Makita HR2641 Manual

W
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)
H
L
TECHNICAL INFORMATION
PRODUCT
P 1/ 25
Model No.
Description 26mm (1") Combination Hammer
HR2641
Specification
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
44
45
42
(c) Inside that 44 touches
(d) Outer periphery that 28 touches
(h)
46
47
[2] LUBRICATION
Fig. 1
Item No. Description Amount
Approx. 2 g
a little
a little
a little
Portion to lubricate
16
129
30
81
Pin 6 Portions to be inserted to 80 and 82
Counter weight
Weight holder guide Portion that Inner housing complete touches
38
Impact bolt A
26
O ring 17.5
(c)
(d)
(e)
(f)
(g)
(j) (i)
Piston cylinder
Piston joint Grooves
Guide plate Inside that 48 touches
56
52
Inner housing
complete
Drum portion
Entire portion
57
55
64
65
58
a little
Makita grease RB No.00
Molybdenum desulfide lubricant
Lubricant
Ring 8
40
Cap 35 Inner groove portion
1
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
28
82
81
80
Inside that 80 touches
28
(a)
(b)
Spur gear 5130 Gear teeth to engage 55
38
45
Striker Entire portion44
O ring 9 Entire portion
42
46
47
48
Approx. 3g
a little
a little
a little
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
52
55
56
57
58
64
65
Gear teeth
(h) Pole portion to be inserted into 48
Flat washer 3036
36
Surface that touches Inner housing complete
57
82
80
48
(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
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
Ring 21
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
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
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 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
or
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 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: ApplyLoctite 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
Pin
Counter weight
Pin 6
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
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
Pin
Fig. 32
P 20/ 25
Repair
Inner housing complete of
a repairing tool