Repair Rotary Hammer Makita HR2600

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Repair Rotary Hammer Makita HR2600

 

 

1. NECESSARY REPAIRING TOOLS

 

 

2. LUBRICATION

 

Apply the following grease/ lubricant to protect parts and product from unusual abrasion.

 

 

 

1. Bit holder section

 

1) Remove Cap 35.

2) Separate Ring spring 14 from the groove of Tool holder complete using 1R003 with 1R212. (Fig. 2) Washer 16 on Ring spring 15 is removed.

3) Remove Ring spring 15 in the same way while pressing down Chuck cover. (Fig. 3) Then pick up Flat washer 17 and Rubber washer 16 from the space between Chuck cover and Tool holder complete. Chuck cover is removed.

4) Remove two Steel balls 7.0 while pressing down Ring 21. (Fig. 4) Ring 21, Guide washer and Conical compression spring 21-29 are removed.

 

 

 

 

Assemble in the reverse order of disassembly. Refer to Fig. 5 for the directions of the components.

 

 

2. Change lever section

 

Insert the tip of thin slot screwdriver into the notch of Gear housing complete, then lever up one side of Change lever cover B. (Fig. 6)

Lever up the other side of Change lever cover B in the same way, then remove Change cover lever B. Change lever B can be removed.

 

 

1) Set Change lever B to 45° position as drawn in Fig. 7.

2) While checking the V-edge of Push corn fits into V-groove of Clutch cam B, insert Change lever B into Gear housing.

3) After turning Change lever B to hammer drill mode position, put Change lever cover B on Change lever B. Note: The V-groove of Change lever B has to come on the center of Leaf spring. (Fig. 8)

4) Be sure to check Change lever B works properly after assembling.

 

 

3. Armature

 

1) Remove three 4x18 Tapping screws and Handle cover.

2) Slide Brush holder unit to the best position to repair, and move the arms of Spiral springs aside, then separate Carbon brushes from Commutator. (Fig. 9)

3) Remove four 4x30 Tapping screws then separate Motor housing from Gear housing complete. Armature is left on Gear housing at that time. (Fig. 10) Note: Do not lose Wave washer 15 on the bottom of Motor housing. Do not fail to set it in place when assembling.

4) Remove Armature ass’y from Gear housing complete by pulling by hand. Note: Ball bearing 6000LLB of Armature ass’y is held in Inner housing complete with O ring 26. Therefore, it is not necessary to tap Gear housing complete with Plastic hammer to remove Armature ass’y.

5) Remove Ball bearings 6000LLB with 1R269. Remove 627DDW and Insulation washer together at one time with 1R269.

6) Assemble the components in the reverse order of disassembly after replacing the damaged parts.

 

 

4. Torque limiter section

 

1) Remove Bit holder section.

2) Remove Change lever section.

3) Separate Gear housing from Motor housing.

4) Remove Tool holder complete by tapping the top as drawn in Fig. 11. Note: Flat washer 30 is located between Tool holder complete and Inner housing complete. Be careful to lose it.

5) Set 1R045 and 1R369 to Tool holder complete. (Fig. 12)

6) Compress Compression spring 32 (Fig. 13), then separate Spiro lock washer 30 from Tool holder complete by sliding a thin slotted screwdriver from the upper end as drawn in Fig. 14. The components are disassembled. (Fig. 15)

 

 

 

 

5. Impact bolt in Tool holder complete

 

1) Put 1R388 into Tool holder complete then push 1R388 in vise with the access holes on Tool holder complete parallel to Vise. (Fig. 16) O-ring case A/ B is moved toward the top of Tool holder complete, and therefore, Ring spring 28 can be relieved from O-ring case A/ B.

2) When the end gap of Ring spring 28 is in the access hole, slide it with slotted screwdriver until it is completely hidden.

3) Using slotted screwdriver, tap Ring spring 28 through the two access holes alternately to push it out of the inner groove of Tool holder complete.

4) The components are removed by tapping with phillips screwdriver and plastic hammer from bit installation side of Tool holder complete. (Fig. 17)

 

 

 

 

6. Impact bolt section in Tool holder complete (cont.)

 

Assemble Impact bolt section to Tool holder complete as drawn in Fig. 18A/ 18B.

 

 

Push Ring spring 28 into the inner groove of Tool holder complete as drawn in Fig. 19. Note: Do not reuse the removed Ring spring 28 if it is deformed or damaged.

 

 

7. Swash bearing section

 

1) Disassemble Motor housing section, Gear housing section and Inner housing section. As for HR2601, remove two M4x12 Hex socket head bolts. And then separate Counter weight section from Inner housing complete. (Fig. 20)

2) Remove two M4x16 Hex socket head bolts with hex wrench 3 and 1R228. (Fig. 21) Then pull Swash bearing section out of Inner housing complete. (Fig. 22)

3) Remove Ball bearing 606ZZ from Gear housing complete using the removed Swash bearing section. (Fig. 23)

4) Receive Clutch cam B on 1R035 and press Spur gear 10 out of Clutch cam B. The swash bearing section can be removed as drawn in Fig. 24.

 

 

 

8. Swash bearing section (cont.)

 

1) Pressfit Ball bearing 608ZZ into Bearing box.

2) Put Clutch cam B, Swash bearing 10, Flat washer 8 and Bearing box to Spur gear 10 in order, then secure them using 1R033, 1R026 and arbor press.

3) Fit Bearing retainer in Bearing box, then pressfit Helical gear 26 to the shaft of Swash bearing section. Be careful of the directions of Bearing box and Helical gear 26. (Fig.25)

 

 

9. How to assembly of Piston cylinder section to Swash bearing section

 

1) Assemble Guide plate and Piston joint to Piston cylinder. Align the holes of Piston joint to the installed direction of Swash bearing 10. (Fig. 26)

2) Set Flat washer 14 and Compression spring 14 on the boss of Inner housing complete. (Fig. 26)

3) Put the opposite end of Compression spring 14 on Guide plate, then push Piston cylinder into the bottom of Inner housing complete and insert the pole of Swash bearing 10.

4) Assemble Striker with O ring 17.5 to Piston cylinder. Refer to Fig 1.

 

 

10. How to assemble Gear housing to Inner housing

 

1) Check that Clutch cam B is engaged with Swash bearing 10. (Fig. 27)

2) Assemble Gear housing complete to Inner housing complete.

 

 

3. Maintenance program

 

It is recommended to replace the following parts at the same time when replacing Carbon brushes. (Fig. 28)

Note: Be sure to put Makita grease RB No. 00 to the specific portions. (Fig. 1)

 

 

Circuit diagram

 

 

Wiring diagram