Makita HR2641 Datasheet

CONCEPT AND MAIN APPLICATIONS

Model HR2641 is a 26mm (1") D-handle combination hammer

developed based on model HR2621 to enhance Operation mode

change lever.

Its main features are:

• Other features except the modification of Operation mode change lever

remain the same as model HR2621.

• 3 modes (Rotation only/ Rotation with hammering/ Hammering only)

• AVT (Anti-Vibration Technology) is equipped to obtain extremely low vibration.

Voltage (V) Current (A) Cycle (Hz) Continuous Rating (W) Max Output (W)

Input Output

110 7.7 50/60 800 370 650

120 8.0 50/60 N/A 370 650

220 3.8 50/60 800 370 650

230 3.7 50/60 800 370 650

240 3.5 50/60 800 370 650

Model No. HR2641

0 - 1,100

0 - 4,500

Shank type Adapted for SDS-PLUS shank bits

Chuck type One-touch sliding chuck

Capacities:

mm (")

Concrete

TCT bit 26 (1)

Core bit 68 (2-11/16)

Diamond core bit 80 (3-1/8)

Steel 13 (1/2)

Wood 32 (1-1/4)

2.4

Operation mode 3 modes

(Rotation only/ Rotation with hammering/ Hammering only)

Variable speed control Yes (by trigger)

Rotation reversing facility Yes

Torque limiter Yes

LED Job light No

Protection from electric shock Double insulation

Power supply cord: m (ft) Europe, North America: 4.0 (13.1), Australia, Brazil: 2.0 (6.6),

Other countries: 2.5 (8.2)

Weight according to

EPTA-Procedure 01/2003*: kg (lbs) 3.1 (6.8)

Dimensions: mm ( " )

Length (L) 422 (16-5/8)

Width (W) 76 (3)

Height (H) 156 (6-1/8)

TECHNICAL INFORMATION

PRODUCT

P 1/ 25

Model No.

Description 26mm (1") Combination Hammer

HR2641

Specification

Impact energy according to EPTA 05/2009: J

(ft.lbs)

No load speed: min.ˉ¹= rpm

Impacts per minute: minˉ¹= ipm

OFFICIAL USE

for ASC & Sales Shop

SDS-PLUS shank TCT hammer drill bits

Taper shank TCT hammer drill bits

Taper shank adaptor

Cotter

Core bits

Center bits

Core bit adaptor

Rod

Grip drills

Grip drill holder

Drill chuck ass'y

Chuck adapter assembly

Drill chuck S13

Chuck key S13

SDS-Plus hammer chuck set

Scraper assembly

Waterproof cover

Quick change drill chuck (keyless)

Dust cups 5 and 9

Hose

Joint 25

Dust cup set

Plastic carrying case

Hammer grease (30g)

Bit grease

Depth gauge

Blow out bulb

Safety goggles

Bull points

Cold chisels

Scaling chisels

Grooving chisels

Standard equipment

Optional accessories

Depth gauge

Dust cup (for some countries only)

Quick change drill chuck (keyless)

Side grip

Carrying case (plastic or aluminum)

Note: The standard equipment may vary by country or model variation.

P 2/ 25

Repair

[1] NECESSARY REPAIRING TOOLS

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

P 3/ 25

Code No. Description Use for

1R003 Retaining ring S pliers ST-2N removing Ring spring 14

1R032

1R034

1R045

1R164 Ring spring setting tool A mounting Oil seal 25 to Gear housing complete

removing Oil seal 25 from Gear housing complete

1R212

1R228

1R232

1R252

1R258

1R269

1R273

1R281

1R369

1R388

Tip for Retaining ring pliers

1/4” Hex. shank bit for M4 removing / assembling M4 Hex socket head bolt

Pipe 30

Round bar for arbor 30-100

V block supporting Gear housing complete when assembling Oil seal 25

Bearing extractor removing Ball bearings 6000LLB, 627DDW

Ring spring 26 setting tool B

Round bar for arbor 7-50

Jig for Spiro lock washer

Ring spring extractor

Piston cylinder

Bearing setting plate 8.2

Bearing setting plate 12.2

Gear extractor (large) removing/ assembling Spiro lock washer 30

removing Ring spring 28

assembling Ring spring 28 to inner groove of Tool holder complete

Note: Prepare another Piston cylinder for repair.

Do not use Piston cylinder once removed from the machine.

removing/ assembling Cup sleeve and Ball bearing 6806LLU from/ to

Gear housing complete

Note: Prepare another Inner housing complete for repair.

Do not use Inner housing complete once removed from the machine.

310345-1

141573-5

assembling Helical gear 26

removing Helical gear 26

1R288 Screwdriver magnetizer removing Brush holder unit and two 3x12 tapping screws

assembling Cup sleeve and Ball bearing 6806LLU to Gear housing

complete

disassembling Helical gear 26

Inner housing complete

Repair

P 4/ 25

(d) Outer periphery that 28 touches

(h)

[2] LUBRICATION

Fig. 1

Item No. Description Amount

Approx. 2 g

a little

Portion to lubricate

129

Pin 6 Portions to be inserted to 80 and 82

Counter weight

Weight holder guide Portion that Inner housing complete touches

Impact bolt A

O ring 17.5

(c)

(d)

(e)

(f)

(g)

(j) (i)

Piston cylinder

Piston joint Grooves

Guide plate Inside that 48 touches

Inner housing

complete

Drum portion

Entire portion

a little

Makita grease RB No.00

Molybdenum desulfide lubricant

Lubricant

Ring 8

Cap 35 Inner groove portion

Gear housing complete

Steel ball 7.0

Tool holder complete

16 Lip portion of Oil seal 25 (the component of 16 )

Entire portion26

Driving flange29 Cam portion that 30 touches

(b) Inside where 46 reciprocates

(a) Periphery that touches 29 and 30

Inside that 80 touches

(a)

(b)

Spur gear 5130 Gear teeth to engage 55

Striker Entire portion44

O ring 9 Entire portion

Approx. 3g

a little

Approx. 3g

Approx. 16g

Swash bearing 10

Flat washer 7

Clutch cam (2 pcs.) Outer groove

(i) Surface that Ring 8 touches

(j) Ball bearing portion

Cam shaft

Spur gear 10

Helical gear 26 Gear teeth to engage Armature gear

O ring 68 Entire portion

Surface that 56 touches

(g) Drum portion to be inserted into 58

(f) Cam portion

Gear teeth

(h) Pole portion to be inserted into 48

Flat washer 3036

Surface that touches Inner housing complete

(e) Portion to be inserted into 56

(Drum portion between groove and Cam end)

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Bit holder section

DISASSEMBLING

ASSEMBLING

(1) Disassemble Bit holder section as drawn in Fig. 2.

Tool holder section can be assembled by reversing the disassembly procedure. Refer to Fig. 2.

Note: • Washer 16, Ring 21, Guide washer and Conical compression spring 21-29 are not reversible, and therefore,

be careful about the direction. See Fig. 3.

• Apply Makita grease No. RB No. 00 to two Steel balls 7.0 to prevent them from falling off.

Refer to Fig. 1 of page 4.

1. Remove Cap 35 with

a slotted screwdriver.

3. Remove Ring spring 15.

4. Remove Flat washer 17

and Chuck cover.

5. Remove two Steel balls 7

while pressing down Ring 21.

6. Ring 21, Guide washer and

Conical compression spring 21-29

are removed from Tool holder.

2. Remove Ring spring 14 using 1R003 with 1R212.

And then, remove Washer 16.

Repair

1R003

1R212

Chuck cover

Fig. 2

Fig. 3

Cap 35 Slotted

screwdriver

Ring spring 14

Washer 16

Face the chamfered portions toward Cap 35.

Cap 35

1R003

1R212

Ring spring 15

Flat washer 17 Steel ball 7 (2pcs.)

Ring 21

Guide

washer

Guide washer

Conical compression

spring 21-29

Conical compression spring 21-29

Steel ball 7.0 (2 pcs.)

Face the projection toward

Conical compression spring 21-29.

Face the small diameter toward

Motor housing.

P 5/ 25

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Change lever

DISASSEMBLING

1. Insert a slotted screwdriver to the notches of Gear housing

and lever it up alternately.

2. Change lever cap, Change lever with Rubber pin 4

and Leaf spring can be removed.

Disassemble Change lever section as drawn in Fig. 4.

Assemble Change lever section as drawn in Fig. 5.

Repair

3. Face the center top of Leaf spring to

Change lever and assemble the hooks

of Leaf spring to the grooves of Gear

housing.

4. Assemble Change lever cap

to Change cover.

Fig. 4

Fig. 5

Change lever capRubber pin 4

Change lever

Leaf spring

Change cover

Pointer

Mark of Rotation with

hammering mode

Rubber pin 4

Change lever

1. Face Pointer to the opposite of the mark of Rotation with hammering

mode and assemble Change lever with Rubber pin 4 to the hole of

Gear housing.

Note: Never connect Plug to

Outlet when the pointer

faces to the opposite of

the mark of Rotation

with hammering mode.

2. Turn Change lever clockwise 90 degrees.

5. Assemble Change lever cover to Gear housing.

6. Make sure that Change lever cap can be shifted to

each operation mode with a click for the range

designated in a black arrows.

Mark of Rotation mode on

Change lever cover will

come here in the step 5.

Change lever

Grooves of

Gear housing

hooks of

Leaf spring

center top of

Leaf spring

notch of

Change lever cap

Change lever cover

ASSEMBLING

P 6/ 25

notch of Gear housing

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Armature

DISASSEMBLING

Remove Armature as drawn in Fig. 6.

Repair

P 7/ 25

2. Remove four 4x30 Tapping screws and then pull off Gear housing complete.

Armature can be removed together with Gear housing complete.

1. After removing Handle cover,

disconnect entirely Brush hoder

and Carbon brush from commutator

of Armature.

3. Remove Armature by pulling it off by hand.

4. Remove Ball bearing 6000LLB together with Sleeve 9

using 1R269. And then remove Flat washer 10.

5. Remove Labyrinth rubber ring 19, and then,

remove Ball bearing 627DDW using 1R269.

6. Remove Insulation washer.

4x30 Tapping screw

( 4 pcs.)

O ring 25

Note: Pull off Armature by hand. It is because O ring 25 is used as

a support for Ball bearing 6000LLB and striking the edge of

Gear housing comlete is not effective for removing.

Fig. 6

Bruch holder

Handle cover

Insulation washer

Ball bearing

627DDW

Labyrinth

rubber ring 19

Ball bearing

6000LLB

Sleeve 9

1R269

Flat washer 10

1R269

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Armature (cont.)

ASSEMBLING

Assemble by reversing the disassembly procedures. Refer to the notes shown in Figs. 7 and 8.

Repair

Fig. 7 Fig. 8

Note: Be sure to put Wave washer 15 into bearing room

in Motor housing.

P 8/ 25

Flat washer 10

Note: Do not fail to assemble Flat washer 10 before

setting Ball beating 6000LLB in place.

Wave washer 15

Ball bearing 6000LLB

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Torque limiter section

DISASSEMBLING

Compression

spring 4

1. Tap Tool holder complete with a plastic hammer

while holding Gear housing complete by hand.

2. Disassemble Change plate section.

It consists of Change plate A, Change plate B

and Compression spring 5.

3. Stop ring U-6 and Flat washer 7 interferes with pulling out Tool holder section.

So, disassemble Stop ring U-6 with long nose pliers and then remove Flat washer 7.

Lock plate

Note: These parts are easy to fall out of

Gear housing complete, and therefore,

be careful not to lose them.

Note: Change plate section can be

easily removed by hand

because it is just fit to the slit

of Clutch cam.

Repair

(1) Disassemble Bit holder section as drawn in Fig. 2 of page 5.

(2) Disassemble Change lever section as drawn in Fig. 4 of page 6.

(3) Disconnecting Carbon brush from Commutator of Armature, pull off Armature from Gear housing complete as

drawn in Fig. 6 of page 7 and Fig. 7 of page 8.

(4) Tap Tool holder with a plastic hammer. Inner housing section comes out from Gear housing complete.

Then, remove Tool holder section from Inner housing complete. (Fig. 9)

Fig. 9

Change plate section

Stop ring U-6

4. Tool holder section

can be pulled out.

Flat washer 7Long nose pliers

Flat washer 30

on Inner

housing

complete side

Tool holder

section

P 9/ 25

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Torque limiter section (cont.)

DISASSEMBLING

ASSEMBLING

1. Set 1R369 to Tool holder complete.

Hook the 1R369 with 1R045, press down the 1R369 with

1R045 until Spiro lock washer appears.

2. Remove Spiro lock washer 30 by levering it up with

a thin slotted screwdriver from the spiral end along

the spiral direction.

3. Remove Flat washer 30 and Compression spring 31. 4. Remove Spur gear 51 and Driving flange.

Repair

(5) The components of Torque limiter mechanism is secured with Spiro lock washer 30. Therefore, they can be

disassembled from Tool holder complete by removing Spiro lock washer 30. (Fig. 10)

Fig. 10

Spiro lock

washer 30

Spiro lock washer 30

removed by the step 2

Flat washer 30 on

Compression spring 31 side

Note: Be careful not to lose four Steel balls 3

when Driving flange is removed from

Tool holder complete.

ﾊﾞ

Tool holder complete

Assemble by reversing the disassembly procedure.

Note: Do not fail to set two Flat washers 30 in place. The one is placed between Compression spring 31 and Spiro lock

washer 31 as drawn in Fig. 10, the other is placed on Inner housing complete as drawn in Fig. 9 of page 9.

Be sure to apply Makita grease RB No. 00 according to the instruction in Fig. 1 of page 4.

1R369

1R045

Compression

spring 31

Spur gear 51

Driving flange

5. Remove four Steel balls 3.

Steel ball 3

(4 pcs.)

thin slotted screwdriver

P 10/ 25

[3] DISASSEMBLY/ASSEMBLY

[3]-5. Impact bolt

DISASSEMBLING

Repair

Fig. 13

Fig. 12

1. Push out Striker with a rod or screwdriver

if it is left in Tool holder complete.

Striker

Slotted

screwdriver

1R388

Side hole

Vise

Rod

Screwdriver

O-ring case B

3. If the gap of Ring spring 28 is located to the hole of Tool holder complete, move the gap completely to outside of

hole by pushing an end of Ring spring 28 with a slotted screwdriver.

2. Insert 1R388 into Tool holde complete and hold Tool holder

complete in Vise.

Then press 1R388 with vise to reserve the allowance between

O-ring case B and Ring spring 28.

Ring spring 28

O-ring case BRing spring 28

Ring spring 28

O-ring case B 1R388

Ring spring 28

1R388

4. Move Ring spring 28 from the inner groove of Tool holder complete with a slotted screwdriver and a plastic

hammer through the side holes of Tool holder complete. Ring spring 28 is completely out of the inner groove of

Tool holder complete.

Ring spring 28

(1) Disassemble Bit holder section as drawn in Fig. 2 of page 5.

(2) Disassemble Tool holder section. Refer to Fig. 9 of page 9.

Ring spring 28 prevents O-ring case B from sliding toward Inner housing complete side, and their allowance is

too tight to apply tools for removing Ring spring 28 as drawn in Fig. 12.

therefore, remove Ring spring 28 from the inner groove of Tool holder complete as drawn in Fig. 13.

P 11/ 25

Crross section viewed from upper

Crross section of Tool holder complete

Crross section viewed from side

Crross section viewed from upper

[3] DISASSEMBLY/ASSEMBLY

[3]-5. Impact bolt (cont)

DISASSEMBLING

Repair

Fig. 14

Fig. 15

Note: If Ring spring 28 has a damage, deformation or wear,

replace it with a new one.

Washer 10

Impact bolt A

Thin end

1. Mount Sleeve 9B, Washer 10, Compression spring 20

and O ring case B with O ring 9 to Impact bolt A.

Note: Face the thin end of Impact bolt A toward Bit holder

side as drawn below.

2. Put the assembled Impact bolt section into

Tool holder complete by pushing them until

they stops.

Side hole

(2) Assemble Tool holder section to Inner housing complete.

Note: Be careful to mount Flat washer 30 to Inner housing complete in advance. See Fig. 9 of page 9.

(1) Assemble Impact bolt section as drawn in Fig. 15.

2. The Push out the parts of Impact driver section.

(3) Disassemble Impact bolt section as drawn in Fig. 14.

ASSEMBLING

gap of

Ring spring 28

O-ring case B

O ring 9

Compression

spring 20

P 12/ 25

3. Put Ring spring 28 into Tool holder complete while

preventing the gap from coming to any holes of

Tool holder complete.

1. Insert a rod or screwdriver into Tool holder

complete from bit installation side, then tap it

with a plastic hammer. Ring spring 28

Compression

spring 20

Impact bolt A

Washer 10

Sleeve 9B

O-ring case B

Sleeve 9B

6. O ring 9 can be removed from O-ring case B.

O-ring case B

O ring 9

Rod or screwdriver

2. The following parts are pushed out from Tool holder complete.

4. Push Ring spring 28 with Piston cylinder of a repairing

tool until it stops.

Piston cylinder

of a repairing tool

Note: Do not use Piston cylinder

once removed from the

machine.

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section

DISASSEMBLING

Repair

(1) Disassemble Bit holder section as drawn in Fig. 2 of page 5.

(2) Disassemble Change lever section as drawn in Fig. 4 of page 6.

(3) Disconnect Carbon brushes from Commutator of Armature, and then pull out Armature from Gear housing complete

as drawn in Fig. 6 of page 7 and Fig. 7 of page 8.

(4) Tap Tool holder complete with a plastic hammer. Inner housing section comes out from Gear housing complete as

drawn in Fig. 9 of page 9.

(5) Remove Tool holder section from Inner housing complete as drawn in Fig. 16.

4. Stop ring U-6 and Flat washer 7 interferes with pulling out Tool holder

section. Therefore, disassemble Stop ring U-6 with long nose pliers.

And then, remove Flat washer 7.

Stop ring U-6

1. Remove two M4x12 Hex socket head bolts and Plate.

Note: M4x12 Hex socket head bolts are threadlocker type,

and therefore, apply adhesive to the threads for

assembling with once removed bolts.

3. Remove Counter weight.

And then, remove Holder guide.

2. Remove Pin 6.

5. Tool holder section

can be pulled out.

Flat washer 7

Flat washer 30

Tool holder

section

Plate Pin 6

Holder guide Counter weight

Fig. 16

P 13/25

M4x12 Hex socket head bolt

(2 pcs./threadlocker type)

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section (cont.)

DISASSEMBLING

Repair

(6) Disassemble Cam shaft portion as drawn in Fig. 17. Then check O Ring 17.5 as drawn in Fig. 18.

(7) Disassemble Swash bearing section, and remove Ball bearing 606ZZ using once removed Swash bearing section

as drawn in Fig. 19.

Already removed in the step shown in

Fig. 28 of page 18

Spur gear 10

Clutch cam

Cam shaft

1. Remove two M4x16

Hex socket head bolts.

Note: M4x16 Hex socket head bolts are thread locker type, and therefore, apply adhesive to the threads when

once removed.

4. Insert Cam shaft of Swash bearing

section into Ball bearing 606ZZ in

Gear housing complete.

5. Tap the edge of Gear housing complete with a plastic hammer

while tilting Cam shaft toward a direction designated with arrows.

Ball bearing 606ZZ removed together with Cam shaft.

2. Bring Piston cylinder to rear dead

point (dead point on Inner housing

complete side) by turning Cam shaft.

3. Pull out the pin portion of Swash bearing

from Piston joint of Piston cylinder.

Swash bearing section is removed.

Fig. 17 Fig. 18

Fig. 19

O Ring 17.5

Try inserting Striker into Piston cylinder and pulling it out.

When you have something resistant through the process and you can

hear a removal sound, O ring 17.5 on Striker is in order.

If not, the O ring has a damage/ wear. Replace it with a new one.

Striker

Piston cylinder

Ball bearing 606ZZ

Gear housing

complete

Cam shaft

Pin portion of

Swash bearing

Ball bearing 606ZZ

Cam shaft

P 14/ 25

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section (cont.)

DISASSEMBLING

(8) The removed Swash bearing section is disassembled as drawn in Fig. 20.

(9) Piston cylinder can be disassemble after removing Swash bearing section as drawn in Fig. 21.

Fig. 20

Fig. 21

1R034

1R281

Cam shaft

Helical gear 26

Bearing retainer

Flat washer 8

Bearing box

Swash bearing 10

Ball bearing 608ZZ

Piston cylinder Piston pin and Guide plate are removed from Piston cylinder.

Compression spring 14

4. Put Swash bearing section on 1R034, and then remove

Cam shaft with Arbor press.

5. Swash bearing section is disassembled as follows.

Piston pin Guide plate

ASSEMBLING

This Swash bearing has

pin to fit Counter weight.

Swash bearings for HR2641 with AVT Swash bearings for HR2630T without AVT

Note: The Swash bearing for HR2641 (with AVT) is different from that for HR2630T (without AVT) as drawn in Fig. 22.

Be careful not to mix them up.

Fig. 22

P 15/ 25

Repair

ASSEMBLING

(1) Assemble Swash bearing section as drawn in Fig. 23.

Fig. 24

1. Stand Compression spring 14 on

Flat washer 14, and then assemble

them to Inner housing complete.

2. Put Piston cylinder on

Compression spring 14.

3. Press Piston cylinder until it stops.

While keeping the pressure to Piston cylinder,

insert the pin of Swash bearing 10 into the hole of

Piston joint.

And then fit Bearing box to Inner housing complete.

Piston cylinder

Note: If Helical gear 26 can be seen through the opening of Bearing box

as designated in a circle, face the opening toward Swash bearing 10

as the above picture.

Compression spring 14

(2) Make sure that Flat washer 14 is mounted to Inner housing complete before assembling Compression spring 14 to

Piston cylinder. After that, assemble Swash bearing 10 section to Inner housing complete. See Fig. 24.

Flat washer 14

Pin Portion that Helical gear teeth

cannot be seen

Pin of

Swash

bearing 10

Piston

cylinder

1. Pressfit Ball bearing

608ZZ to Bearing box.

2. Stand Cam shaft on 1R032, and then pass the Cam shaft through Swash bearing 10,

Flat washer 8, Bearing box, Bearing retainer and Helical gear 26.

Note: Face this projection of Helical gear 26 toward Bearing retainer.

3. Receive the stepped portion of Cam shaft around

the hole of 1R032, and align the hole of 1R034 to

Cam shaft end.

Then pressfit Helical gear 26 to Cam shaft carefully

until Helical gear 26 stops.

Note: Cam shaft end must be protruded a little from

the top of Helical gear 26. Therefore,

1R034 is necessary.

1R034

Cam shaft

stepped

portion

Bearing box

Flat washer 8

Helical gear 26

Side view of

Helical gear 26 Bearing retainer

Swash bearing 10

1R032

Ball bearing

608ZZ

Fig. 23

P 16/ 25

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section

Repair

Cam shaft end protruded

from the top of Helical

gear 26

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section

ASSEMBLING

Fig. 25

(3) Refer to Fig. 25.

Note: Apply grease according to Fig. 1 of page 4.

1. Tighten Swash bearing section with

two M4x16 Hex socket head bolts.

Note: Apply ThreeBond 1342 or

Loctite 243 to the thread of

the bolts.

2. Mount Striker into Piston cylinder.

Note: Try inserting Striker into Piston cylinder

and pulling it out in advance as drawn in

Fig. 18 of page 14.

Flat washer 30

Tool holder section

O ring 17.5

Striker

Pliers

3. Mount two Clutch cams to

Cam shaft.

Note: They have same shape.

However, one must be

engaged with Spur gear 10.

The other must be engaged

with the gear teeth of

cam shaft.

4. Make sure that Flat washer 30 is put on Inner housing

complete in advance.

And then set Tool holder section in place, after that,

Assemble Flat washer 7 to Cam shaft and secure it by

fitting Stop ring EXT U-6 into the groove of Cam shaft.

6. Insert Pin 6 into Inner housing complete

through Counter weight and Weight holder.

7. Mount Plate as a stopper for Pin 6, and tighten it with

two M4x12 Hex socket head bolts.

Note: ApplyLoctite 243 or ThreeBond 1342

to the threads of the bolts in advance.

Spur gear 10

Gear teeth of

Cam shaft

Clutch cam

(2 pcs.)

Flat washer 7

Stop ring EXT U-6

Weight holder

hole

Counter weight

Pin 6

Plate

5. Assemble Counter weight and two Weight holders

so that there holes align the projection of Swash

bearing/ the holes of Inner housing complete.

Spur gear 10

Swash bearing 10

P 17/ 25

Repair

M4x16 Hex

socket head

bolt (2 pcs.)

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section (cont.)

ASSEMBLING

Fig. 26

Fig. 27

Fig. 28

(4) Assemble Change plate B to Change plate A as drawn in Fig. 26.

(5) Put the tab portion onto the edge of Inner housing complete while fitting Change plates to cam grooves as drawn in

Fig. 27.

(6) Assemble Ball bearing 606ZZ, Compression spring 4 and Lock plate to Gear housing complete as drawn in Fig. 28.

Compression spring 5

Fit these engaging plates to Cam grooves and

mount Change plate section to Clutch cam.

Change plate A

Change plate B

Cam groove

1. Assemble Ball bearing 606ZZ into the bearing room in Gear housing complete.

2. Insert Compression spring 4 into the hole of Gear housing complete.

3. Put Lock plate on Compression spring 4.

Opposite side view

TabRib

Tab

Rib

1. Assemble one end of

Compression spring 5 to

the rib of Change plate A.

2. Pass the tabs of Change plate A through the holes of Change plate B, and assemble

Change plate A to Change plate B by inserting the another end of Compression

spring 5 to the rib of Change plate B.

Ball bearing

606ZZ

Compression

spring 4

Lock plate

Put this Tab portion onto the edge of

Inner housing complete.

P 18/ 25

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-6. Swash bearing 10, Inner housing section (cont.)

ASSEMBLING

Fig. 31

Lock plate

Change plate

(7) Assemble Gear housing complete to Inner housing complete carefully in vertical direction as drawn in Fig. 31.

(8) Assemble Armature to Motor housing. Refer to Fig. 9 of page 9.

(9) Assemble Change lever as drawn in Fig. 6 of page 7.

(10) Assemble Bit holder section. Refer to Fig. 4 of page 6.

Hold Lock plate by finger

through the hole of Change lever.

Lock plate is easily fallen off from Gear housing

complete as drawn below, and therefore, support

Lock plate by finger through the hole of

Change lever insertion as the right picture.

hole of Change

lever insertion.

P 19/ 25

Repair

Be careful not to touch the edge of

Gear housing complete with Change plates.

Otherwise, they will be easily fallen off

from Clutch cam.

[3] DISASSEMBLY/ASSEMBLY

[3]-7. The components for Gear housing complete

DISASSEMBLING

Oil seal 25, Cup sleeve, Ball bearing 6806LLB are factory assembled in Gear housing complete. These parts can be

replaced from Gear housing complete individually with new ones.

(1) Disassemble Bit holder section as drawn in Fig. 3 of page 6.

(2) Disassemble Change lever section as drawn in Fig. 5 of page 7.

(3) Disconnect Carbon brushes from the commutator of Armature, and then pull off Armature from Gear housing complete

as drawn in Fig. 7 of page 8 and Fig. 8 of page 9.

(4) Tap Tool holder with a plastic hammer. Inner housing section comes out from Gear housing complete.

Remove Tool holder section from Inner housing complete as drawn in Fig. 10 of page 10.

(5) Disassemble Inner housing complete as drawn in Fig. 17 of page 15.and Figs. 18, 19 and 20 of page 16.

(6) Remove Oil seal 25, Cup sleeve, Ball bearing 6806LLB from Gear housing as drawn in Fig. 32.

1. It is difficult to stand Gear housing complete as it is, because the edge is

not flat. Therefore, use Inner housing complete of a repairing tool to

stand Gear housing complete vertically.

Note: Do not use Inner housing complete once removed from the machine.

1R258

1R252

3. Press down Oil seal 25

carefully with 1R252.

4. Oil seal 25, Cup sleeve with

Ball bearing 6806LLU are removed.

5. Remove Ball bearing

6806LLU from Cup

sleeve.

2. Put Inner housing complete onto 1R258

as drawn below so as

not to put Pin on

1R258.

Oil seal 25

Cup sleeve

Ball bearing

6806LLU

Ball bearing

6806LLU

Cup sleeve

Fig. 32

P 20/ 25

Repair

Inner housing complete of

a repairing tool

Makita HR2641 Datasheet

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