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.