Makita HR2440F Manual

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
50 / 60
50 / 60
50 / 60
50 / 60
780
780
780
780
780
370
370
370
370
370
650
650
650
650
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
L
W
H
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)
65 (2-9/16)
2.7
Yes
Yes
Yes
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
Whole part
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 RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
Grease RA No.1 (Brown)
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
Carbon brush
Handle
cover
Tapping s
crew 4 x 25 : 3 pcs.
Tapping s
crew 4 x 45 : 4 pcs.
Brush holder
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
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

Repair P 11 / 14
<13> Assembling swash bearing section to piston cylinder
<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.
1. Apply MAKITA grease to piston cylinder and swash bearing 10 referring to <1> Lubrication at page 2.
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.
< Note >
Cover the work table with something soft to avoid the damage on gear housing. before disassembling.
Flat washer 12
Flat washer 12
Piston cylinder
Piston cylinder
Piston joint
Fig. 11
Fig. 11A
Fig. 11B
Fig. 11C
Inner housing
2 pcs. of hex socket
head bolts M4 x 12
for tightening bearing
retainer
Piston cylinder
Needle bearing
complete
Fig. 12

Back side
Repair P 12 / 14
< 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.
< 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.
< 17 > Maintenance
It is recommended to change the following parts, when replacing carbon brushes. See Fig. 15.
No.1R165
Ring spring setting tool B
Needle bearing
complete
Gear housing
< 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.
Fig. 13.
Belly side
Needle bearing
complete.
Flat portion of
needle bearing complete
Belly side
Back side
Fig. 14
Tapping s
crew 4 x 25 : 3 pcs.
Handle
cover
Brush holder
Brush holder
Switch
Noise
suppressor
Power supply cord
Cord guard
Strain relief
Tapping screw 4x18 : 2 pcs.
Steel ball 7.0 O ring 12 O ring 15
O ring 16
O ring 9
Fig. 15

Circuit diagram P 13 /14
Model HR2440F
Color index of lead wires
Black
White
Red
Blue
See-through
1
23
4
12C1 C2
M1 M2
Switch
Field
Noise suppressor
Power supply cord
Brush holder Brush holder
Connected
to field ore
For some countries, noise
suppressor of two lead wire
type is used, or noise suppressor
is not used.
LED job kight
Blue or red

Wiring diagram P 14 / 14
Model HR2440 with reverse switch
Fix field lead wire (black)
with lead holder as per
the illustration.
Fix field lead wire (black)
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 (red) and
field lead wire (white)
with lead holder as per
the illustration.
* Do not slack brush holder's lead
wire (red) between brush holder and
lead holder.
Fix brush holder's
lead wire (blue) and
field lead wire (black)
with lead holder as per
the illustration.
* Pass brush holder's lead wire (blue)
under the field lead wire (black).
* Do not slack brush holder's lead
wire (blue) between brush holder and
lead holder.
Fix field brush holder's
lead wire (blue) and
field lead wire (black)
with lead holder as per
the illustration.
Fix lead wires which are passed
through this area, with any of
these lead holders.
Noise suppressor
Noise suppressor is not
used in some countries
Fix the following lead wires with this
lead holder.
* Brush holder's lead wire (red)
* 2 field's lead wires (black)
* Noise suppressor's lead wire (see-through)
Bottom view
of handle portion
Lead wires of power supply cord,
and grounding lead wire (see-through)
LED lead wires
(blue or red)
Noise suppressor
LED circuit
Pass LED lead wires, kead wires of power supply
cord and grounding lead wire as illustrated
above.
LED circuit
Fix lead wire (white) of
LED job-light with
lead holder as illustrated.
LED
job-light
LED
job-light