Makita HR2440F Handbuch

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output Max. Output(W)

Rotary Hammer 24mm (15/16")

The above models is the advanced version of HR2440,

equipped with LED job light for lighting up the drilling point.

HR2440F

110

120

220

230

240

* Side grip .................................. 1 pc. * Plastic carrying case ............... 1 pc.

* Stopper pole (Depth gauge) .... 1 pc.

7.5

6.7

3.7

3.6

3.4

50 / 60

780

370

650

Model No.

Description

PRODUCT

Current (A)

TECHNICAL INFORMATION

CONCEPT AND MAIN APPLICATIONS

Specification

Standard equipment

Optional accessories

< Note > The standard equipment for the tool shown may differ from country to country.

P 1 / 14

Dimensions : mm ( " )

Width ( W )

Height ( H )

Length ( L ) 352 (13-7/8)

212 (8-3/8)

72 (2-13/16)

* SDS plus TCT. bits 5.5mm(7/32") - 24mm)15/16") * Safety goggle * Dust extractor attachment

* Drill chuck assembly * Bit grease * Diamond core bits (wet and dry)

* Chuck adapter * Blow out bulb 32mm, 38mm, 54mm, 65mm

* Chuck key S-13 * Core bits 32mm, 45mm, 54mm * Water protection collar

* Drill chuck S-13 * Core bit * Various taper shank TCT. bits

* Holder driver * Core bit adapter * Taper shank adapter

* Dust cups 5 and 9 * Rod * Cotter

Model No.

No load speed : (min -1= rpm)

Blows per min : (min -1= bpm).

Type of bit shank

Drilling

capacity : mm ( " )

Steel

Wood

Concrete TCT. hammer bit

Core bit Wet

Dry

Diamond

core

Single blow energy ( J )

Working mode

Variable switch

Reverse switch

Clutch for protecting user from lock of bit

Cord length : m (ft)

Net weight : kg (lbs)

< Note > When using wet type dia. core, employ HR2440 series models connecting with residual current device.

Protection from electric shock

rotation

rotation+percussion

SDS - plus

0 - 1,100

0 - 4,500

13 (1/2)

32 (1-1/4)

24 (15/16) 25 (1) for North America

54 (2-1/8)

65 (2-9/16)

2.7

Yes

by double insulation

4(13.1) 2.5(8.2) for Asia 2.0(6.6) for Australia

2.3 (5.1)

Chuck ability 10 (3/8)

2 modes

HR2440F

LED job-light

Repair P 2 / 14

< 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

Cap 35

Change lever

Spur gear 51

Piston cylinder

Gear housing Needle baring

O ring 17

O ring 68

Piston joint Inner housing

Helical gear 26

Spur gear 10

Clutch cam Swash bearing

Tool holder

Steel ball 7.0

Change lever

O ring 17

Piston cylinder

O ring 68

Inner housing

Helical gear 26

Spur gear 10

Swash bearing 10

Tool holder

Steel ball 7.0

Cap 35 Inner lip of bit inserting side

Inner ring

Inner portion where tool holder contacts

Convex portion of cam

Inner portion where piston cylinder contacts

The portion where inner housing contacts

Inner portion where striker contacts

The portion where piston joint is assembled

Inner portion where tool holder contacts

The groove where O ring 68 is assembled

Inner portion where cam shaft contacts

The surface where helical gear 26 contacts

The portion where balls are installed

Convex portion of cam

Spline portion

Top of the pins

Whole part

Inner portion where the mechanical parts are installed.

Groove for O ring 17 assembling portion

Spur gear 51

Gear housing

Needle bearing

Grease RA No.1 (Brown)

Grease FA No.2

Grease RA No.1 (Brown) : 60g

Grease FA No.2

Grease RA No.1 (Brown) Whole of teeth portion

Repair P 3 / 14

< 2 > Disassembling chuck section

1. Slide chuck cover in the direction of gear housing, and pull out cap 35 by turning. See Fig. 1.

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.

2. Take off ring spring 19. Then, the following parts can be disassembled from tool holder. See Fig. 1A.

* Chuck cover

* Ring 21

Fig. 1 Fig. 1A Fig. 1B

Cap 35

Chuck cover

Ring spring 19

Chuck cover

Ring 21

Steel ball 7.0

Gear housing

Guide washer

Conical compression

spring 21-29

Tool holder

< 3 > Assembling chuck section

1. Apply grease to steel ball 7.0 and cap 35 referring to < 1 > Lubrication at page 2.

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.

< Note in assembling >

A. Pay attention to the assembling direction

of conical compression spring 21-29. Cap 35 side

The small portion : Gear housing side

The large portion : Cap 35 side

Gear housing side

Conical compression

spring 21-29

B. The cut portion of ring spring 19 has to come

to the opposite side of the flat portion of

tool holder.

The cut portion

of ring spring 19

The flat portion of

tool holder.

Repair P 4 / 14

< 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.

< 5 > Assembling change lever

1. Apply grease RA No.1 (Brown) to the top of change lever's pin. See Fig. 2B.

Fig. 2

Fig. 2A

Fig. 2B

Approach first from this side.

Apply grease to the pin, before assembling.

Cap

Change lever

< 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.

Fig. 3 Fig. 3A

Fig. 3C

Fig. 4B

Carbon brush

Handle

cover

Tapping s

crew 4 x 25 : 3 pcs.

Tapping s

crew 4 x 45 : 4 pcs.

Brush holder

Gear housing

Motor housing

Gear housing

Inner housing

Plastic hammer

No.1R269 "Bearing extractor (small)"

Ball bearing

Armature

Fig. 3B

Inner housing

Plastic hammer

Repair P 5 / 14

< 7> Disassembling tool holder section

1. Disassemble change lever from gear housing as mentioned in < 4 > Disassembling change lever at page 4.

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 4.

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.

Plastic hammer

Fig. 4 Fig. 4A

Swash bearing

section

Swash bearing

section

Tool holder

section

Tool holder

section

Flat washer 28

Inner housing

Piston cylinder

Washer 30

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.

Fig. 4B

Fig. 4E

Fig. 4C Fig. 4D

Washer 30 Spur gear 51

Compression

spring 31

Washer 30

Round bars

for arbor

Ring spring 28

Retaining ring

plier

Retaining ring

plier

No. 1R306 Ring spring

extractor

< 8 > Assembling tool holder section

1. Apply grease to spur gear 51 and tool holder referring to < 1 > Lubrication at page 2.

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 5.

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 6 / 14

< 9 > Disassembling impact bolt

1. Referring to "< 7 > Disassembling tool holder section" at page 5, 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.

Cap 35 side Inner housing side

Ring spring 28 showing its

cut portion Ring spring

Push the cut portion to

the out side of the hole.

Push out ring spring 28 from

the inner groove.

O ring case O ring case

Fig. 5 Fig. 5A

Inner

housing side

Inner

housing side

Cap 35 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.

Inner

housing side

Cap 35 side

O ring case

Inner groove of

tool holder

Ring spring 28

off from inner groove

Fig. 5C

Vise

No.1R038

Armature holder

Fig. 5B

Repair P 7 / 14

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.

Fig. 5D.

Fig. 5E

Ring spring 28

Fig. 5F

O ring case equipped

with O ring 9

O ring 15

Ring 9

Impact bolt equipped

with O ring 12

< 10 > Assembling impact bolt

1. Apply grease to the O rings referring to < 1 > Lubrication at page 2

* 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.

Fig. 6

O ring case

O ring 9

O ring 15

O ring 12

Ring spring 28

Ring 9

Impact bolt < Note >

Do not install the used ring spring 28.

Always assemble the fresh one.

Repair P 8 / 14

< 11 > Disassembling swash bearing

1. Referring to Fig. 3, 3A, 3B at page 4, 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.

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.

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.

Plastic hammer

Fig. 8 Fig. 8A

Swash bearing

section

Swash bearing

section

Tool holder

section

Tool holder

section

Flat washer 28

Inner housing

Piston cylinder

Washer 30

Hex socket head bolts M4x12

Fig. 8B

Fig. 8C

Piston cylinder

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.

Fig. 8D

Ball bearing 606ZZ

Repair P 9 / 14

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.

1R022 Bearing

extractor plate

1R023 Bearing

extractor ring

Ring 8 Ring 8

1R236 Round bar

for arbor 1R236 Round bar

for arbor

Ball bearing

608ZZ

Ball bearing

606ZZ

Flat washer 8

Bearing retainer

Helical

gear 26

Swash

bearing 10

Clutch cam

Fig. 9

Fig. 9A Fig. 9B Fig. 9C

Fig. 9D Fig. 9E

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

spring 12

Flat washer 12

Spur gear 10 Ball bearing

606ZZ

Repair P 10 /14

<12> Assembling swash bearing section

1. Apply grease to the parts of swash bearing section referring to < 1 > Lubrication at page 2.

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

4. Swash bearing 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.

Align the splines of clutch cam and swash bearing with the same of spur gear 10,

when setting them to spur gear 10.

Ball bearing

606ZZ

Spur gear 10

Fig. 10 Fig. 10A

Fig. 10C Fig. 10D

Helical gear 26

Flat washer 12

Compression

spring 12

Clutch cam

Swash bearing 10 Align the splines of clutch cam

and swash bearing with the same

of spur gear 10.

Bearing setting pipe

No. 1R034

Bearing setting plate

No. 1R034

Bearing setting plate

No. 1R034

Bearing setting plate Fig. 10B

Ball bearing 608ZZ

Flat washer 8

Bearing retainer

Ring 8

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