Makita HK1820 Manual

PRODUCT
P 1/17
TECHNICAL INFORMATION
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 351 (13-3/4)
102 (4)
203 (8)
L
H
W
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
110
120
220
230
240
5.3
5.0
2.6
2.5
2.4
50/60
50/60
50/60
50/60
50/60
550
---
550
550
550
260
260
260
260
260
390
390
390
390
390
Models No.
Description
Current (A)
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
HK1820
Power Scraper
Model HK1820 has been developed as the successor model of HK1810,
featuring vibration absorbing handle additionally to the same compact
and lightweight design as the predecessor model.
Also features the chuck adapted for SDS-PLUS bits.
Bull point ................................. 1
Scaling chisel ........................... 1
Scaling chisel (for tile) ............. 1
Hook complete ......................... 1
Plastic carrying case ................. 1
Bull points
Cold chisel
Grooving chisels
Scaling chisel
Scaling chisel (for tile)
Hook complete
Scraper assembly
Grease vessel (containing Hammer grease)
Bit grease
Safety goggles
Impacts per min: ipm=min-1
Protection from electric shock
Net weight: kg (lbs)
Power supply cord: m (ft)
Shank type: mm (")
0 - 3,200
3.3 (7.3)
SDS-Plus
Double insulation
Impact energy [catalog value]: J 3.9
Variable speed control Yesby dial
Yesby trigger
Chile, Brazil: 2m (6.6ft)
Other countries: 5m (16.4ft)
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P 2/17
[2] LUBRICATION
Apply the following lubricants to protect parts and product from unusual abrasion:
*Makita grease N.No.1 to the portions designated with black triangle
*Makita grease R.No.00 to the portions designated with gray triangle
*Makita grease N.No.2 to the portions designated with white triangle
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the bits from the machine for safety before repair/maintenance
in accordance with the instruction manual!
Fig. 1
Repair
DescriptionCode No. Use for
Item No. Description Portion to lubricate
1R003
1R022
1R023
1R029
1R212
1R228
1R229
1R258
1R288
Retaining ring pliers ST-2N
Bearing plate
Pipe ring
Bearing setting pipe 23-15.2
Tip for retaining ring pliers
1/4" Hex shank bit for M4
1/4" Hex shank bit for M5
V Block
Screwdriver magnetizer
Removing/mounting Ring spring
Stabilizing Bearing box when removing Ball bearing 6002LLU
Stabilizing Crank housing complete when removing Armature
Removing Oil seal 15 and Ball bearing 6002LLU from Bearing box
Removing/mounting Ring spring (for modular use with 1R003)
1R225 Bearing extractor Removing Armature and Ball bearing 6001DDW from Crank housing comp.
Removing M4x25 Hex socket head bolt from Crank housing cover
Removing M5x25 Hex socket head bolt from Barrel
Stabilizing Bearing box when removing Helical gear 36
Magnetizing Screwdriver when removing Steel balls and Pins
Ring 25 Impact bolt
Tool holder
Compression spring 32
23 27 7
Striker
30
Piston
Connecting rod
38
68
37
27 O Ring 12 Whole portion
Cylinder Inside surface that Piston and Striker contacts
Whole portion
30
7 Steel ball 4.8 (3 pcs) Whole portion
23 Steel Ball 7.0 (2 pcs) Whole portion
37 O Ring 18 on Striker
O Ring 18 on Piston Whole portion
38
32
32 Ring 29 Inside periphery that contacts 30 Cylinder
3g
17g
4g
39 Pin 7 Cylindrical surface that contacts Connecting rod
Flat washer 22
Crank housing complete Crank room
Whole portion for smooth rotation
of Helical gear 36
58 59
61
68 Armature Gear portion for smooth rotation
of Helical gear 36
39
AmountLubricant
Makita grease
N.No.2
Makita grease
N.No.1
Makita grease
R.No.00
a little
a little
a little
Crank shaft
Bearing box
Helical gear 36
58
59
61
23
a little
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Motor housing
P 3/17
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Chuck Section
Repair
DISASSEMBLY
DISASSEMBLY
M5x20 Pan head screw (2 pcs)
Handle section
Cap 38
Do the reverse of the disassembling steps.
2) Remove Cap 38 with
slotted screwdriver.
4) Remove Chuck cover and
Compression spring 42.
Steel ball guide
1) For easy repairing, separate Handle section and stand the machine on a workbench as illustrated below on right.
Note: Remove Compression spring 14 before standing the machine if it is left on Crank housing complete.
Disassemble the Chuck section as described in Figs. 2 and 3.
5x25 Tapping screw (2 pcs)
Fig. 2
Fig. 3
Change ring
Guide washer
Conical compression
spring 21-29
Ring 21
Crank housing complete
Disconnect Connector housing
of Controller from Motor housing.
Compression spring 42
Chuck cover
3) Remove Ring spring 19 with 1R212 and
1R003 while pressing down Chuck cover.
5) Remove Steel ball 7 (2 pcs)
using screwdriver magnetized
with 1R288 while pressing
down Ring 21.
7) Change ring can
now be removed.
6) The parts inside Change ring can
be removed.
Ring 21
Steel ball 7 (2 pcs)
Screwdriver magnetized
with 1R288
Chuck cover
Ring spring 19
1R212 and 1R003
Note:
Be sure to press down
Chuck cover or it will
pop off due to the pressure
of Compression spring 42.
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Remove Barrel cover support
and Barrel cover.
P 4/17
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Barrel, Tool Holder, Cylinder Section
Repair
DISASSEMBLY
1) Disassemble the Chuck section as described in Figs. 2, 3.
2) Disassemble Tool holder, Ring 25 and Cylinder section from Barrel as described in Figs. 4,5,6.
Crank housing cover
Ring spring 43
M4x25 Hex socket
head bolt (1 pc)
Steel ball 4.8 (3 pcs)
Remove Crank housing cover. Remove Ring spring 43
with slotted screwdriver.
Remove Steel ball 4.8 (3 pcs) from each hole
of Ring 25 with slotted screwdriver.
Strike Tool holder against work bench. Tool holder, Ring 25 and Cylinder section can now be removed
from Barrel. Remove O ring 48 from Barrel.
Barrel section can now be separated from
Crank housing complete by unscrewing
four M5x25 Hex socket head bolts with 1R229.
Ring 25 Ring 25
Barrel
1R229
Tool holder
Cylinder section O Ring 48
Fig. 4
Fig. 5
Fig. 6
Screwdriver magnetized
with 1R288
Barrel cover
support
Barrel cover
M5x25 Hex socket
head bolt (4 pcs)
Barrel section
Turn counterclockwise.
Ring 25
Barrel
Tool holder
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P 5/17
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Barrel, Tool Holder, Cylinder Section
Repair
DISASSEMBLY
Ring 39
1. Pull out Striker from
Cylinder section.
2. Remove ring 25, Urethane ring 26
and Ring spring 37 from Cylinder.
3. By removing Ring 39, you can see
Pin 6 (3 pcs) that join Tool holder
with Cylinder.
Ring 25
Urethane ring 26
Ring spring 37
Rod 2.5 (3 pcs)
Tool holder
Impact bolt section
Pin 6 (3 pcs)
Cylinder section
Fig. 7
4. By removing Pin 6, Tool holder can be separated from Cylinder section.
Remove Rod 2.5 (3 pcs) from the grooves of Cylinder.
5. Push out Impact bolt section from
Cylinder section using screwdriver.
Note: Pin 6 can be removed as described below if it is difficult to remove.
1. Apply magnetized
screwdriver to Pin 6.
Cylinder
Pin 6
Tool holder
3. Remove Pin 6 using
magnetized screwdriver
when the two holes are
aligned.
Rubber ring 13
Disassembling Impact Bolt Section Disassembling Cylinder Section
Flat washer 12
After removing O Ring 26, the following parts
can be removed from Cylinder:
Cup washer 29, Compression Spring 32, Ring 29
Impact bolt
Fig. 8
Ring 29
Compression Spring 32
Cylinder
Cup washer 29
O Ring 26
3) Separate Tool holder from Cylinder section as described in Fig. 7.
4) Disassemble Impact bolt and Cylinder section as described in Fig. 8.
Striker
Cylinder section
Pin 6 (3 pcs)
Screwdriver,
magnetized with 1R288
2. Align the through hole
of Tool holder with that
of Cylinder by pushing
Tool holder.
Screwdriver,
magnetized with 1R288
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P 6/17
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Barrel, Tool Holder, Cylinder Section
Repair
ASSEMBLY
Fig. 9
Do the reverse of the disassembling steps.
Note: Rubber ring 13 is directional when assembled to Impact bolt.
Be sure to assemble as illustrated to left in Fig. 9.
ASSEMBLY
Do the reverse of the disassembling steps.
DISASSEMBLY
[3] -3. Electrical Parts in Handle Section
Correct Wrong
Rubber ring 13
Impact bolt Flat washer 12
Rubber portion
Metal portion Rubber portion Metal portion
Rubber ring 13
Impact bolt Flat washer 12
1) Disassemble Handle section as described in Fig. 2
2) The electrical Parts can be replaced as described in Fig. 10.
1. Disassemble Handle cover from Handle
by unscrewing 4x18 tapping screw.
2. Disconnect all the Lead wires from Switch.
Controller, Switch and Power supply cord can now be replaced.
Fig. 10
Handle cover
Handle base
4x18 Tapping screw (1 pc)
Handle
Controller
Switch
4x18 Tapping
screw (1 pc)
Power supply cord
Strain relief
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P 7/17
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Motor Section
Repair
1) Disassemble Handle section as illustrated in Fig. 2
2) Separate the contact of Carbon brushes from Commutator as described in Fig. 11.
3) Disassemble Crank housing complete from Motor housing as illustrated in Fig. 12.
4) Remove Piston from Crank shaft as illustrated in Fig. 13.
DISASSEMBLY
1. Disconnect Crank housing cover
from Crank housing complete
by unscrewing M4x25 Hex socket
head bolt; no need to remove the
cover in this step.
2. Lifting up Crank housing cover,
remove Barrel section from
Crank housing by unscrewing
four M5x25 Hex socket head
bolts.
3. Disassemble Crank housing
complete from Motor housing
by unscrewing four 5x25
Tapping screws.
1. Remove Rear cover from Motor housing.
Fig. 11
Fig. 12
Crank housing cover
M4x25 Hex socket
head bolt (1 pc) 5x25 Tapping
Screw (4 pcs)
M5x25 Hex socket
head bolt (4 pcs)
Motor housing
Crank housing complete
Rear cover
4x18 Tapping screw
(2 pcs)
Motor housing
2. Remove the end of Spiral spring
from Carbon brush because
Carbon brush is pressed with
Spiral spring to maintain secure
contact with Commutator.
3. By pulling Carbon brush,
separate the contact of
Carbon brushes from
Commutator.
[Spiral spring and Carbon brush
viewed from A]
Carbon brush Spiral spring
M4x18 Pan head
screw (4 pcs)
Crank cap
Crank housing
complete Crank chamber,
viewed from Crank cap side
1. Remove Crank cap by unscrewing
four M4x18 Pan head screws.
Piston
Fig. 13
2. For easy removal of Piston,
move it to the front dead center.
PistonM4x16 Hex socket
head bolt (2 pcs)
3. Remove Piston, then unscrew
two M4x16 Hex socket head
bolts that fasten Crank section
to Crank housing complete.
A
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P8/17
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Motor Section
Repair
5) Remove Crank section from Crank housing complete by tapping
Crank housing complete with plastic hammer. (Fig. 14)
6) Remove Armature from crank housing complete using 1R023,
1R225 and arbor press as described in Fig. 15.
DISASSEMBLY
1. Set Crank housing complete
on 1R023, and apply the thin
end of 1R225 to Armature shaft.
Then press down 1R225 using
arbor press until it stops.
2. Turn over 1R225, and fit the pin on the thick end of 1R225
in the inner race of Ball bearing 6001DDW.
Armature can now be removed by pressing down 1R225
using arbor press.
Fig. 15
Ball bearing
6001DDW
1R023
Armature shaft
thin end
of 1R225
thick end
of 1R225
Fig. 14
Crank section
O Ring 39
thin end
of 1R225
thick end
of 1R225
Note:
1R225 of old specification cannot
be set in place due to the height A
of 20mm. If your 1R225 is old one,
grind down the height A to 15mm
or less using power grinder.
[Cross-sectional view] [Cross-sectional view]
pin
height A
1R225
ASSEMBLY
Do the reverse of the disassembling steps.
Note: Make sure that O Ring 39 is mounted to Bearing box of Crank section before assembling Crank section
to Crank housing complete. (Fig. 14)
Crank housing complete
Crank housing
complete
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P 9/17
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Gear (Crank) Section
Repair
DISASSEMBLY
Fig. 16
ASSEMBLY
Do the reverse of the disassembling steps.
Note: Make sure that O Ring 39 is mounted to Bearing box of Crank section before assembling Crank section
to Crank housing complete. (Fig. 14)
1) Disassemble Gear (Crank) section from Crank housing complete as described in Figs. 11 - 14.
2) Gear (Crank) section can now be disassembled as described in Fig. 16.
Ball bearing 6002LLU
1R029
1R022
Bearing box
Crank shaft
1R258
Oil seal 15
1. Stabilizing Bearing box
of Gear section on 1R258,
remove Crank shaft using
arbor press.
2. Remove Helical gear 36
and Flat washer 22 (2 pcs)
from Bearing box.
3. Put 1R022 under Bearing box to make
Bearing box parallel to arbor press,
then apply 1R029 to Oil seal 15.
By pressing down 1R029 with arbor press,
Oil seal 15 and Ball bearing 6002LLB
can be removed from Bearing box.
Flat washer 22
(2 pcs)
Helical gear 36
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P 10/17
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Handle Section
Repair
DISASSEMBLY
M5x20 Pan head
screw (2 pcs)
5x25 Tapping
screw (2 pcs)
Handle section
Handle section consists of the following main parts: Handle base, Handle, Handle cover
And it can be disassembled as illustrated in Figs. 17 - 20.
Handle base
Handle
Lock-on button
Stop ring E-4
Switch Lever
Compression spring 8
Dust cover
Dust cover support
Spring guide
Handle cover
Handle base
3. Separate Handle from Handle base.
Note: See Fig. 10 for disassembling the electrical parts
in Handle section.
4. Remove Switch lever and Stop ring E-4
from Handle. Compression spring 8 and
Lock-on button can now be removed.
Handle
Shoulder sleeve 6 (2 pcs)
Fig. 17 Fig. 18
Fig. 19 Fig. 20
4x18 Tapping screw (2 pcs)
4x18 Tapping screw (1 pc)
1. Separate Handle section from the machine first by removing the four
screws illustrated below, then by disconnecting Connector housing of
Controller from Motor housing; Compression spring 14 can be
removed from Crank housing in this step.
2. Remove Handle cover and
Spring guide from Handle base.
Connector housing
of Controller
Compression spring 14
5x25 Tapping screw (2 pcs)
ASSEMBLY
Do the reverse of the disassembling steps.
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P 11/17
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Recommended Fastening Torque of Screws and Bolts
Repair
Tighten the bolt to the recommended torque described in Fig. 21.
Fig. 21
Fig. 22
[4] MAINTENANCE PROGRAM
When replacing carbon brush, it is recommended to do the following maintenance at the same time
for longer service life of the machine.
1) Replace the parts described in Fig. 22 with new ones.
2) Wash out or wipe off old grease in Crank housing complete, and lubricate the parts
in accordance with the instructions in [2] LUBRICATION. (Refer to Fig. 1.)
Chuck cover Guide washer Change ring
Impact boltTool holder
Steel ball 4.8
Ring 21 Striker Cylinder Piston
Connecting rod
Ring 29
1
23
Cap 38
Item No. Description
Urethane Ring 26
Steel ball 7.0 (2 pcs)
O Ring 12
Rubber Ring 13
O Ring 18 (thick one)
27
28
37 38
9
Barrel
Crank housing
complete
19
19
Item No. Fastening Torque
Q'ty
Description
47.8 - 11.8 N.m M5 x 25 Hex socket head bolt
1
239 27 28 3837
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P 12/17
Circuit diagram
White
Red
Orange
Blue Brown
Color index of lead wires' sheath
Black Clear
Fig. D-1A
Connector housing A
Polyolefin tube (Protective tube)
Connector housing B
Switch
Connector
Power supply cord
Controller
High Voltage Areas where Radio Interference Suppression Is Required
Fig. D-1B
Fig. D-1C
Low Voltage Areas where Radio Interference Suppression Is Required
Other Areas where Radio Interference Suppression Is Not Required
Connector housing A
Switch
Controller
Noise
suppressor
Connector housing A
Grounding (Earth) terminal
Switch
Controller
Power supply cord
Power supply cord
Connector
Connector
Polyolefin tube (Protective tube)
Polyolefin tube (Protective tube)
Choke coil
Noise
suppressor
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Wiring diagram
P 13/17
Handle base,
viewed from
Controller side
Handle
Through hole for
passing Lead wires
from Controller and
Connector housing
to the opposite side
Handle cover
Handle,
viewed from Handle cover side
Handle base
Controller
Be careful not to pinch the Lead wires with the ribs. (Figs. D-2, D-3)
[1] Routing Wires Through Handle Base and Handle
Fig. D-2
Fig. D-3
Do not put the Lead wires on this rib
or they will be pinched between the rib
and Handle.
Do not to put the Lead wires on these ribs
or they will be pinched between the ribs
and Motor housing.
Through hole for
passing Grounding
(Earth) wire from
the opposite side
Through hole for
passing Lead wires
to the opposite side
Do not to put the Lead wires on this rib
or they will be pinched between the rib
and Handle cover.
Noise suppressor
(if used)
Do not to put the Lead wire (clear)
of Noise suppressor on these ribs.
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Wiring diagram
P 14/17
Fig. D-4A
Fig. D-5A
Handle base,
viewed from Controller side
Handle base,
viewed from Handle side
Handle, viewed from Handle cover side
red
blue
Lead wires covered with
Polyolefin tube (black)
Controller
Connector housing A
Connector housing B
Choke coil
Controller
Noise suppressor
Switch
Switch holder
Pass the following Lead wires
through this hole:
*Noise suppressor's Lead
wires (black)
*Controller’s Lead wires covered
with Polyolefin tube (black)
*Lead wire (red) from
Connector housing A
*Controller's Lead wire (white)
Pass Controller’s Lead wires covered
with Polyolefin tube (black) between
Switch and Switch holder's wall.
[2] Wiring in Handle Base and Handle
High Voltage Areas where Radio Interference Suppression Is Required
boss
rib
Put the slack portion of
Lead wires in this space.
Route all of the Controller's
Lead wires through this slit.
Fix the following Lead wires of
Controller with this Lead wire holder:
*Lead wire (orange) to Choke coil
*Lead wires (black, red) to Connector
housing A
Pass these Lead wires from Controller
and Connector housing A through
the hole illustrated to right in Fig. D-2.
The Lead wires to Connector
housings must be tight between
Controller and Lead wire holder.
Route all of the Lead wires
to Switch through between
the boss and the rib.
Fix all of the Lead wires to Switch
with this Lead wire holder of
Switch holder complete.
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Wiring diagram
P 15/17
Fig. D-4B
Fig. D-5B
[2] Wiring in Handle Base and Handle
Low Voltage Areas where Radio Interference Suppression Is Required
The Lead wires to Connector
housing A must be tight between
Controller and Lead wire holder.
Terminal of Grounding wire
Grounding wire (clear)
Controller
Put the slack portion of
Lead wires in this space.
Route all of the Lead wires
to Switch through between
the boss and the rib.
Fix all of the Lead wires to Switch
with this Lead wire holder of
Switch holder complete.
Handle Base,
viewed from Handle side
Handle, viewed from Handle cover side
Noise suppressor
Switch
Switch holder
Pass Controller’s Lead wires covered
with Polyolefin tube (black) between
Switch and Switch holder's wall.
boss
rib
Handle base,
viewed from Controller side
Pass the following Lead wires
through this hole:
*Noise suppressor's Lead
wires (black)
*Controller’s Lead wires covered
with Polyolefin tube (black)
*Lead wire (red) from
Connector housing A
*Controller's Lead wire (white)
Pass Grounding wire (clear)
through the hole illustrated
to right in Fig. D-2.
red
white
Route all of the Controller's
Lead wires and grounding
wire (clear) through this slit.
Fix the following Lead wires of
Controller with this Lead wire holder:
*Grounding wire (clear)
*Lead wires (black, red) to Connector
housing A
Controller
Connector housing A
Lead wires covered with
Polyolefin tube (black)
Pass these Lead wires from Controller
and Connector housing A through
the hole illustrated to right in Fig. D-2.
Grounding wire (clear)
Fix Grounding wire (clear)
with this Lead wire holder.
Put the slack portion of
Grounding wire in this space.
Fix Grounding wire (clear)
with this Lead wire holder.
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Wiring diagram
P 16/17
Fig. D-4C
Fig. D-5C
[2] Wiring in Handle Base and Handle
Other Areas where Radio Interference Suppression Is Not Required
Put the slack portion of
Lead wires in this space.
Route all of the Lead wires
to Switch through between
the boss and the rib.
Fix all of the Lead wires to Switch
with this Lead wire holder of
Switch holder complete.
Handle base,
viewed from Handle side
Handle, viewed from Handle cover side
Switch
Switch holder
Pass Controller’s Lead wires covered
with Polyolefin tube (black) between
Switch and Switch holder's wall.
boss
rib
Handle base,
viewed from Controller side
Pass the following Lead wires
through this hole:
*Controller’s Lead wires covered
with Polyolefin tube (black)
*Lead wire (red) from
Connector housing A
*Controller's Lead wire (blue)
The Lead wires to Connector
housing A must be tight between
Controller and Lead wire holder.
Controller
red
blue
Connector housing A
Lead wires covered with
Polyolefin tube (black)
Pass these Lead wires from Controller
and Connector housing A through
the hole illustrated to right in Fig. D-2.
Controller
Route all of the Controller's
Lead wires through this slit.
Fix the following Lead wires of
Controller with this Lead wire holder:
*Lead wires (black, red) to Connector
housing A
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Wiring diagram
P 17/17
Fig. D-6
[3] Connecting Connector Housing with Brush Holder Unit
Rear cover
The side where Lead wires are drawn out must be placed on Rear cover side as illustrated blow.
to Controller
on Handle base
Connector housing A
Connector housing B
(if used)
Motor housing
Choke coil
(if used)
Connector housing is directional when connected with Brush holder complete in Motor housing.
Be sure to connect as described in Fig. D-6.
2. Do not put Lead wires on Connector
housing(s) or Lead wires will be
pinched between Handle base and
Motor housing.
[DO NOTs]
1. The side where Lead wires are drawn out
must not be placed on the opposite side to
Rear cover.
side where Lead wires
are drawn out
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