Makita HR3541FC Manual

PRODUCT
P 1/ 19
TECHNICAL INFORMATION
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
HR3541FC, HR3540C
Combination Hammer 35mm (1-3/8")
Models HR3541FC and HR3540C have been developed
from HR3200C series models as 35mm (1-3/8") SDS-Max
rotary hammers.
Listed below are specification differences between the two models.
HR3540C
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
Model No. HR3540CHR3541FC
439 (17-1/4)
114 (4-1/2) 108 (4-1/4)
239 (9-3/8)
Active dynamic vibration absorber
Model No.
AVT Vibration absorbing handle Yes No
LED Job light Yes No
HR3541FC
L
H
W
HR3540CHR3541FC
Specification
Standard equipment
Optional accessories
Side handle (Bar-shaped) ................................ 1
Depth gauge .....................................................1
Grease vessel (containing 100g bit grease) ..... 1
TCT bits
Core bits
Bull points
Cold chisels
Scaling chisels
Scaling chisel (for Tile)
Grooving chisel
Clay spade
Bushing tool
Rammer
Shank (for Bushing tool and Rammer)
Chemical anchor adapter
Bit grease
Grease vessel (containing 30g hammer grease)
Plastic carrying ........................ 1
Cleaning cloth .......................... 1
Note: The standard equipment for the tool shown above may differ by country.
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
110
120
220
230
240
8.6
8.2
4.4
4.4
4.4
50/60
50/60
50/60
50/60
50/60
850
---
850
850
850
300
300
300
300
300
1,100
1,100
1,100
1,100
1,100
Current (A)
Plastic carrying case
Blow out bulb
Safety goggles
Hammer service kit
Chuck adapter
Keyless drill chuck assembly
No load speed: min-1=rpm
Impacts per min: min-1=ipm
Model No. HR3540CHR3541FC
Europe: 4.0 (13.1), Brazil: 2.0 (6.6), Other countries: 5.0 (16.4)
Shank diameter: mm (")
Capacities: mm (")
Torque limiter
Double insulation
Power supply cord: m (ft)
Electronic
features
Variable speed control by dial
Constant speed control
Soft start
Yes
Yes
Yes
Yes
Yes
13 (1/2)
32 (1-1/4)
315 - 630
1,650 - 3,300
Wood
Steel
35 (1-3/8)
90 (3-1/2)Core bit
TCT bit
5.2 (11.4) 4.8 (10.6)
5.6 (12.3) 5.2 (11.4)
Net weight: kg (lbs)
18 (11/16)
Operation mode 3 modes
(Rotation only/ Rotation with hammering/ Hammering only)
Shank type SDS-Max
Concrete
Weight according
EPTA-Procedure 01/2003*: kg (lbs)
*includes Side handle.

P 2/ 19
Repair
CAUTION: Remove the Bit from the machine for safety before repair/ maintenance
in accordance with the instruction manual!
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATIONS
Fig. 1
Code No. Description Use for
Item No.
Apply the following grease to protect parts and product from unusual abrasion.
* Makita grease R.No.00: the portions designated with black triangles
* Makita grease N.No.2: the portions designated with gray triangle
Description AmountPortion to lubricate Lubricant
1R003 Retaining ring S pliers ST-2N Removing / Assembling Ring spring 15
1R045 Gear extractor (large) Removing Armature from Gear housing
1R346 Center attachment for 1R045
1R212 Tip for Retaining ring pliers Tip for Retaining ring pliers
1R228 1/4” Hex. shank bit for M4 Removing M4x25 Hex socket head bolt for tightening Crank housing
1R288 Screwdriver magnetizer Magnetizing Screwdriver when removing Pin
1R230 1/4” Hex. shank bit for M6 Removing M6x25 Hex socket head bolt for tightening Barrel complete
1R269 Bearing extractor Removing Ball bearings
1R367 Taper sleeve Fitting Fluoride ring to Impact bolt
1
5
a
Ring 38
Impact bolt
Striker
Piston
Chuck cover
a little
a little
approx. 2 g
Tool holder cap
Tool holder
O Ring 19
O Ring 18
Spiral bevel gear 32
Pin 7
Cylinder 25
Tool retainer
Chuck ring
Ring spring 25
Spring guide
Spring holder
Compression spring 52
Compression spring 42
Urethane ring 38
Flat washer 39
26
5
Barrel complete
24
27
32
b
42 43 44
44
48
Flat washer 40
Lock sleeve
Driving sleeve
Slide sleeve
82
1
5
24
26 27
32
Oil seal
Plane
bearing 38
c
c The drum portion which is accepted by
Plane bearing 40 in 82 Crank housing.
d
d Gear teeth
a The portion where Plane bearing 38 in Barrel contacts
b The space between Striker and Piston
The portion where Oil seal 32 in Barrel contacts
The portion where 24 Tool holder contacts
The portion where 32 Cylinder 25 contacts
The drum portion
42 43
48
The lip portion which accepts Bit shank
The portion where Bit shank contacts
Plane
bearing 40
Makita grease
N.No.2
Makita grease
R No.00

P 3/ 19
Repair
[2] LUBRICATIONS (cont.)
Fig. 2
Item No.
Apply Makita grease R.No.00 to the following portions designated with the black triangle to protect parts
and product from unusual abrasion.
Description Portion to lubricate
55
57
50
Pipe 15
AVT Section
Crank and Gear Section
Spring guide
Compression
spring 10
Spring guide
Counter weight
Change lever
Gear shaft
Crank cap
Crank shaft
Spur gear 33
Torque limiter
52
52
58
61 63
101
101
76
76
86
86 Crank gear
Spur gear 33
Crank housing complete
Pipe holder
Pipe holder
75
75
102
Armature
107
107 Oil seal
82
82
50 61 63 O ring 8 Whole portion
Whole portion
Whole portion
The lip portion
Gear teeth for smooth engaging with Gear shaft
Gear teeth for smooth engaging with Gear shaft
Crank room
Whole portion
The drum portion for smooth reciprocation in
Pipe 15
O ring 1855 57
58
102 O ring 28
O ring 16
Gear housing complete Around Spur gear 33 and Torque limiter complete
AmountLubricant
a little
Makita grease R
No.00
a little
a little
approx. 13g
approx. 13g
Crank housing complete
Barrel complete
M6x25 Hex socket
head bolt (4pcs.)
When assembling Barrel complete to Crank
housing complete, tighten with M6x25 Hex socket
head bolts to 7.8 up to 11.8 N.m fastening torque.
(Fig. 3)
Fig. 3
[3] Fastening Torque

P 4/ 19
Repair
[4] Tapping Screws
4x14 and 4x18 Tapping screws are used as illustrated in Fig. 4. Pay attention not to confuse them.
Change lever 4x14 Tapping screw for tightening:
4x14
4x14
4x14
4x1869
69
4x18
4x18
4x14
4x14
4x18
Crank cap cover
Cap holder
Brush holder unit
Spur gear 33
complete
Rear cover
Cord clamp base
Handle
Handle
cover
Controller
Cord clamp
Crank cap
Motor housing
Crank gear
2pcs.
6pcs.
1pc.
1pc.
1pc.
1pc.
Crank cap cover to Crank cap
Cap holder to Crank gear
Controller to Motor housing
Cord clamp base to Controller
Cord clamp to Cord clamp base
Total
Total
4x18 Tapping Screw for tightening:
1pc.
8pcs.
2pcs.
4pcs.
1pc.
Change lever to Spur gear 33 complete
Rear cover to Motor housing
Brush holder unit to Motor housing
Handle cover to Handle
67
67 67
89
89
128
125
128
131
131
133
133
124
124
125
153
153
Fig. 4
4x14

P 5/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5]-1. Chuck
DISASSEMBLING
ASSEMBLING
Fig. 5
Fig. 6
5x25 Tapping screw (2pcs.)
Compression spring 11
M5x20 Pan head
screw (2pcs.)
Handle section
Controller
Tool holder cap
Remove Tool holder cap.
While pressing down Spring guide,
remove Tool retainer.
Remove Chuck cover.
Remove Spring guide. Remove Compression spring 52 and Spring holder.
Remove Ring spring 25. Remove Chuck ring.
4x18 Tapping screw (2pcs.)
(1) Remove Controller and Handle section and then upright the machine as illustrated in Fig. 5.
(2) Disassemble Chuck section as illustrated in Fig. 6.
Take the disassembling step in reverse.
Refer to Figs. 6 and 5.
Chuck cover
Chuck cover
Ring spring 25
1R212 Chuck ring
Chuck ring
Spring guideSpring guide
Spring
holder
Tool retainer
Tool retainer
Tool retainer
Compression spring 52
Compression spring 52

P 6/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5]-2. Tool holder section
DISASSEMBLING
(1) Disassemble Chuck section as illustrated in Figs. 5 and 6.
(2) Disassemble Tool holder section together with Cylinder section as illustrated in Fig. 7.
(3) Separate Tool holder section from Cylinder section as illustrated in Fig. 8.
Disassemble Crank housing
cover and Barrel complete.
M6x25 Hex socket
head bolt (4pcs.)
M4x16 Hex socket
head bolt (1pc.)
Barrel
complete
Crank housing cover
Cylinder
section
Tool holder
section
Disassemble Tool holder section from Barrel
complete together with Cylinder section by
striking Tool holder.
Pin 6 joining Tool holder
to Cylinder 25 (4pcs.)
Ring 38 Flat washer 39
1. Remove Ring 38,
Urethane ring 38 and
Flat washer 39.
2. Apply magnetized
Screwdriver to Pin 6,
Screwdriver
magnetized
with 1R288
Urethane ring 38
Pin 6 (4pcs.)
Cylinder 25
Pin 6
Tool holder
Tool holder
Cylinder 25
3. Align Tool holder's hole
with that of Cylinder 25
by pushing Tool holder.
4. Remove Pin 6 with
magnetized Screwdriver
when the both holes are
aligned each other.
Remove Tool holder and Striker
from Cylinder 25. And then, pull
out Impact bolt, Ring 13 and Rubber
ring 13 from Tool holder.
Tool holder section
Impact bolt
Ring 13
Rubber
ring 13
Cylinder section
Striker
Fig. 7
Fig. 8
Impact bolt
O ring 19
Fig. 9
(4) If O ring 19 (black) can be seen through the worn Fluoro carbon resin ring 24 as illustrated in Fig. 9, all the Rings on
Impact bolt have to be replaced by new ones.
Fluoro carbon resin ring 24
(the worn one)
O ring 19
(black)

P 7/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5]-2. Tool holder Section (cont.)
[5]-3. Cylinder Section
DISASSEMBLING
ASSEMBLING
Fig. 10
1) Replace Rings on Impact bolt as illustrated in Fig. 10.
1R367
Correction
Insert Impact bolt into
1R367 and keep them
approx. 60 seconds in
1R367.
Impact bolt
Assemble of Rings to Impact Bolt
Before Correction:
The edges of Rings are protruding
from the top edge of the groove on
Impact bolt.
Groove on Impact bolt
Fluoride ring 24
O ring 19 O ring 19
After Correction:
The edges of Rings are positioned
under the top edge of the groove
on Impact bolt.
Corrected
2) Take the the disassembling step in reverse. Refer to Figs. 7 and 8.
Note: Flat washer, and Rings have to be assembled to Cylinder 25 to fix Pin 6 as illustrated in Fig. 11.
Pin 6 joining Tool holder
to Cylinder 25 (4pcs.)
Urethane ring 38
Flat washer and Rings has to
be assembled in the following order.
1. Flat washer 39
2. Urethane ring 38
3. Ring 38
Ring 38
Flat washer 39
Tool holder guide
Cylinder 25
Fig. 11
Fig. 12
(1) Disassemble Chuck section as illustrated in Figs. 5, 6.
(2) Separate Cylinder section form Crank housing together with Tool holder section as illustrated in Fig. 7.
(3) Separate Cylinder section from Tool holder section as illustrated in Fig. 8.
(4) Cylinder section is disassembled as illustrated in Fig. 12.
Driving
sleeve
Pressing down Driving sleeve, remove O Ring 26. So, Cylinder section is disassembled as illustrated above.
O ring 26
Driving sleeve Compression
spring 34
Lock sleeve
Flat
washer 40
Slide
sleeve
Compression
spring 42
Ring 29
Slide
sleeve
Cylinder 25

P 8/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5]-3. Cylinder section (cont.)
DISASSEMBLING
ASSEMBLING
Fig. 13
Rubber ring 13
Remove Rubber ring 13 and Ring 13
if they are left in Cylinder 25 in
disassembling Tool holder section.
Slide plate
Slide plate is removed from
Cylinder 25.
Align Slide plate with the
elliptic hole of Cylinder 25
by turning approx. 90 degree.
Ring 13
(5) Remove Slide plate from Cylinder 25 as illustrated in Fig. 13.
Take the disassembling step in reverse. Refer to Figs. 13 and 12.
Join the assembled Cylinder section to Tool holder with Pin 6. Refer to Fig. 8 And Secure Pin 6 with Flat washer 39,
Urethane ring 38 and Ring 38 as illustrated in Fig. 11.
Impact bolt Rubber ring 13
Cylinder 25
Ring 13
Tool holder
Fig. 14
Note: Ring 13 is not reversible. Assemble it to Impact bolt as illustrated in Fig. 14.
Slide plate
Facing this Conical portion
to Impact bolt, assemble Ring 13.

P 9/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -4. Active Dynamic Vibration Absorber
DISASSEMBLING
4x14 Tapping screw (2pcs.)
Crank cap cover
(1) Disassemble Crank housing cover. (Fig. 7)
Then remove Crank cap cover as illustrated in Fig. 15.
Fig. 15
Compression
spring 11
Spring guide
Absorber holder of
Crank housing complete
Pipe holder
Push Spring guide
(inner part of
Absorber).
Absorber holder
The Spring guide tilts to be
locked inside Absorber,
and the end of Absorber is
released from Crank housing
complete.
Disassemble Active dynamic
vibration absorber by levering up
with two Slotted screwdriver.
Active dynamic
vibration absorber
Phillips
screwdriver Phillips
screwdriver
Slotted screwdriver
(2) Remove Active Dynamic Vibration Absorber from Crank housing complete as illustrated in Fig. 16.
And disassemble as illustrated in Fig. 17.
Fig. 16
Fig. 17
Pipe holder Pipe holder
O ring 8
O ring 8 O ring 8O ring 8
O ring 18 O ring 18
Compression spring 10 Compression spring 10
Spring guide
Pipe 15
Counter weight Spring guide
Pipe holders can now be
separated by turning Pipe
holders while pushing
strong toward each other.

P 10/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -4. Active Dynamic Vibration Absorber (cont.)
ASSEMBLING
(1) Assemble Active dynamic vibration absorber. Refer to Fig. 17.
(2) Set Spring guide to the position in place as illustrated in Fig. 18.
(3) Mount the Active dynamic vibration absorber on the both side of Crank housing complete. (Fig. 19)
(4) After the step of Fig. 19, take the reverse of disassembling.
Spring guide
Compression
spring 10
Compression
spring 10
Spring guide
If Spring guide is locked
in Absorber;
1) push Spring guide so as
not to be stuck.
2) check that the tip of
Spring guide comes out
by return force of
Compression spring 10.
Spring guide
Assemble Active dynamic vibration absorber
by pressing while maintaining the position
parallel to Crank housing.
Spring guide
Fig. 18 Fig. 19
[5] -5. Motor Section, Torque Limiter Section
DISASSEMBLING
Fig. 20
4x18 Tapping screw (2pcs.)
4x14 Tapping screw (2pcs.)
5x25 Tapping screw (2pcs.)
5x20 Pan head screw (2pcs.)
Active dynamic
vibration absorber
Active dynamic
vibration absorber
Handle section
Rear cover
Crank cap cover
(1) Disassemble Chuck section. (Figs. 5, 6).
(2) Remove Crank housing cover. (Fig. 7)
(3) As illustrated in Fig. 20, disassemble Crank cap cover, Active dynamic vibration absorber, Handle section and Rear
cover from Crank housing complete and Motor housing.

In case of HR3541FC, disconnect the connector
of LED Circuit.
Controller and Cord clamp base can be
removed from Motor housing by unscrewing
4x18 Tapping screws.
Controller
P 11/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -5. Motor Section, Torque Limiter Section
DISASSEMBLING
Disconnect the connector of Lead unit from Controller.
Handle section can be separated completely from machine.
4) Disconnect connectors to disassemble Handle section as illustrated in Fig. 21.
Handle section
Cord clamp base
4x18 Tapping screw (2pcs.)
Fig. 21
Carbon brush
Disconnection of Carbon brush with Commutator
Spiral spring
Carbon brush
Carbon brush
Spiral spring
Detach Spiral spring
from Carbon brush.
By pulling Carbon brush,
disconnect the contact with
Armature's commutator.
Armature is ready to be
removed.
Fig. 22
5) Disconnect the contact between Carbon brush and Commutator as illustrated in Fig. 22.

P 12/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -5. Motor Section, Torque Limiter Section (cont.)
DISASSEMBLING
Crank
housing
Gear housing
5x25 Tapping screw (4pcs.)
Torque limiter section
Torque limiter section may be left
in Crank housing at this time.
Remove 5x25 Tapping screws. And separate Motor housing from Gear housing.
Do the disassembling work on the cloth to accept the grease from Gear housing
and to prevent Torque limiter from having damage.
Armature
Use cloth to accept the grease from Gear
room and to prevent Torque limiter from
having damage.
Motor housing
6) Remove Armature as illustrated in Figs. 23 and 24.
Fig. 23
Fig. 24
1R346
Note: Be careful not to lose
Cup washer 18 for
Crank shaft.
Armature
Handle
of 1R045
Cup washer 18
Remove Torque limiter section by striking the Gear housing's
edge with Plastic hammer, if Torque limiter section is left on
the Gear housing.
Remove Armature from Gear housing.
Torque limiter
section
7) Torque limiter section can be disassembled as illustrated in Fig. 25.
Take the disassembling step in reverse. Refer to Figs. from 25 to 20.
Ball bearing
608DDW
Ball bearing 6001LLU
Ring 10
1R269
Key 4 (2pcs.)
Spiral bevel
gear 9
Torque
limiter ass’y
Fig. 25
ASSEMBLING

P 13/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -6. Gear Section in Crank Housing Complete
DISASSEMBLING
Change lever
Rotary hammer
mode mark on
Crank cap cover
Triangle mark
on Crank cap
Triangle mark
on Change lever
Fig. 26A
1) Disassemble Handle Section. (Fig. 5) And then, disassemble Chuck Section (Fig. 6)
2) Remove Crank housing cover and Barrel complete together with Cylinder section. ( Fig. 7)
3) Set Change lever to Rotary hammer mode as illustrated in Fig. 26. Remove Crank cap cover. (Fig. 15)
4) Disassemble Active Dynamic Vibration Absorber. (Fig. 16)
5) Remove Rear cover from Motor housing. (Fig. 20)
6) Disconnect the contact between Carbon brush and Commutator. (Fig. 22)
7) Separate Crank housing complete from Motor housing. (Fig. 23)
8) If it is omitted to set Change lever to Rotary Hammer Mode in removing Crank cap cover, set Change lever as
illustrated in Fig. 26A.
9) Disassemble the remaining parts as illustrated in Figs 27 and 28.
Set Change lever to Rotary hammer mode. If Crank cap is already removed, align the triangle mark
on Change lever with that on Crank cap.
Fig. 26
Fig. 27
Note: When disassembling Crank cap,
do not move Change lever from
the position illustrated in Fig. 26A.
Remove Crank cap by unscrewing
M4x16 Pan head screws. And then,
remove Link plate.
M4x16 Pan head screw: 5 pcs.
Crank cap
Seal ring B
Link plate
Link arm
Torque limiter
section If Torque Limiter Section is left in Crank
housing complete in the step of Fig. 28,
disassemble it.
Otherwise, it is impossible to remove
Spiral bevel gear 37.
Spiral bevel gear 37 and Link arm
can be removed.
Spiral bevel gear 37
Piston and Crank at the dead
point on Striker side
Set Crank and Piston to the
dead point on Striker side.
Remove Air pipe.
Crank
Because Cylinder 25 has been already
removed, Connecting rod can be easily
disassembled from Pin of Crank shaft.
Now pull out Piston from Crank
housing complete.
Piston
Connecting rod of Piston
Striker
side
Connecting rod Air pipe
Fig. 28

P 14/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -6. Gear Section in Crank Housing Complete (cont.)
DISASSEMBLING
ASSEMBLING
(10) Gear unit for Changing operation mode is still left in Crank housing complete. Without removing this Gear unit,
it is impossible to disassemble Crank section.
Disassemble in order of Gear shaft and Crank gear as illustrated in Fig. 29.
Crank gear
Gear
shaft
Crank gear
Gear shaft
Crank gear
Gear shaft
Fig. 29
Fig. 30
(11) Crank Section can be disassembled as illustrated in Fig. 30.
Ball bearing
6004LLU
Retaining
Ring WR-10
Spur gear 33
Clutch
Crank shaft
Conical compression
spring 21-31
Flat washer 10
Flat washer 22
Key 4
Retaining
ring S-20
Crank section
(1) Assemble Crank section by taking the reverse of Disassembling steps. Refer to Fig. 30.
And then, mount the Crank section to Crank housing complete.
Note: When assembling Retaining ring WR-10 to Crank shaft, assemble it as illustrated in Fig. 31R.
Crank shaft Crank shaft
Retaining
ring WR-10
Claws of
Pliers
Claws of Pliers can exactly fit with Retaining ring
WR-10, and the Retaining ring is removed easily.
Claws of Pliers can hardly fit with Retaining ring WR-10.
Consequently, it is difficult to remove the Retaining ring.
Claws
of Pliers
Fig. 31R Fig. 31F
Retaining
ring WR-10
Retaining
ring WR-10
Retaining
ring WR-10

P 15/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[3] -6. Gear Section in Crank Housing Complete
ASSEMBLING
(2) Assemble Gears for changing operation mode as illustrated in Fig. 32.
Pin
(factory assembled)
Crank
housing
complete
These notches are important Marks to assemble
the Gear unit in Rotary hammer mode exactly.
Insert Crank gear while fitting
this notch to Pin.
Handle side
Crank
gear
Crank gear
Gear shaft
Gear shaft
Face this notch to Handle
side and insert Gear shaft.
Crank housing
complete
Fig. 32
(3) Assemble Spiral bevel gear 37, Link arm, Seal ring B and Link plate as illustrated in Fig. 33. And assemble Crank
cap as illustrated in Fig. 34.
(4) Assemble Crank cap cover. The triangle mark on Change lever has to designate the mark of Rotary hammer mode on
Crank cap cover as illustrated in Fig. 26. And assemble the remaining parts by taking the reverse of the disassembling
steps.
Spiral bevel gear 37 Notches of
Link arm
The notches of Link arm
come into sight.
Push Link arm into Crank housing complete
until the notches of Link arm come into
sight in Crank housing complete.
Push Spiral bevel gear 37 into
Crank housing complete until
it stops.
Boss
Link plate
Assemble Link plate by
fitting its bosses to the
notches of Link arm.
Seal ring B
Fig. 33
Pin of Spur gear 33 complete which is mounted on
the reverse side of Crank cap is fit into this hole.
Assemble Crank cap to Crank housing complete
while keeping Change lever in the position
illustrated in Fig. 26A.
Link plate
Crank cap
Fig. 34

P 16/ 19
Repair
[5] DISASSEMBLY/ASSEMBLY
[5] -7. Handle Section and Electrical Parts
DISASSEMBLING
Unscrew 4x18 Tapping screw. And separate
Handle cover with slotted screwdriver.
Unscrew 4x18 Tapping screw.
And separate Handle cover
with Slotted screwdriver.
Replace ON-OFF Switch etc.
Replace ON-OFF Switch etc.
(1) Disassemble Handle section as illustrated in Figs. 20 , 21.
(2) Controller and Power supply cord can be removed. (Fig. 21)
(3) HR3540C: Disassemble Handle cover. ON-OFF Switch can be replaced as illustrated in Fig. 35.
(3A) HR3541FC: After removing ON-OFF Switch, Handle section can be disassembled as illustrated in Fig. 35A.
5x25 Tapping
screw (2pcs.)
4x18 Tapping screw (1pc.)
4x18 Tapping
screw (1pc.)
Handle cover
Switch lever
Switch lever
Handle base
Handle Section can be disassembled
as illustrated below.
Shoulder sleeve
6 (2pcs.)
Handle
Dust cover support
Dust cover
Lead unit
Handle
cover
HR3540C
HR3541FC
Fig. 35A
Lead unit
Switch holder complete
Switch holder
complete
ON-OFF Switch
ON-OFF Switch
Handle Handle
5x40 Tapping Screw (2pcs.)
Flat washer 5 (2pcs.)
Compression spring 11
Fig. 35
ASSEMBLING
Face the bow portion of
Dust cover to the upper side
and assemble Dust cover to
Handle.
Triangle mark of Dust cover support
Handle
Handle base
Face the triangle mark of Dust cover support
to the upper side and insert it to Dust cover.
Bow portion
of Dust cover
5x40 Tapping
screw: 2 pcs.
Flat washer 5
Take the disassembling step
in reverse.
Note: Dust cover support and
Dust cover are directional.
Refer to Fig. 36.
Fig. 36

P 17/ 19
Repair
[6] MAINTENANCE PROGRAM
Replacing the following parts at the same time is recommended when replacing Carbon brushes is required. See Fig. 37.
Note: Be sure to put Makita grease R No. 00 and N No. 2 to the specific portions. Refer to Figs. 1, 2.
Item No. Description
1 Tool Holder Cap
3Ring Spring 25
26 27 O ring 19 (for Impact bolt)
28 Fluoro carbon resin ring 24
42
43
O ring 18 (for Striker)
O ring 18 (thin type for Piston)
46
O ring 18 (thick type for Piston)
Fig. 37
1
3
26
Spring guide
Striker
Flat washer 40
Lock sleeve
Driving sleeve
Cylinder 25
Compression spring 52
Spring holder
Tool holder
Impact bolt
Barrel complete
Chuck cover
27
42 43
46 28
Piston
Spiral bevel
gear 37
Circuit diagram
Red
Power Supply Cord
Lead unit
Lead wire (white) of Power
supply cord is blue for some
countries.
Switch
Connector of
Lead Unit
Fig. D-1
White
Color index of lead wires' sheath
Black
HR3540C
Handle Motor Housing
Lead wire (black) of Power supply cord
is brown for some countries.
Power Supply Cord
Lead unit
Lead wire (white) of Power supply cord is
blue for some countries.
Switch Connector of
Lead Unit
Lead wires of LED
circuit are covered
by Polyolefine
tube.
HR3541FC
Handle
Handle
base
Motor Housing
Lead wire (black) of Power supply cord is
brown for some countries.
LED Circuit

Wiring diagram
P 18/ 19
Fig. D-2
HR3540C
Controller
Dial
Lead wire of
Power supply cord
Rib
Switch
Do not slack the Lead wires in this area.
Fix them with Lead wire holders and Ribs.
Do not put the Lead wires of Power supply cord
on the Ribs (A) and (B).
(A) Rib for Controller
(B) Rib of Motor
housing
Power supply cord
Cord guard Connector of
Lead unit Lead unit
Lead wire holder
Rote the Lead wires of Lead unit
through the opening of Handle.
Handle
Motor housing
Motor housing (Bottom view)
Lead wire holder
Route the Lead wire as
illustrated on left. Fix it
with Lead wire holder.
Do not slack it between
LED circuit and Lead
wire holder.
Controller
Rib
Rib
Rib
LED Circuit
Motor Housing (Rear View)
Motor Housing (Rear View)
Dial
(C) Rib A of
Motor housing
Rib B of
Motor housing
Route Lead wire of Light circuit between (B) and (C).
Do not put Lead wire of Light circuit on the Rib B of Motor
housing.
Lead wire of
Light circuit
(B) Rib of
controller
* Put the extra portion of the Lead wire of Light
circuit into the space between Rib of Motor
housing and Rib for Controller.
* Put Connector into Cord clamp base.
Cord clamp
base
Rib of Motor housing
Rib for Controller
(after assembling Cord Clamp Base)
Rib for Controller Controller
Connector
Controller
HR3541FC

Wiring diagram
P 19/ 19
Fig. D-3
Do not put the lead wires of Power supply cord
on the Ribs (A) and (B).
Switch
Do not slack the lead wires in this area.
Fix them with Lead wire holders and Ribs.
Route the lead wires of Lead unit
through the opening of Handle base
and Handle.
Handle
Lead wire
holder
Motor housing
Handle base Rib
Lead unit
Lead wire of
Power supply cord
Power supply
cord
Connector of Lead unit
Controller
Cord guard
(B) Rib of
Motor housing
(A) Rib for Controller
Dial
HR3541FC