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HR2020-TE


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T    ECHNICAL INFORMATION
    Model No.                    HR2020, HR2021, HR2022
                                                                                                                                PRODUCT
                                                                                                                                  P 1 / 21

    Description                  20mm (3/4") Rotary Hammer                                                        L

CONCEPT AND MAIN APPLICATIONS
  The above models are 20mm(3/4") version of HR2440 series
                                                                                                                                     H
  rotary hammer. Their performances are much better than competitors
  in both drilling and hammer drilling.
  Specifications for each new model are;                                            W
  HR2020: with variable switch and reverse switch                Dimensions: mm (")
  HR2021: with variable switch, without reverse switch
  HR2022: with single speed switch, without reverse switch    Length (L) 352 (13-7/8)
                                                              Width (W) 72 (2-13/16)
                                                              Height (H) 204 (8)
 Specification
                                                                                   Continuous Rating (W)
      Voltage (V)              Current (A)                  Cycle (Hz)                                                   Max. Output(W)
                                                                                  Input           Output
          110                       6.8                       50 / 60               710              340                       600
          120                       6.1                       50 / 60               710              340                       600
          220                       3.4                       50 / 60               710              340                       600
          230                       3.2                       50 / 60               710              340                       600
          240                       3.1                       50 / 60               710              340                       600
    Model No.                                                            HR2020                       HR2021                      HR2022
    No load speed : (min -1= rpm)                                                       0 - 1,050                                 1,050
    Blows per min : (min -1= bpm).                                                      0 - 4,050                                 4,050
    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                                             20 (3/4)
                       Concrete Core bit                                                      54 (2-1/8)
                                 Diamond Wet                                                  65 (2-9/16)
                                   core    Dry                                                65 (2-9/16)
    Single blow energy ( J )                                                                           2.2
                                                                                                        rotation
   Working mode                                                                         2 modes rotation+percussion
   Variable switch                                    Yes                      Yes                     No
   Clutch for protecting user from lock of bit        Yes                      Yes                     Yes
   Reverse switch                                     Yes                      No                      No
   Protection from electric shock                                    by double insulation
   Cord length : m (ft)                                                 4(13.1)
   Net weight : kg (lbs)                                              2.3 (5.1)
   < Note > When using wet type dia. core, employ HR2020 series models connecting with residual current device.
 Standard equipment
     * Side grip .................................. 1 pc.                * Plastic carrying case ............... 1 pc.
     * Stopper pole (Depth gauge) .... 1 pc.
   < Note > The standard equipment for the tool shown may differ from country to country.
 Optional       accessories
     * SDS plus TCT. bits 5.5mm(7/32") - 20mm(3/4")        * Safety goggle   * Dust extractor attachment
     * Drill chuck assembly                                * Bit grease     * Diamond core bits (wet and dry)
     * Chuck adapter                                       * Blow out bulb       32mm, 38mm, 54mm, 65mm
     * Chuck key S-13                          * Core bits 32mm, 45mm, 54mm * Water protection collar
     * Drill chuck S-13                        * Core bit                   * Various taper shank TCT. bits
     * Holder driver                           * Core bit adapter           * Taper shank adapter
     * Dust cups 5 and 9                       * Rod                        * Cotter
Features   and benefits                                                                 P 2 / 21



                                                                    In-line and ergonomical
                                                                    designed palm fitting grip
                      Superiority to competitors
                      in both drilling and hammer drilling




 Applicable SDS plus type bits




      Quick bit change thanks to
      slide lock type drill chuck



                                         Built in torque limiter




                                        Cord guard is not only
                                        tough but also excellent
                                        in flexibility to protect
                                        cable from disconnection.

     with 2-modes settings,
     rotation   rotation + percussion
Comparison                        of products                                                                 P 3 / 21

                                    Model No.                          MAKITA                 Competitor A
                                Variable speed+Reverse   * HR2020               *HR2410           *A-VR
  Specifi-     Variable peed                             * HR2021               *HR2413           * A-V
  cations      Single peed                                 HR2022                HR2412              A
  Power input : W                                            710                   680              500
  No load                                                * 0 - 1,050            * 0 - 1,050     * 0 - 1,100
        speed: min-1=rpm.                                      1,050                  1,050           1,100
   Blows per                                             * 0 - 4,050            * 0 - 4,900     * 0 - 3,900
         min. : min-1=bpm.                                     4,050                  4,900           3,900
   Bit type                                               SDS-plus               SDS-plus        SDS-plus
           TCT.hammer bit : mm                                20                    24               20
                            (")                              (3/4)                (15/16)           (3/4)
                 Concrete




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




                            Diamond                         **65                     65
                            core : mm       Wet           (2-9/16)                (2-9/16)
                                  (")                         65                     65
                                            Dry
                                                           (2-9/16)               (2-9/16)
                            Steel : mm                        13                     13              10
                                    (")                      (1/2)                  (1/2)           (3/8)
                            Wood : mm                         32                     32              30
                                    (")                     (1-1/4)                (1-1/4)        (1-3/16)
   Single blow energy : J                                   2.2                    2.0              1.5
  Working mode                                           2 Modes                2 Modes          2 Modes
  R     : Rotation                                          R                      R                R
  R + P : Rotation+Percussion                              R+P                    R+P              R+P
 Vibration    Instruction manual                             9                      8               11
    : m / s2 Measured by us                                  9                     7.8              5.2
 Noise      Instruction manual                              99                    103              101
    : dB(A)                    Measured by us               99                    103              99
   Protection from                                       by double              by double       by double
   electric shock                                        insulation             insulation      insulation
   Cord length : m (ft)                                   4.0 (13.1)             2.5 (8.2)       4.0 (13.1)
                            Length : mm                     352                    371             332
    Dimensions




                                     (")                  (13-7/8)               (14-5/8)        (13-1/8)
                            Width : mm                      72                     70               77
                                    (")                  (2-13/16)               (2-3/4)            (3)
                            Height : mm                     204                    197             208
                                     (")                    (8)                  (7-3/4)         (8-3/16)

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



         Diamond Core : mm ( " ) ; When using wet type dia core, employ HR2020 series model connecting
                                   with residual current device.
Comparison      of products                                                                                   P 4 / 21
 Numbers in graph below are relative values when setting Model A-VR 's capacity as 100.
 Testing conditions in concrete
 Material : Concrete with pressure strength, 350kg/cm2                                                  80 N
 Pressure added to the products : 80 N                            Concrete
                                                                  350kg/cm2
 Working mode : Rotation + Percussion


                           Bit diameter : 6.5mm                                         Bit diameter : 8.5mm
 MAKITA                                                       MAKITA
 HR2020                     120                               HR2020                      140
 (HR2021)                                                     (HR2021)
 Competitor A                                                Competitor A
 A-VR                       100                              A-VR                       100

 For reference only                                           For reference only
 MAKITA                     120                               MAKITA                    175
 HR2410                                                       HR2410
                      0    50   100 150 200 250 300                                0   50   100 150 200 250 300


                           Bit diameter : 12..5mm                                       Bit diameter : 20mm
 MAKITA                                                       MAKITA
 HR2020                     150                               HR2020                      180
 (HR2021)                                                     (HR2021)
 Competitor A               100                              Competitor A               100
 A-VR                                                        A-VR
 For reference only                                           For reference only
 MAKITA                      180                              MAKITA                    265
 HR2410                                                       HR2410
                      0    50   100 150 200 250 300                                0   50   100 150 200 250 300




                                                         60mm (2-3/8")
 Testing conditions in wood

 Material : Douglas fir, 60mm (2-3/8") in thickness
 Pressure added to the products : 80 N
 Working mode : Rotation only



                          Auger bit diameter : 24mm                                    Auger bit diameter : 32mm
 MAKITA                                                       MAKITA
 HR2020                     110                               HR2020                    100
 (HR2021)                                                     (HR2021)
 Competitor A                                                Competitor A
                            100                                                         100
 A-VR                                                        A-VR
 For reference only                                           For reference only
 MAKITA                     115                               MAKITA                    125
 HR2410                                                       HR2410
                      0    50   100 150 200 250 300                                0   50   100 150 200 250 300
Repair                                                                                                                P 5 / 21
< 1 > Lubrication
     Apply the following MAKITA grease to protect parts and product from unusual abrasion.
      * Grease RA No.1(Brown) to the portions marked with black triangle
      * Grease FA No.2 to the portions marked with gray triangle

               Gear housing
 Cap 35                                         Needle baring




        O ring 17

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

          Spur gear 51




                                                                                                            Helical gear 26
                                     Clutch cam                          Swash bearing
                                                        Spur gear 10


   Cap 35                Grease RA No.1 (Brown)                          Inner lip of bit inserting side
                                                                         Inner portion where the mechanical parts are installed.
   Gear housing          Grease RA No.1 (Brown) : 60g
                                                                         Groove for O ring 17 assembling portion
   Needle bearing        Grease RA No.1 (Brown)                          Inner ring
   Change lever          Grease RA No.1 (Brown)                          Top of the pins
   O ring 17             Grease RA No.1 (Brown)                          Whole part
                                                                         Inner portion where 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

   Spur gear 10          Grease FA No.2                                  Spline 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 RA No.1 (Brown)                          Whole of teeth portion
  Repair                                                                                                                  P 6 / 21
< 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 / 21

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



                               Cap




                                                                                                        Fig. 2A

                                                                                   Apply grease to the pin, before assembling.

                                Approach first from this side.

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

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

                            Brush holder                                     Motor housing



   Brush holder                            Carbon brush


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

                                            No.1R269 "Bearing extractor (small)"

                                                                                                      Fig. 3C
                                                                                                                        P 8 / 21
 Repair
< 7> Disassembling tool holder section
     1. Disassemble change lever from gear housing as mentioned in < 4 > Disassembling change lever at page 7.
     2. Separate gear housing from motor housing as illustrated in Fig. 3 and Fig. 3A. And disassemble armature
        as illustrated in Fig. 3B at page 7.
     3. Disassemble inner housing from gear housing as illustrated in Fig. 4.
     4. Separate tool holder section from inner housing as illustrated in Fig. 4A. Pay attention, not to lose flat washer 28,
        when separating tool holder section.
                                                                                 Tool holder
                                                                                 section


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


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

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

                   No. 1R306 Ring spring                         Ring spring 28
                             extractor




                                Round bars
                                for arbor

                                                               Washer 30



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

                             Compression
                             spring 31
                                       Spur gear 51
                     Washer 30

                                                                                      Fig. 4E


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

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


                              O ring case                              O ring case

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



                                            Cap 35 side                                                     Inner housing side




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



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

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



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



                                            Fig. 5B
  Repair                                                                                                           P 10 / 21
       4. Insert "No.1R236 Round bar for arbor" and push ring spring 28 as deep as possible to the inner housing side
          by striking the round bar for arbor as illustrated in Fig. 5D.
       5. Pick up ring spring 28 with plier and take off it from tool holder as illustrated in Fig. 5E.
       6. Disassemble the following parts from tool holder as illustrated in Fig. 5F.
             * O ring case equipped with O ring 9
             * O ring 15
             * Ring 9
             * Impact bolt equipped with O ring 12
       7. Clean the inside of tool holder completely.

                                                                                                  Ring spring 28




                                                                                Fig. 5E




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




                                                                                Fig. 5F
                                          Fig. 5D.


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




                                          Fig. 6
   Repair                                                                                                              P 11 / 21
< 11 > Disassembling swash bearing
      1. Referring to Fig. 3, 3A, 3B at page 7, disassemble the product.
         And separate inner housing together with tool holder section and swash bearing section from gear housing as
         illustrated in Fig. 8 and Fig. 8A. Ball baring 606ZZ can remain in gear housing in this stage. If so, refer to Fig. 8D.
      2. Separate tool holder section from inner housing as illustrated in Fig. 8A.
                                                                                      Tool holder
                                                                                      section


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


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

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

                       Hex socket head bolts M4x12




                                                                 Fig. 8B

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




                                                           Fig. 8C


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

                Ball bearing 606ZZ



                                                                           Fig. 8D
Repair                                                                                                           P 12 / 21
  6. Swash bearing section can not be disassembled in one action by pressing cam shaft with arbor press, because
     Take the following steps for disassembling them.
       1. Disassemble ring 8 by pressing with arbor press as illustrated in Fig. 9.
       2. Disassemble ball bearing 608ZZ with bearing extractor as illustrated in Fig. 9A.
       3. Disassemble flat washer 8 and bearing retainer as illustrated in Fig. 9B.
       4. Disassemble helical gear 26 by pressing with arbor press as illustrated in Fig. 9C.


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

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




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

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



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


                                          Fig. 9D                                      Fig. 9E
  Repair                                                                                                            P 13 / 21

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

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

                               Compression
     Spur gear 10              spring 12

                               Flat washer 12
                                                                           Bearing setting pipe
     Ball bearing
     606ZZ



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




                                    Ball bearing 608ZZ
                                                                          Ring 8
                                    Flat washer 8
                                    Bearing retainer




                                    No. 1R034
                                    Bearing setting plate

                    Fig. 10C                                          Fig. 10D
 Repair                                                                                                         P 14 / 21

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



                                      Flat washer 12

                                 Piston cylinder
                           Piston joint
                     Flat washer 12


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

                                  Piston cylinder




                                                                                                 Fig. 11C




                                Fig. 11B




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




                                                              Needle bearing
                                                              complete


                                                         Fig. 12
  Repair                                                                                                           P 15 / 21
< 15 > Assembling needle bearing complete
       1. Apply MAKITA grease RA No.1 to the inside of needle baring complete.
       2. Putting needle bearing complete on No.1R165 "Ring spring setting tool B" press gear housing onto the needle
          bearing complete with arbor press as illustrated in Fig. 13.


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

                 Back side                                Gear housing                     Back side
                                                                                                            Needle bearing
                                                                                                            complete.

                                                              Belly side

             Needle bearing
             complete

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

                                             Fig. 13.

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



                                                        Brush holder



                                                                           Switch
                                                                                    Noise suppressor
                              Brush holder
                                                                                                       Handle
                                                                                                       cover



                                             Cord guard                                     Tapping s
                                                                                            crew 4 x 25 : 3 pcs.

                                     Power supply cord
                                                   Strain relief
                                                                       Tapping screw 4x18 : 2 pcs.

                                                   Fig. 14
Circuit  diagram                                                                                           P 16 / 21
Model HR2020 with reverse switch,
without choke coil for radio interference suppression
                                     Brush holder                       Brush holder
     Color index of lead wires
  Black
  White
  Red
  Blue
See-through                                                                                       Connected
                                                                                                  to field ore




                                      2                                     3
                                                    Switch
                                     4                                      1


                                     1      2       M1       C1 C2         M2



                                                                        Noise suppressor
       Power supply cord

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

Model HR2020 for 230- 240V with reverse switch
and choke coil for radio interference suppression
     Color index of lead wires
  Black                              Choke coil
  White                                                                 Brush holder
  Red
                                                                                            Connected
  Blue
                                                                                            to field ore
  Orange
See-through

                      Brush holder




                                      2                                     3
                                                    Switch
                                     4                                      1


                                     1      2       M1       C1 C2         M2


                                                                            Noise
       Power supply cord                                                    suppressor


                                             For some countries, noise suppressor of two lead wire type is used,
                                             or noise suppressor is not used.
Circuit diagram                                                                                                  P 17 / 21
   Model HR2021, HR2022 without reverse switch,
   without choke coil for radio interference suppression
                                          Brush holder                     Brush holder
      Color index of lead wires
   Black
   White
   Red                                                                                           Connected
   Blue                                                                                          to field ore
 See-through




                                                  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.

   Model HR2021, HR2022 for 230- 240V without reverse switch,
   with choke coil for radio interference suppression
      Color index of lead wires
   Black                                                        Choke coil
   Red
                                                                                                  Connected
   Blue
                                                                        Brush holder              to field ore
 See-through


              Brush holder




                                               Switch


                             1        2       M1         C1 C2        M2


 Power supply cord
                                                                     Noise suppressor
Wiring     diagram                                                                              P 18 / 21
Model HR2020 with reverse switch,
without choke coil for radio interference suppression
                                                                 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 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 / 21
Model HR2020 for 230 - 240V with reverse switch
and choke coil for radio interference suppression

Fix choke coil's lead wires                                  Fix field lead wire (black)
(orange) with lead holder as per                             with lead holder as per
the illustration.                                            the illustration.


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




                                                             Fix brush holder's
                                                             lead wire (blue) and
                                                             field lead wire (white)
                                                             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 (black)                                        under the field lead wire (white).
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 (black).
* 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 brush holder's                         * 2 choke coil's lead wires (orange)
             lead wire (blue) and                       * Noise suppressor's lead wire (see-through)
             field lead wire (white)
             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
Wiring  diagram                                                                                P 20 / 21
 Model HR2021, HR2022 without reverse switch
 and choke coil for radio interference suppression

                                                               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
Wiring   diagram                                                                               P 21 / 21
 Model HR2021, HR2022 without reverse switch,
 with choke coil for radio interference suppression

                                                                Fix field lead wire (black)
Fix choke coil's lead wires (black                              with lead holder as per
and blue) with lead holder as per                               the illustration.
the illustration.

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




                                                                Fix brush holder's
                                                                lead wire (black) and
                                                                brush holder's lead wire (red)
                                                                with lead holder as per
                                                                the illustration.
                                                                * Pass brush holder's lead wire (black)
                                                                  under the brush holder lead wire (red).
Fix brush holder's                                              * Do not slack brush holder's lead
lead wire (red) and field                                         wire (black) between brush holder and
lead wire (black) with lead holder.                               lead holder.
* Pass brush holder's lead wire (red)
  under the field lead wire (black).
* Do not slack brush holder's lead                    Fix the following lead wires with this
  wire (red) between brush holder and                 lead holder.
  lead holder.                                         * Choke coil's lead wire (blue)
                                                       * Field's lead wire (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



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