/4)           (1-1/4)       (1-3/16)       (1-1/4)
   Single blow energy : J                                   2.7                2.0           2.2            2.2
  Working mode                                           2 Modes            2 Modes       2 Modes        2 Modes
  R     : Rotation                                          R                  R             R              R
  R + P : Rotation+Percussion                              R+P                R+P           R+P            R+P
 Vibration    Instruction manual                             9                  8            10             10
    : m / s2 Measured by us                                 8.7                7.8           8.7            9.7
 Noise      Instruction manual                             101                103           101
    : dB(A)                    Measured by us              101                103           102            102
   Protection from                                       by double          by double     by double      by double
   electric shock                                        insulation         insulation    insulation     insulation
   Cord length : m (ft)                                   4.0 (13.1)        2.5 (8.2)      4.0 (13.1)     5.0 (16.4)
                            Length : mm                     352               371           360             318
    Dimensions




                                     (")                  (13-7/8)          (14-5/8)      (14-1/8)        (12-1/2)
                            Width : mm                      72                 70            70             72
                                    (")                  (2-13/16)           (2-3/4)       (2-3/4)       (2-13/16)
                            Height : mm                     204                197           205            185
                                     (")                    (8)              (7-3/4)       (8-1/8)        (7-1/4)

  Net weight : Kg                                           2.3                2.3           2.4            2.3
               (lbs)                                       (5.1)              (5.1)         (5.3)          (5.1)



         Diamond Core : mm ( " ) ; When using wet type dia core, employ HR2440 series model connecting
                                   with residual current device.
Comparison     of products                                                                              P 4 / 18
  Numbers in chart below are relative values when setting the capacity of competitor A's A-VR as 100.
                                                                                                          80 N
  Testing conditions
   * Materials : Concrete with compressive               Concrete with
                 strength, 350Kg/cm2                     compressive strength
   * Pressure added to the products : 80 N               350Kg/cm2
    * Working mode : Rotation + Percussion

   Comparison in hammer drilling

     Bit diameter : 6.5mm

     MAKITA HR2440                                                               105

     MAKITA HR2410                                                       90

     Competitor A A-VR                                                        100

     Competitor B B-VR                                           75

                                0                   50                   100                  150
      Bit diameter : 8.5mm

     MAKITA HR2440                                                                    110

     MAKITA HR2410                                                                105

     Competitor A A-VR                                                          100

     Competitor B B-VR                                                   90

                                0                   50                   100                  150
      Bit diameter : 12.5mm

     MAKITA HR2440                                                               105

     MAKITA HR2410                                                            100

     Competitor A A-VR                                                        100

     Competitor B B-VR                                                   90

                                0                   50                   100                  150
   Comparison in drilling        Testing conditions
                                   * Materials : Douglas fir (Wood) of 60mm (2-3/8") in thickness
                                   * Working mode : Rotation only
      Auger bit diameter : 32.0 mm

     MAKITA HR2440                                                                    110

     MAKITA HR2410                                                                    110


     Competitor A A-VR                                                          100

     Competitor B B-VR                                              80

                                0                   50                   100                  150
Repair                                                                                                                P 5 / 17
< 1 > Lubrication
     Apply the following MAKITA grease to protect parts and product from unusual abrasion.
      * Grease RA No.1(Brown) to the portions marked with black triangle
      * Grease FA No.2 to the portions marked with gray triangle

               Gear housing
 Cap 35                                         Needle baring




        O ring 17

   Change lever                                                               Piston joint            Inner housing
                              Steel ball 7.0
                                               Tool holder                            O ring 68
                                                                Piston cylinder

          Spur gear 51




                                                                                                            Helical gear 26
                                     Clutch cam                          Swash bearing
                                                        Spur gear 10


   Cap 35                Grease RA No.1 (Brown)                          Inner lip of bit inserting side
                                                                         Inner portion where the mechanical parts are installed.
   Gear housing          Grease RA No.1 (Brown) : 60g
                                                                         Groove for O ring 17 assembling portion
   Needle bearing        Grease RA No.1 (Brown)                          Inner ring
   Change lever          Grease RA No.1 (Brown)                          Top of the pins
   O ring 17             Grease RA No.1 (Brown)                          Whole part
                                                                         Inner portion where tool holder contacts
   Spur gear 51          Grease RA No.1 (Brown)
                                                                         Convex portion of cam
   Steel ball 7.0        Grease RA No.1 (Brown)                          Whole part
                                                                         Inner portion where piston cylinder contacts
   Tool holder           Grease RA No.1 (Brown)
                                                                         The portion where inner housing contacts
                                                                         Inner portion where striker contacts
   Piston cylinder       Grease RA No.1 (Brown)
                                                                         The portion where piston joint is assembled
   O ring 68             Grease RA No.1 (Brown)                          Whole part
                                                                         Inner portion where tool holder contacts
   Inner housing         Grease RA No.1 (Brown)
                                                                         The groove where O ring 68 is assembled

   Spur gear 10          Grease FA No.2                                  Spline portion

                                                                         Inner portion where cam shaft contacts
   Swash bearing 10                                                      The surface where helical gear 26 contacts
                         Grease FA No.2
                                                                         The portion where balls are installed
                                                                         Convex portion of cam

   Helical gear 26       Grease RA No.1 (Brown)                          Whole of teeth portion
  Repair                                                                                                                  P 6 / 18
< 2 > Disassembling chuck section
   1. Slide chuck cover in the direction of gear housing, and pull out cap 35 by turning. See Fig. 1.
   2. Take off ring spring 19. Then, the following parts can be disassembled from tool holder. See Fig. 1A.
           * Chuck cover
           * Ring 21
   3. Take off steel ball 7.0 with which guide washer and conical compression spring 21-29 are held. See Fig. 1A.
      Then, guide washer and conical compression spring 21-29 can be disassembled from tool holder. See Fig. 1B.

                                          Ring spring 19
                  Cap 35                         Chuck cover
                                                                Steel ball 7.0                       Guide washer
                                                                                                          Conical compression
                                                                                                          spring 21-29
                                                                                                                   Tool holder
                                      Ring 21



       Chuck cover
        Gear housing


                         Fig. 1                                      Fig. 1A                                   Fig. 1B




< 3 > Assembling chuck section
      1. Apply grease to steel ball 7.0 and cap 35 referring to < 1 > Lubrication at page 5.
      2. Assemble conical compression spring 21-29 and guide washer, and hold guide washer with steel ball 7.0.
         See Fig. 1B and Fig. 1A.
      3. Assemble ring 21 and chuck cover to tool holder. And then, hold them with ring spring 19. See Fig. 1A.
      4. Slide chuck cover in the direction of gear housing, and assemble cap 35 by turning. See Fig. 1.

                                                                                  Conical compression
         < Note in assembling >
                                                                                  spring 21-29
         A. Pay attention to the assembling direction
            of conical compression spring 21-29.                  Cap 35 side                         Gear housing side



                                                                   The small portion : Gear housing side
                                                                   The large portion : Cap 35 side

                                                                                 The cut portion
          B. The cut portion of ring spring 19 has to come                       of ring spring 19
             to the opposite side of the flat portion of
             tool holder.



                                                                                                The flat portion of
                                                                                                tool holder.
  Repair                                                                                                             P 7 / 18

< 4 > Disassembling change lever
     1. Disassemble cap from change lever by twisting the flat head screwdriver inserted between cap and change lever,
        as illustrated in Fig. 2.
     2. Turn the change lever fully to the direction of rotary hammer mode and pull off change lever from gear housing
        as illustrated in Fig 2A.
                                                                             Change lever



                               Cap




                                                                                                        Fig. 2A

                                                                                   Apply grease to the pin, before assembling.

                                Approach first from this side.

                                             Fig. 2
                                                                                                        Fig. 2B
 < 5 > Assembling change lever
       1. Apply grease RA No.1 (Brown) to the top of change lever's pin. See Fig. 2B.
           < Note > The neglect of the grease to the pin portion can be cause of the damage on the change lever.
                      during the work in "rotation only" mode.
       2. Aligning change lever with the rotary hammer mode, assemble it by pressing to the assembling hole
          as illustrated in the above Fig. 2A. And assemble cap by pressing to change lever.
< 6 > Disassembling armature
      1. Disassemble handle cover by unscrewing tapping screw 4 x 25. And disassemble carbon brushes
         as illustrated in Fig. 3.
       2. Separate gear housing together with armature, from motor housing by unscrewing tapping screws 4 x 45
          as illustrated in Fig. 3A.
       3. Slightly hitting the edge of gear housing with plastic hammer, remove armature from inner housing assembled in
          gear housing. See Fig. 3B.
       4. Ball bearings of fan side and commutator side can be disassembled with No.1R269 "Bearing extractor (small)".
          See Fig. 3C.

                                                          Tapping s                                Gear housing
                                                          crew 4 x 45 : 4 pcs.
                                                                                                             Inner housing
                                                                       Gear housing

                            Brush holder                                     Motor housing



   Brush holder                            Carbon brush


                                                                                              Plastic hammer
       Carbon brush
                                                                                                        Fig. 4B
                                                                                                             3B
                                                      Tapping s
                  Handle                              crew 4 x 25 : 3 pcs.
                                                                                                                Ball bearing
                  cover
                                                                       Fig. 3A                                         Armature
                            Fig. 3

                                            No.1R269 "Bearing extractor (small)"

                                                                                                      Fig. 3C
                                                                                                                        P 8 / 18
 Repair
< 7> Disassembling tool holder section
     1. Disassemble change lever from gear housing as mentioned in < 4 > Disassembling change lever at page 7.
     2. Separate gear housing from motor housing as illustrated in Fig. 3 and Fig. 3A. And disassemble armature
        as illustrated in Fig. 3B at page 7.
     3. Disassemble inner housing from gear housing as illustrated in Fig. 4.
     4. Separate tool holder section from inner housing as illustrated in Fig. 4A. Pay attention, not to lose flat washer 28,
        when separating tool holder section.
                                                                                 Tool holder
                                                                                 section


                                                     Washer 30                                        Piston cylinder
                                                                                                            Inner housing
    Plastic hammer                                  Tool holder
                                                    section     Flat washer 28


                                                                        Swash bearing
                  Swash bearing                                         section
                  section
                              Fig. 4                                              Fig. 4A

      5. Ring spring 28 can not be removed without pressing washer 30 down to the spur gear 51 side, because it is
         almost covered by washer 30. See Fig. 4B.
      6. Disassemble ring spring 28 with retaining ring plier, pressing washer 30 down to the spur gear 51 side as
         illustrated in Fig. 4C and Fig. 4D.
      7. Disassemble washer 30, compression spring 31 and spur gear 51 from tool holder as illustrated in Fig. 5E.

                   No. 1R306 Ring spring                         Ring spring 28
                             extractor




                                Round bars
                                for arbor

                                                               Washer 30



                                  Retaining ring                           Retaining ring
                                  plier                                    plier
                      Fig. 4B                      Fig. 4C                                  Fig. 4D

                             Compression
                             spring 31
                                       Spur gear 51
                     Washer 30

                                                                                      Fig. 4E


< 8 > Assembling tool holder section
      1. Apply grease to spur gear 51 and tool holder referring to < 1 > Lubrication at page 5.
      2. Assemble spur gear 5, compression spring 31 and washer 30 to tool holder as illustrated in Fig. 4E.
      3. Pressing the washer 30 down to the spur gear 51 side, with arbor press, assemble ring spring 28 as illustrated
         in Fig. 4D and Fig.4C.
      4. Assemble flat washer 28 to the position illustrated in Fig. 4A at page 8.
      5. Insert piston cylinder of swash bearing section into tool holder. And assemble tool holder section by pressing
         into inner housing as illustrated in fig. 4A.
 Repair                                                                                                                P 9 / 18
< 9 > Disassembling impact bolt
     1. Referring to "< 7 > Disassembling tool holder section" at page 8, disassemble ring spring 28, washer 30,
        compression spring 31 and spur gear 51 from tool holder. See Fig. 4, Fig. 4A, 4B, 4C, D and 4E.
     2. Push the cut portion of ring spring 28 to the out side of the hole as illustrated in Fig. 5 and Fig. 5A.

                            Ring spring 28 showing its
                            cut portion                             Ring spring
                                                                                                     Inner
                Cap 35 side                                                                           housing side


                              O ring case                              O ring case

                                                        Push the cut portion to
                                                        the out side of the hole.
                                                      Fig. 5                         Fig. 5A



                                            Cap 35 side                                                     Inner housing side




    3. Hold tool holder with "No.1R038 Armature holder" and vise as illustrated in Fig. 5B. Insert screwdriver
       between ring spring 28 and O ring case. and push out ring spring 28 from the inner groove as illustrated in Fig. 5C.



                  Cap 35 side                                                          Push out ring spring 28 from
                                                                                       the inner groove.

                                                                        Inner groove of                        Cap 35 side
                      No.1R038                                          tool holder
                      Armature holder
                                                                                       O ring case



                                                                               Ring spring 28
            Inner                                                              off from inner groove            Inner
             housing side                                                                                        housing side
                                                                                                     Fig. 5C
                              Vise



                                            Fig. 5B
  Repair                                                                                                           P 10 / 18
       4. Insert "No.1R236 Round bar for arbor" and push ring spring 28 as deep as possible to the inner housing side
          by striking the round bar for arbor as illustrated in Fig. 5D.
       5. Pick up ring spring 28 with plier and take off it from tool holder as illustrated in Fig. 5E.
       6. Disassemble the following parts from tool holder as illustrated in Fig. 5F.
             * O ring case equipped with O ring 9
             * O ring 15
             * Ring 9
             * Impact bolt equipped with O ring 12
       7. Clean the inside of tool holder completely.

                                                                                                  Ring spring 28




                                                                                Fig. 5E




                                                                     Impact bolt equipped               O ring case equipped
                                                                     with O ring 12       Ring 9        with O ring 9
                                                                                                    O ring 15




                                                                                Fig. 5F
                                          Fig. 5D.


< 10 > Assembling impact bolt
       1. Apply grease to the O rings referring to < 1 > Lubrication at page 5
          * O ring 9 for O ring case
          * O ring 15
          * O ring 12 for impact bolt
       2. Insert impact bolt, ring 9, O ring 15 and O ring case with O ring 9 into tool holder as illustrated in Fig. 5F.
       3. Assemble ring spring 28 to the inner groove of tool holder by pushing it with screwdriver. Ring spring 28 has to be
          assembled as illustrated in Fig. 6.
                                                              Ring spring 28
                                        Ring 9 O ring 15       O ring case
                                 O ring 12                     O ring 9
                       Impact bolt
                                                                         < Note >
                                                                         Do not install the used ring spring 28.
                                                                         Always assemble the fresh one.




                                          Fig. 6
   Repair                                                                                                              P 11 / 18
< 11 > Disassembling swash bearing
      1. Referring to Fig. 3, 3A, 3B at page 7, disassemble the product.
         And separate inner housing together with tool holder section and swash bearing section from gear housing as
         illustrated in Fig. 8 and Fig. 8A. Ball baring 606ZZ can remain in gear housing in this stage. If so, refer to Fig. 8D.
      2. Separate tool holder section from inner housing as illustrated in Fig. 8A.
                                                                                      Tool holder
                                                                                      section


                                                       Washer 30                                     Piston cylinder
                                                                                                            Inner housing
      Plastic hammer                                  Tool holder
                                                      section     Flat washer 28


                                                                           Swash bearing
                    Swash bearing                                          section
                    section
                                Fig. 8                                               Fig. 8A

      3. Swash bearing section is held in inner housing with bearing retainer which is fastened with 2 pcs. of hex socket
         head bolts M4x12. Take off these hex socket head bolts M4x12 for disassembling swash bearing section. See Fig. 8B.

                       Hex socket head bolts M4x12




                                                                 Fig. 8B

      4. Bring piston cylinder to the dead point. And , twist the the swash bearing section, with pulling off them
         from inner housing. Then swash bearing section and change plate can be disassembled from piston cylinder.
         See Fig. 8C.
                                         Piston cylinder




                                                           Fig. 8C


     5 If ball bearing 606ZZ remains in gear housing in the step of Fig. 8, reassemble swash bearing section temporarily
       to gear housing, and hold gear housing as illustrated in Fig. 8D. So, swash bearing section tilts in the direction of arrow.
       Keeping the illustrated position, disassemble swash bearing section by striking the edge of gear housing
       with plastic hammer. So, ball bearing 606ZZ can be removed together with swash bearing section.

                Ball bearing 606ZZ



                                                                           Fig. 8D
Repair                                                                                                           P 12 / 18
  6. Swash bearing section can not be disassembled in one action by pressing cam shaft with arbor press, because
     Take the following steps for disassembling them.
       1. Disassemble ring 8 by pressing with arbor press as illustrated in Fig. 9.
       2. Disassemble ball bearing 608ZZ with bearing extractor as illustrated in Fig. 9A.
       3. Disassemble flat washer 8 and bearing retainer as illustrated in Fig. 9B.
       4. Disassemble helical gear 26 by pressing with arbor press as illustrated in Fig. 9C.


  1R236 Round bar                                                                                          1R236 Round bar
        for arbor                                                   Bearing retainer    Flat washer 8            for arbor

                                                                                                 Helical
                     1R022 Bearing              Ring 8                                           gear 26
  Ring 8                   extractor plate




                                                            Ball bearing
                                                            608ZZ
                      1R023 Bearing                               Fig. 9A         Fig. 9B                  Fig. 9C
                            extractor ring
                                 Fig. 9

      5. After disassembling helical gear 26, swash bearing 10, clutch cam, compression spring 12 and flat washer 12
         can be separated from spur gear 10 as illustrated in Fig. 9.
      6. Disassemble ball bearing 606ZZ with bearing extractor as illustrated in Fig. 9E.



                                                    Compression
     Ball bearing                                   spring 12
                                                              Clutch cam
     606ZZ                                                                                             Ball bearing
            Spur gear 10                                      Swash
                                                                                                       606ZZ
                                                              bearing 10
                  Flat washer 12


                                          Fig. 9D                                      Fig. 9E
  Repair                                                                                                            P 13 / 18

<12> Assembling swash bearing section
     1. Apply grease to the parts of swash bearing section referring to < 1 > Lubrication at page 5.
     2. Assemble ball bearing 606ZZ by pressing spur gear 10 with arbor press as illustrated in Fig. 10.
     3. Set the parts on spur gear 10 in the following order. See Fig. 10A.
                 1. Flat washer 12
                 2. Compression spring 12
                 3. Clutch cam                Align the splines of clutch cam and swash bearing with the same of spur gear 10,
                 4. Swash bearing 10          when setting them to spur gear 10.
                 5. Helical gear 26
     4. Put the above temporarily assembled swash bearing section on the bearing setting plate, and press them
        with arbor press as illustrated in Fig. 10B.
     5. Assemble flat washer 8 and bearing retainer. And then, assembled ball bearing 608ZZ by pressing with arbor press
        as illustrated in Fig. 10C.
     6. Assemble ring 8 by pressing with arbor press as illustrated in Fig. 10D.

                               Helical gear 26
                                                                             Align the splines of clutch cam
                               Swash bearing 10                              and swash bearing with the same
                                                                             of spur gear 10.
                               Clutch cam

                               Compression
     Spur gear 10              spring 12

                               Flat washer 12
                                                                           Bearing setting pipe
     Ball bearing
     606ZZ



                 Fig. 10                            Fig. 10A            No. 1R034                  Fig. 10B
                               No. 1R034                                Bearing setting plate
                               Bearing setting plate




                                    Ball bearing 608ZZ
                                                                          Ring 8
                                    Flat washer 8
                                    Bearing retainer




                                    No. 1R034
                                    Bearing setting plate

                    Fig. 10C                                          Fig. 10D
 Repair                                                                                                         P 14 / 18

<13> Assembling swash bearing section to piston cylinder
    1. Apply MAKITA grease to piston cylinder and swash bearing 10 referring to <1> Lubrication at page 5.
    2. Assemble 2 pcs. of flat washers 12 and piston joint to piston cylinder as illustrated in Fig. 11.
    3. Insert the above piston cylinder into inner housing as illustrated in Fig. 11A.
    4. Moving piston cylinder to the dead point for swash bearing 10, assemble swash bearing 10 to piston cylinder by
       inserting its pole into the hole of piston joint as illustrated in Fig. 11B.
    5. Fasten bearing retainer which has been assembled to swash bearing section in the step of Fig. 10C, with adhesive
       hex socket head bolt M4 x 12, onto inner housing as illustrated in Fig. 11C. Fig. 11
       < Note >
       Do not fasten with the used hex socket head bolt M4 x 12. Always use the fresh adhesive
       hex socket head bolt M4 x 12.
                                                                    Piston cylinder



                                      Flat washer 12

                                 Piston cylinder
                           Piston joint
                     Flat washer 12


                      Fig. 11                                                       Inner housing
                                                       2 pcs. of hex socket
                                                                                      Fig. 11A
                                                       head bolts M4 x 12
                                                       for tightening bearing
                                                       retainer

                                  Piston cylinder




                                                                                                 Fig. 11C




                                Fig. 11B




<14> Disassembling needle bearing complete
    Strike the work table with gear housing. Then, needle baring complete can be disassembled from gear housing
    as illustrated in fig. 12.
          < Note >
          Cover the work table with something soft to avoid the damage on gear housing. before disassembling.




                                                              Needle bearing
                                                              complete


                                                         Fig. 12
  Repair                                                                                                                  P 15 / 18
< 15 > Assembling needle bearing complete
       1. Apply MAKITA grease RA No.1 to the inside of needle baring complete.
       2. Putting needle bearing complete on No.1R165 "Ring spring setting tool B" press gear housing onto the needle
          bearing complete with arbor press as illustrated in Fig. 13.

                                                                   < Note in assembling >
                                                                   Pay attention to the assembling position of needle bearing
                                                                   complete.
                                                                   The fat portion of needle bearing complete has to be faced
                                                                   to the belly side of gear housing.

                 Back side                               Gear housing                          Back side
                                                                                                               Needle bearing
                                                                                                               complete.

                                                             Belly side

             Needle bearing
             complete

      No.1R165                                              Flat portion of
      Ring spring setting tool B                            needle bearing complete
                                                                                              Belly side
                                                               Fig. 13.

< 16 > Replacing electrical parts in handle
      Disassemble handle cover by unscrewing 3 pcs. of tapping screws 4x25, and disassemble strain relief
      by unscrewing 2 pcs. of tapping screws 4x18 as illustrated in Fig.14.
      Then, switch, noise suppressor, power supply cord, etc. can be replaced.

                                             Brush holder                    Noise                 Handle
                                                                             suppressor            cover
                                                                   Switch




                              Brush holder
                                                                                                     Tapping s
                                                                                                     crew 4 x 25 : 3 pcs.
                                                  Cord guard
                                                                                            Tapping screw 4x18 : 2 pcs.
                                                Power supply cord
                                                                            Strain relief
                                                                                                     Fig. 14

< 17 > Maintenance
      It is recommended to change the following parts, when replacing carbon brushes. See Fig. 15.

                                     Steel ball 7.0    O ring 12     O ring 15        O ring 9




                                                                          O ring 16

                                             Fig. 15
Circuitdiagram                                                                                             P 16 / 18
   Model HR2440 with reverse switch
                                                  Brush holder
         Color index of lead wires                                        Brush holder
      Black
      White
      Red
      Blue
    See-through

                                                                                                   Connected
                                                                                                   to field ore




                                         2                                    3
                                                         Switch
                                         4                                    1


                                         1    2         M1        C1 C2     M2



          Power supply cord




                                                                       Noise suppressor
                                                                                    For some countries, noise
   Model HR2441, HR2442 without reverse switch
                                                                                    suppressor of two lead wire
         Color index of lead wires                                                  type is used, or noise suppressor
      Black                                                                         is not used.
      Red
      Blue
                                                                    Brush holder
    See-through


             Brush holder                                                                Connected
                                                                                         to field ore




                                             Switch


                            1        2       M1        C1 C2      M2



 Power supply cord
                                                                  Noise suppressor
                                                                                     For some countries, noise
                                                                                     suppressor of two lead wire
                                                                                     type is used, or noise suppressor
                                                                                     is not used.
Wiring diagram                                                                  P 17 / 18
 Model HR2440 with reverse switch


                                                 Fix field lead wire (black)
                                                 with lead holder as per
  Fix field lead wire (black)                    the illustration.
  with lead holder as per
  the illustration.
                                                  Fix noise suppressor's
                                                  lead wire (see-through)
                                                  with lead holder
                                                  as per the illustration.




                                                 Fix brush holder's
                                                 lead wire (blue) and
                                                 field lead wire (black)
                                                 with lead holder as per
Fix brush holder's                               the illustration.
lead wire (red) and                              * Pass brush holder's lead wire (blue)
field lead wire (white)                            under the field lead wire (black).
with lead holder as per                          * Do not slack brush holder's lead
the illustration.                                  wire (blue) between brush holder and
* Pass brush holder's lead wire (red)              lead holder.
  under the field lead wire (white).
* Do not slack brush holder's lead
  wire (red) between brush holder and      Fix the following lead wires with this
  lead holder.                             lead holder.
                                            * Brush holder's lead wire (red)
             Fix field brush holder's       * 2 field's lead wires (black)
             lead wire (blue) and           * Noise suppressor's lead wire (see-through)
             field lead wire (black)
             with lead holder as per
             the illustration.

     Fix lead wires which are passed       Pass lead wires inside of the rib.
     through this area, with any of
     these lead holders.




                                        Noise suppressor
                                        Noise suppressor is not
                                        used in some countries
Wiring  diagram                                                                          P 18 / 18
 Model HR2441, HR2442 without reverse switch


                                                         Fix brush holder's wire (red)
                                                         with lead holder as per
  Fix field lead wire (black)                            the illustration.
  with lead holder as per
  the illustration.
                                                          Fix noise suppressor's
                                                          lead wire (see-through)
                                                          with lead holder
                                                          as per the illustration.




                                                         Fix brush holder's
                                                         lead wire (blue) and
                                                         field lead wire (black)
                                                         with lead holder as per
                                                         the illustration.
Fix brush holder's                                       * Pass brush holder's lead wire (blue)
lead wire (red) and (blue)                                 under the field lead wire (black).
with lead holder as per                                  * Do not slack brush holder's lead
the illustration.                                          wire (blue) between brush holder and
* Pass brush holder's lead wire (red)                      lead holder.
  under the same of (blue).
* Do not slack brush holder's lead
  wire (red) between brush holder and          Fix the following lead wires with this
  lead holder.                                 lead holder.
                                                * 2 field's lead wires (black)
                                                * Noise suppressor's lead wire (see-through)




      Fix lead wires which are passed              Pass lead wires inside of the rib.
      through this area, with any of
      these lead holders.




                                                Noise suppressor
                                                Noise suppressor is not
                                                used in some countries



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