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HR2450F-TE


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T    ECHNICAL INFORMATION
   Model No.              HR2450F
                                                                                                               PRODUCT
                                                                                                                 P 1 / 18

   Description            Rotary Hammer 24mm (15/16")                                                L
CONCEPT AND MAIN APPLICATIONS
   The above models is the advanced version of HR2450,
   equipped with LED job light for lighting up the drilling point.                                                     H

                                                                       Dimensions : mm ( " )               W
                                                                  Length ( L )  360 (14-1/8)
                                                                  Height ( H )  212 (8-3/8)
                                                                  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.                                                    HR2450F
    No load speed : (min -1= rpm)                                0 - 1,100
    Blows per min : (min -1= bpm).                               0 - 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 core                   65 (2-9/16) Dry
    Single blow energy ( J )                                         2.7
                                                                          Rotation
    Working mode                                         3 modes          Rotation+Percussion
                                                                          Percussion
    Variable switch                                             Yes
    Clutch for protecting user from lock of bit                 Yes
    Reverse switch                                              Yes
    LED job-light                                               Yes
    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)                                      2.4 (5.3)



 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.

 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 (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


                                          HR2450F

                                                                                       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
                                                         Equipped with
Practical positioning chisel angle                       reverse switch
desired 40 positions without using
chisel adapter
                                                                                                Cord guard is not
                                                                                                only tough but also
                                                                                                very flexible to
                   Change lever for
                                                                                                protect cable from
                   3 mode settings
                                                                                                disconnection.




                                                                  LED job-light for lighting up
                  Rotation + Percussion
                                                                  your working point in shadow

  Rotation only                  Percussion only
                                                                                                                       P 3 / 18
Comparison                       of products


                                      Model No.                MAKITA                   Competitor A     Competitor B
   Specifications                                        HR2450F      HR2450                A                 B
  Power input : W                                          780         780                   620            620
  No load
                                                         0 - 1,100      0 - 1,100           0 - 870       0 - 1,350
       speed: min-1=rpm.
  Blows per
        min. : min-1=bpm.                                0 - 4,500      0 - 4,500          0 - 4,850      0 - 4,400
  Switch                                            Variable+Reverse Variable+Reverse Variable+Reverse Variable+Reverse
  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                  68            50
                     (")                                  (2-1/8)        (2-1/8)           (2-11/16)         (2)
 Capacity




                           Diamond core : mm               65               65                 68           120
                                                Dry
                                          (")           (2-9/16)         (2-9/16)          (2-11/16)       (4-3/4)
                           Steel : mm                       13             13                  13            13
                                   (")                     (1/2)          (1/2)               (1/2)         (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            2.7                2.2            2.2
  Working mode                                          3 Modes          2 Modes          3 Modes          3 Modes
  R     : Rotation                                         R                R                R                R
  R + P : Rotation+Percussion                             R+P              R+P              R+P              R+P
  P      : Percussion                                      P                                 P                P
  LED job-light                                           Yes               No               No              No
  Angle settings for chisel etc.                          Yes               Yes              Yes             Yes
 Vibration    Instruction manual                            9                9                10
    : m / s2 Measured by us                                9.4              8.7              8.8             10.8
 Noise      Instruction manual                            101              101               99
   : dB(A)                    Measured by us              101              101              102             100
  Protection from                                       by double        by double        by double       by double
  electric shock                                        insulation       insulation       insulation      insulation
  Cord length : m (ft)                                   4.0 (13.1)       4.0 (13.1)       4.0 (13.1)     5.0 (16.4)
                           Length : mm                     360              352              360            318
   Dimensions




                                    (")                  (14-1/8)         (13-7/8)         (14-1/8)       (12-1/2)
                           Width : mm                      72               72                70            72
                                   (")                  (2-13/16)        (2-13/16)          (2-3/4)      (2-13/16)
                           Height : mm                     212              204              205            185
                                    (")                    (8)              (8)            (8-1/8)        (7-1/4)
  Net weight : Kg                                          2.4              2.3               2.4           2.4
               (lbs)                                      (5.3)            (5.1)             (5.3)         (5.3)
                                                                                                          P 4 / 18
Comparison      of products
 Numbers in chart below are relative values when setting the capacity of competitor A's model A as 100.
                                                                                                          80 N
  Comparison in hammer drilling
                                                         Concrete with
 Testing conditions
                                                         compressive strength
  * Materials : Concrete with compressive
                                                         350Kg/cm2
                strength, 350Kg/cm2
  * Pressure added to the products : 80 N
   * Working mode : Rotary hammer

    Bit diameter : 6.5mm

    MAKITA          HR2450F                                                       105

    MAKITA          HR2440                                                        105

    MAKITA          HR2400                                             85

    Competitor A Model A                                                      100

                               0                    50                      100                150
     Bit diameter : 8.5mm

    MAKITA          HR2450F                                                         110

    MAKITA          HR2440                                                          110

    MAKITA          HR2400                                            80

    Competitor A Model A                                                      100

                               0                    50                      100                150
     Bit diameter : 12.5mm

    MAKITA          HR2450F                                                       105

    MAKITA          HR2440                                                        105

    MAKITA          HR2400                                      70

    Competitor A Model A                                                      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          HR2450F                                                         110

    MAKITA          HR2440                                                          110

    MAKITA          HR2400                                                          110

    Competitor A Model A                                                      100

                               0                    50                      100                150
Repair                                                                                                                 P 5 / 18
< 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 contacts tool holder
   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 contacts piston cylinder
   Tool holder            Grease RA No.1 (Brown)
                                                                          The portion where contacts inner housing
                                                                          Inner portion where contacts striker
   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 contacts tool holder
   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 contacts cam shaft
                          Grease RA No.1 (Brown)                          Convex portion of cam
   Clutch cam
                          Disulphide molybdenum alloyed grease            Whole of groove portion
                                                                          Inner portion where contacts cam shaft
   Swash bearing 10                                                       The surface where contacts helical gear 26
                          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 / 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. 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 / 18
< 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 / 18

       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 / 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. 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 / 18
< 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 / 18
  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 / 18
< 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 / 18

       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 / 18
< 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




                               Brush holder                                                         Tapping s
                                                                                                    crew 4 x 25 : 3 pcs.
                                                  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
Circuit   diagram                                                                                      P 17 /18

                                        Brush holder
        Color index of lead wires                                   Brush holder
     Black
     White                                                                              Connected
     Red                                                                                to field ore
     Blue
                                                  Field
   See-through




                                    2                                  3
                                                   Switch
                                    4                                  1


                                    1   2        M1         C1 C2     M2



          Power supply cord                                         Light circiut
                                            Blue or red




                                                                                   Noise suppressor
                                                                               For some countries, noise
                                                                               suppressor of two lead wire
                                                                               type is used, or noise suppressor
                                                                               is not used.



                                                                                    LED job light
Wiring     diagram                                                                                          P 18 / 18


                                                                              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
                                                                              the illustration.
                                                                              * Pass brush holder's lead wire (blue)
Fix brush holder's                                                              under the field lead wire (black).
lead wire (red) and                                                           * Do not slack brush holder's lead
field lead wire (white)                                                         wire (blue) between brush holder and
with lead holder as per                                                         lead holder.
the illustration.
* 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                                                   Noise suppressor
             the illustration.                                                         Noise suppressor is not
                                                                                       used in some countries
     Fix lead wires which are passed
     through this area, with any of                                                    LED circuit
     these lead holders.
                                                                                       Noise suppressor

                 LED circuit

                                                                                                  Bottom view
                                                                                                  of handle portion

                                                                      LED lead wires
                                                                      (blue or red)


                                    LED
                                                                         Lead wires of power supply cord,
                                    job-light                            and grounding lead wire (see-through)
                                                                      Pass LED lead wires, kead wires of power supply
                                                                      cord and grounding lead wire as illustrated
                                        Fix lead wire (white) of      above.
                                        LED job-light with
                                        lead holder as illustrated.

                                        LED
                                        job-light



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