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HR2450-TE


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T    ECHNICAL INFORMATION
   Model No.                HR2450, HR2451, HR2452
                                                                                                           PRODUCT
                                                                                                             P 1 / 19

   Description              24mm (15/16 " ) Rotary Hammer                                         L
CONCEPT AND MAIN APPLICATIONS
   The above models are the advanced version of MAKITA's                                                           H
   famous 3 -modes rotary hammer HR2400.
   Each new model features :                                                                           W
   HR2450 : with variable speed and reverse switch
   HR2451 : with variable switch without reverse switch                       Dimensions : mm ( " )
   HR2452 : with single speed switch without reverse switch              Length ( L ) 360 (14-1/8)
                                                                         Height ( H ) 204 (8)
                                                                         Width ( W )   72 (2-13/16)
 Specification
                                                                     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.                             HR2450                  HR2451                 HR2452
   Power input : W                          780                     780                   780
   No load speed : (min -1= rpm)          0 - 1,100              0 - 1,100                1,100
   Blows per min, :(bpm=min -1)           0 - 4,500              0 - 4,500                4,500
   Single blow energy ( J )                 2.7                      2.7                    2.7
   Variable switch                         Yes                       Yes                  No
   Reverse switch                          Yes                       No                   No
               SDS max        SDS
                              MAX



               SDS plus

   Bit type    SDS top        SDS
                               top



               Spline

               Hex
   Max. diameter : mm (")                * 24 (15/16 )           * 24 (15/16 )         * 24 (15/16 )
   Max. core bit diameter: mm (")          54 (2-1/8 )             54 (2-1/8 )           54 (2-1/8 )
   Protection from electric shock by double insulation by double insulation by double insulation
   Cord length : m ( ft )           ** 4 (13.1)            ** 4 (13.1)          ** 4 (13.1)
   Net weight :Kg (lbs )             2.4 (5.3)              2.4 (5.3)            2.4 (5.3)
                                        * 25mm (1") for USA.
                                        ** 2.5m (8.2) for Asia   ** 2.0m (6.6) for Australia

 Standard equipment
    * Stopper pole ........................................... 1 pc.
    * Side grip ................................................. 1 pc.
    * Plastic carrying case ............................... 1 pc.
   < Note > The standard equipment for the tool shown may differ from country to country.
Features    and benefits                                                                                     P 2 / 19


        HR2450, HR2451, HR2452

                                                                                      In-line and ergonomical designed
                                                                                      palm fitting soft grip
                     Lock button on change lever for
                     firmly holding the position of             Built-in torque limiter
                     selected mode



                                                                                                     Lock ON button




                                                                                                       Palm fitting
                                                                                                       soft grip
Accepting SDS-plus shank bit
Slide lock type chuck
for rapid changing bits

Practical positioning chisel angle
desired 40 positions without using
chisel adapter
                                                       Equipped with
                                                       reverse switch
                                                       (only HR2450)



                              Change lever for
                              3 mode settings


                                                                           Cord guard is not
                                                                           only tough but also
                                                                           very flexible to
                                                                           protect cable from
                                                                           disconnection.


                             Rotation + Percussion


             Rotation only                  Percussion only
                                                                                                                                   P 3 / 19
Comparison                        of products

                                   Model No.                           MAKITA                    Competitor A Competitor B
                               Variable speed+Reverse   * HR2450       *HR2440       HR2400       * A-1           B-b
 Specifi-                      Variable peed            * HR2451       *HR2441                    * A-2
 cations      Single peed                                 HR2452        HR2442                      A-3
 Power input : W                                            780           780          750           620          620
 No load                                                * 0 - 1,100   * 0 - 1,100                * 0 - 870
                                                                                     0 - 1,200                 0 - 1,350
       speed: min-1=rpm.                                      1,100         1,100                      870
  Blows per                                             * 0 - 4,500   * 0 - 4,500                * 0 - 4,850
                                                                                     0 - 4,200                  0 - 4,400
        min. : min-1=bpm.                                     4,500         4,500                      4,850
  Bit type                                               SDS-plus      SDS-plus SDS-plus           SDS-plus     SDS-plus
          TCT.hammer bit : mm                                24            24         24              24            24
                           (")                             (15/16)       (15/16)    (15/16)         (15/16)      (15/16)
                Concrete




          Core bit : mm                                      54            54                         68           50
                     (")                                   (2-1/8)       (2-1/8)                   (2-11/16)       (2)
 Capacity




                           Diamond core : mm                 65            65                         80          120
                                          (")             (2-9/16)      (2-9/16)                    (3-1/8)     (4-3/4)
                           Steel : mm                        13            13         13              13           13
                                   (")                      (1/2)         (1/2)      (1/2)           (1/2)        (1/2)
                           Wood : mm                         32            32    a:24(15/16)          32           32        a:24(15/16) with
                                   (")                     (1-1/4)       (1-1/4) b:38(1-1/2)        (1-1/4)      (1-1/4)       Auger bit
  Single blow energy : J                                   2.7           2.7           1.5           2.2          2.2        b:38(1-1/2) with
                                                                                                                               Spade bit
  Working mode                                          3 Modes       2 Modes       3 Modes       3 Modes      3 Modes
  R     : Rotation                                         R             R             R             R            R
  R + P : Rotation+Percussion                             R+P           R+P           R+P           R+P          R+P
  P      : Percussion                                      P                           P             P            P
  Angle settings for chisel etc.                           Yes                      ** No            Yes          Yes
 Vibration    Instruction manual                            9             9            11            10
    : m / s2 Measured by us                                9.4           8.7          11.7           8.8         10.8
 Noise      Instruction manual                            101           101           102            99
   : dB(A)                    Measured by us              101           101           101           102          100
  Protection from                                       by double     by double     by double     by double    by double
  electric shock                                        insulation    insulation    insulation    insulation   insulation
  Cord length : m (ft)                                   4.0 (13.1)    4.0 (13.1)   2.5 (8.2)     4.0 (13.1)   5.0 (16.4)
                           Length : mm                     360           352          347           360          318
   Dimensions




                                    (")                  (14-1/8)      (13-7/8)     (13-5/8)      (14-1/8)     (12-1/2)
                           Width : mm                      72            72            71            70           72
                                   (")                  (2-13/16)     (2-13/16)     (2-13/16)      (2-3/4)     (2-13/16)
                           Height : mm                     204           204           185           205          185
                                    (")                    (8)           (8)         (7-1/4)       (8-1/8)      (7-1/4)

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



        Diamond Core : mm ( " ) ; Cutting capacity with both wet and dry type diamond core.
                                  When using wet type dia core, employ HR2450 series model connecting
                                  with residual current device.
                    ** No ; But possible to set the chisel angle with chisel adapter.
                                                                                                        P 4 / 19
Comparison      of products
 Numbers in chart below are relative values when setting capacity of competitor A's model A-1 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 : Rotary hammer

  Comparison in hammer drilling

    Bit diameter : 6.5mm

    MAKITA HR2450                                                                 105

    MAKITA HR2440                                                                 105

    MAKITA HR2400                                                      85

    Competitor A A-1                                                          100

                                0                   50                      100                150
     Bit diameter : 8.5mm

    MAKITA HR2450                                                                   110

    MAKITA HR2440                                                                   110

    MAKITA HR2400                                                     80

    Competitor A A-1                                                          100

                                0                   50                      100                150
     Bit diameter : 12.5mm

    MAKITA HR2450                                                                 105

    MAKITA HR2440                                                                 105

    MAKITA HR2400                                               70

    Competitor A A-1                                                          100

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

    MAKITA HR2450                                                                   110

    MAKITA HR2440                                                                   110

    MAKITA HR2400                                                                   110

    Competitor A A-1                                                          100

                                0                   50                      100                150
Repair                                                                                                                 P 5 / 19
< 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
     * Disulphide molybdenum alloyed grease to the portion marked with white triangle


                    Gear housing
     Cap 35                                          Needle baring




    Change lever
                                                                                   Piston joint            Inner housing
       O ring 17                   Steel ball 7.0
                                                    Tool holder                             O ring 68
                                                                     Piston cylinder

               Spur gear 51




                         Spur gear 10                         Cam shaft                                          Helical gear 26
                                                Clutch cam                    Swash bearing


   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
                                                                          Spiral portion
   Spur gear 10           Grease RA No.1 (Brown)
                                                                          The hole where cam shaft contacts
                          Grease RA No.1 (Brown)                          Convex portion of cam
   Clutch cam
                          Disulphide molybdenum alloyed grease            Whole of groove 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 FA No.2                                  Whole of teeth portion
 Repair                                                                                                               P 6 / 19
< 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 / 19
< 4 > Disassembling change lever
     1. Separate cap from change lever. See Fig. 1.
     2. Fully turn change lever in the direction of drill mode. Then, change lever can be pulled out from gear housing.
        See Fig. 2A and Fig. 2B



                                                                                                                 Gear housing
  Cap




            Gear housing
  Fig. 2                                                          Fig. 2A
                                                                                                                O ring 17
                             Lock button
                                    Compression spring 3               Change lever                   Fig. 2B


     Cap
                                                      < Note >
                                                      Be careful, not to lose lock button and compression spring 3.
                                                      They can easily spring off. See Fig. 2C.

                 Gear housing               Fig. 2C



< 5 > Assembling change lever
      1. Apply grease to the pin of change lever and O ring 17 referring to < 1 > Lubrication at page 5.
      2. Assemble compression spring 3 and lock button to change lever. And temporarily assemble cap to the position
         illustrated in Fig. 3 in order to stop springing off of lock button. Do not forget to assemble O ring 17. See Fig. 3.
      3. Insert the change lever in which compression spring 3 and lock button have been temporarily fixed with cap, into
         the assembling hole of gear housing. See Fig. 3A. The change lever can not be inserted completely in this stage.
      4. Pressing the change lever, turn it in the direction of drill mode. Then, it can be inserted completely
         in any position of area B. See Fig. 3B.
      5. Turn the change lever to the area C. See Fig. 3B. And assemble cap completely to the original position
         of change lever, by pressing to gear housing side.

           Lock button
   Compression spring 3                                                               A    Insert the change lever
      Change lever                                                                         within the area A.
     Cap


                                                                            Fig. 3A
                                                                                                Cap assembled        Lock button
                                O ring 17
                                                                                                completely by
                                                                   C                            pressing.
  Lock button
                                 Cap assembled
                                                             B
                                 temporarily                                                        Compression
                                                                                                    spring 3
 Compression
 spring 3                                                                                           Change lever
                                                                                          Fig. 3B
  Change lever
                                                      If the change lever can not be inserted completely
             Fig. 3                                   in any position of area B, pressing lock button, turn it to the direction
                                                      of drill mode again in order to insert completely in any position of area B.
 Repair                                                                                                                 P 8 / 19
< 6 > Disassembling armature
     1. Disassemble handle cover by unscrewing tapping screw 4 x 25. And disassemble carbon brushes
        as illustrated in Fig. 4.
      2. Separate gear housing together with armature, from motor housing by unscrewing tapping screws 4 x 45
         as illustrated in Fig. 4A.
      3. Slightly hitting the edge of gear housing with plastic hammer, remove armature from inner housing assembled in
         gear housing. See Fig. 4B.
      4. Ball bearings of fan side and commutator side can be disassembled with No.1R269 "Bearing extractor (small)".
         See Fig. 4C.

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


                                            No.1R269 "Bearing extractor (small)"


                                                                                                         Fig. 4C

< 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. 4 and Fig. 4A. And disassemble armature as
        illustrated in Fig. 4B.
     3. Disassemble inner housing from gear housing as illustrated in Fig. 5.
     4. Separate tool holder section from inner housing as illustrated in Fig. 5A. Pay attention, not to lose flat washer 28,
        when separating tool holder section.

                                                                         Tool holder section


                                 Tool holder section                                   Piston cylinder

                                                                                               Inner housing

                                         Inner housing        Flat washer 28

         Plastic hammer
                                                       Swash bearing section


       Swash bearing section

                  Fig. 5                                                   Fig. 5A
 Repair                                                                                                             P 9 / 19

       5. Ring spring 28 can not be removed without pressing washer 30 down to the spur gear 51 side, because it is
          assembled between tool holder and washer 30. See Fig. 5B.
       6. Disassemble ring spring 28 with retaining ring plier, pressing washer 30 down to the spur gear 51 side as
          illustrated in Fig. 5C and Fig. 5D.
       7. Disassemble washer 30, compression spring 31 and spur gear 51 from tool holder as illustrated in Fig. 5E.
                                                                       Ring spring 28
                    No. 1R306 Ring spring
                              extractor




                         Round bars
                         for arbor



                                                                 Washer 30




                         Retaining ring                                      Retaining ring
                         plier                                               plier

              Fig. 5B                           Fig. 5C                                          Fig. 5D


                    Compression
                    spring 31
                               Spur gear 51
             Washer 30




                                            Fig. 5E


< 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. 5E.
      3. Pressing the washer 30 down to the spur gear 51 side, with arbor press, assemble ring spring 28 as illustrated
         in Fig. 5D and Fig.5C.
      4. Assemble flat washer 28 as illustrated in Fig. 5A 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. 5A.
 Repair                                                                                                              P 10 / 19
< 9 > Disassembling impact bolt
     1. Referring to < 7 > Disassembling tool holder section at page 8 and 9, disassemble ring spring 28, washer 30,
        compression spring 31 and spur gear 51 from tool holder. See Fig. 5, Fig. 5A, B, C, D and E.
     2. Push the cut portion of ring spring 28 to the out side of the hole as illustrated in Fig. 6 and Fig. A.

                            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. 6                         Fig. 6A



                                            Cap 35 side                                                   Inner housing side




    3. Hold tool holder with "No.1R038 Armature holder" and vise. Insert screwdriver between ring spring 28
       and O ring case. and push out ring spring 28 from the inner groove as illustrated in Fig. 6B.



                  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. 6B
                              Vise
 Repair                                                                                                          P 11 / 19
      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. 6C.
      5. Pick up ring spring 28 with plier and take off it from tool holder as illustrated in Fig. 6D.
      6. Disassemble the following parts from tool holder as illustrated in Fig. 6E.
            * 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. 6D




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




                                                                              Fig. 6E
                                         Fig. 6C.


< 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. 6E.
     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. 7.
                                                             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. 7
 Repair                                                                                                              P 12 / 19
< 12 > Disassembling swash bearing
      1. Referring to at page 8, disassemble the product in the order of Fig.4, Fig.4A and Fig.4B at page 8.
         And separate inner housing together with tool holder section and swash bearing section from gear housing as
         illustrated in Fig. 8C. Ball baring 606ZZ can remain in gear housing in this stage. If so, refer to Fig. 8H at page 13.
      2. Separate tool holder section from inner housing as illustrated in Fig. 8D.

                                                                           Tool holder section


                                  Tool holder section                                   Piston cylinder

                                                                                                 Inner housing

    Plastic
    hammer                                Inner housing           Flat washer 28

     *Ball bearing 606ZZ
                                                        Swash bearing section
    Swash bearing section

                  Fig. 8C                                                    Fig. 8D

      3. Disassemble stop ring E-4, flat washer 5 and compression spring 6 with which change plate is fixed, from the pin
         of inner housing as illustrated in Fig. 8E.
                                                                      Piston cylinder

                     Stop ring E-4
                    Fat washer 5
                                                                                                 Inner housing
                  Compression spring 6
                           Pin of inner housing
                                  Change plate

                                                        Fig. 8E

      4. 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.
       Hex socket head bolts M4x12




                                                        Fig. 8F

      5. 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. 8G.
                            Piston cylinder




          Change plate

                                              Fig. 8G
Repair                                                                                                           P 13 / 19
  6. Reassemble swash bearing section temporarily to gear housing, and hold gear housing as illustrated in Fig. 8H.
     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.




                                           Fig. 8H
  7. Swash bearing section can not be disassembled in one action by pressing cam shaft with arbor press, because
     retaining ring S-7 is assembled between ball bearing 608ZZ and compression spring 7.
     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. Disassemble swash bearing 10 and clutch cam as illustrated in Fig. 9D. And disassemble ball bearing 606ZZ
         with bearing extractor as illustrated in Fig. 9D.
      6. Disassemble retaining ring S-7 with retaining ring plier as illustrated in Fig. 9E.
      7. Separated compression spring 7 and spur gear 10 from cam shaft as illustrated in Fig. 9F.


          Swash
          bearing 10                       Retaining ring S-7                   Cam shaft
                                                                                            Spur gear 10
                    Clutch cam
                           Ball bearing                                                          Compression
                           606ZZ                                                                 spring 7


          Fig. 9D                                Fig. 9E                               Fig. 9F
Repair                                                                                                           P 14 / 19
< 13 > Assembling swash bearing section
     1. Apply grease to the parts of swash bearing section referring to < 1 > Lubrication at page 5.
     2. Assemble swash bearing 10 by pressing cam shaft with arbor press as illustrated in Fig. 10.
     3. Assemble helical gear 26 by pressing cam shaft with arbor press as illustrated in Fig. 10A.
     4. Assemble flat washer 8, bearing retainer and ball bearing 608ZZ by pressing cam shaft with arbor press
        as illustrated in Fig. 10B.
     5. Assemble ring 8 by pressing cam shaft with arbor press as illustrated in Fig. 10C.




     Cam shaft                                         Flat washer 8
    Swash                                              Bearing
                                 Helical
    bearing 10                                         retainer                   Ball bearing
                                 gear 26                                                                       Ring 8
                                                                                  608ZZ




                                                  No.1R034
                                                  Bearing setting plate

                    Fig. 10                 Fig. 10A                   Fig. 10B                  Fig. 10C

< 14 > 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. Bringing 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, with adhesive hex socket head
        bolt M4x12, onto inner housing as illustrated in Fig. 11C.
         Do not fasten with the used hex socket head bolt M4x12. Always use the fresh adhesive
                 hex socket head bolt M4x12
                                                                            Inner housing
                        Flat washer 12
  Piston cylinder



  Piston joint

          Flat washer 12
                    Fig. 11                                                  Fig. 11A


                                                                                            2 pcs. of Hex socket
                                                                                            head bolts M4x12 for tightening
                                                                                            bearing retainer.
                               Piston cylinder




                                 Fig. 11B                                                          Fig. 11C
  Repair                                                                                                           P 15 / 19

       6. Set change plate in the groove of clutch cam, and assemble the clutch cam with change plate to cam shaft
          as illustrated in Fig. 11D.
       7. Assemble spur gear 10 to cam shaft as illustrated in Fig. 11E.
       8. Assemble compression spring 7 to cam shaft, and fix the parts on cam shaft with retaining ring S-7 as illustrated
          in Fig. 11F.
       9. Assemble compression spring 6 and flat washer 5 to the pin of inner housing. And fix them with stop ring E-5
          as illustrated in fig. 11G.
       10. Apply 55g of MAKITA grease RA No.1in gear housing.


        Change plate                                                               Change plate


                                                                       Spur gear 10




                Clutch cam       Cam shaft                                                        Clutch cam
                                               Fig. 11D                                                Fig. 11E


                                                                                            Compression spring 6
    Retaining       Change plate                                           Stop ring E-5
    ring S-7

           Spur gear 10

                                                                           Flat washer 5



    Compression spring 7
                                   Clutch cam

                                    Fig. 11F                                                      Fig. 11D


< 15 > Disassembling needle bearing complete
      Strike the work table with gear housing. Then needle bearing complete can be disassembled from gear housing
      as illustrated in Fig. 12.




                                                          Needle bearing
                                                          complete


                                                   Fig. 12
  Repair                                                                                                              P 16 / 19
< 16 > 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.

< 17 > 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 suppressor
                                                          Switch                            Handle
                                                                                            cover

                                                                                            Tapping s
                                                                                            crew 4 x 25 : 3 pcs.


                         Brush holder

                                            Cord guard
                                                                                 Tapping screw 4x18 : 2 pcs.
                                         Power supply cord
                                                             Strain relief
                                                                                  Fig. 14

 < 18 > 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 17 / 19
   Model HR2450 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 HR2451, HR2452 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 18 / 19
 Model HR2450 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 19 / 19
 Model HR2451, HR2452 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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