Makita HR2641, Technical Information

Page 1: ...DS 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 Po...

Page 2: ...ly 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...

Page 3: ... 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 fr...

Page 4: ...p portion of Oil seal 25 the component of 16 Entire portion 26 Driving flange 29 Cam portion that 30 touches b Inside where 46 reciprocates a Periphery that touches 29 and 30 28 82 81 80 Inside that 80 touches 28 a b Spur gear 51 30 Gear teeth to engage 55 38 45 Striker Entire portion 44 O ring 9 Entire portion 42 46 47 48 Approx 3g a little a little a little a little Approx 3g Approx 16g Swash be...

Page 5: ...g 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 Washer 16 Face the chamfered portion...

Page 6: ... of Rotation with hammering mode Rubber pin 4 Change lever 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...

Page 7: ... 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 n...

Page 8: ...ly 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 ...

Page 9: ...t 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...

Page 10: ...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 5 Tool holder complete Assemble by reversing the disassembly procedure Note Do not fail to set two Flat washers 30 in place The one is place...

Page 11: ...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 o...

Page 12: ... 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 insta...

Page 13: ...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 ...

Page 14: ... 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 se...

Page 15: ...all 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 ...

Page 16: ...ousing 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 ...

Page 17: ...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 so...

Page 18: ...te 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 Tab Rib 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 throug...

Page 19: ...ver 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 th...

Page 20: ... 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 comp...

Page 21: ... of 1R232 is larger than that of Oil seal setting hole 1 Receive the stepped collar of Gear housing complete on U shaped base of Arbor press 3 Pressfit Oil seal 25 to the original position with 1R164 until it stops 37mm 37mm 1R164 30mm 34mm the stepped collar gray color portion to be put on 1R258 Gear housing complete Cup sleeve with Ball bearing 6806LLU 5 Pressfit Cup sleeve with Ball bearing 680...

Page 22: ... ty Part No Description 1 1 1 1 1 1 1 2 6 26 213073 6 233979 2 233992 0 O ring 9 O ring 17 5 Ring spring 28 105 286288 8 Cap 35 233989 9 Ring spring 14 Ring spring 15 216022 2 Steel ball 7 42 43 45 213258 4 It is recommended to replace the following parts at the same time when the worn Carbon brushes are replaced with new ones Fig 34 ...

Page 23: ... Circuit without equipment for Radio interference suppression Switch Grounding terminal Switch Noise suppressor Power supply cord Insulated receptacle Field Circuit diagram of Inside of the Switch Choke coil Flag receptacle Flag receptacle Brush holder B Brush holder A Circuit for ON OFF Circuit for Forward Reverse control Brush holder B Brush holder A Power supply cord ...

Page 24: ...and pass it through opening to Handle section Pass Field lead wire black through this opening to Handle section Field lead wire white Rib Viewed from Armature Fan side Commutator side Armature fan side Connecting lead wire of Noise suppressor Clamp Mount Grounding terminal to Field core at the place between Terminal plate and Clamp Grounding terminal Field lead wire black Wiring in Motor housing F...

Page 25: ...necting lead wires white purple between rib B and rib C Rib D Put connecting lead wire purple to lead wire holder and tighten it between lead wire holder and terminal of Switch And put Field lead wire white between Rib D and inner wall of Switch trigger side Put Connecting lead wires white orange to lead wire holder of Switch And tighten them between lead wire holder and the switch s terminal to w...