Makita HM0860C Manual

PRODUCT
TECHNICAL INFORMATION
* Bar style side handle ............................ 1 pc.
* Bit grease .............................................. 1 pc.
* Plastic carrying case ............................. 1 pc.
Model No.
Description
HM0860C
Demolition Hammer
Now the 5 kg class SDS-max demolition hammer has been released.
Its features and benefits are as follows.
* SDS-max bit can be used.
* Lightest weight 4.7kg (10.4lbs) in this class, but high performance
* Electronic features for soft start and speed control
* Indication lamp informs operator of the machine's condition.
* 12 angle settings of hammer bit
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
< 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 )
223 (8-3/4)
99 (3-7/8)
454 (17-7/8)
Blows per min: bpm=min
Protection from electric shock
Net weight :Kg (lbs)
Cord length : m (ft)
Single blow energy : J
Shank SDS-max
1.8 - 12
1,100 - 2,650
by Double insulation
5.0 (16.4) For Europe : 4.0 (13.1)
4.7 (10.4)
L
H
W
Optional accessories
* Various bull points
* Various cold chisels
* Various scaling chisels
* Clay spade
* Bushing tool
* Rammer
* Shank for rammer
* Shank for bushing tool
* D formed side handle
* Hammer service kit
(a set of repairing parts)
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output(W)
110 1,100
1,100
1,100
1,100
1,100
1,200
1,200
1,200
1,200
1,200
120
220
230
240
540
540
540
540
540
11
10
5.6
5.3
5.1
Current (A)
50 / 60
50 / 60
50 / 60
50 / 60
50 / 60
Diameter :18mm (11/16")
-1

Handling
<1> Necessary repair tools
<2> Lubrication
Refer to instruction manual for handling of the tool and follow the instructions.
Apply a tube (30g) of Makita grease R No. 00 in total to the portions designated by arrows as shown below.
Also apply a little bit of Makita grease N No.2 to the portions by designated by circles.
(Code No.)
<3> Fastening torque for screws/bolts
Fasten various screws/bolts of the tool with specified torque as shown below.
M5x20 Pan head screws
5x25 Tapping screws Handle
Screws/bolts Position in use Fastening torque
Handle 1.8 up to 3.5 N.m.
Crank cap 1.8 up to 3.5 N.m.
1R003
1R269
1R034
1R005
1R225
1R214
Retaining ring pliers ST-2N 250mm for external ring
Bearing extractor
Bearing setting plate 12.2
Retaining ring pliers RT-2N 250mm for internal ring
Bearing extractor
Taper sleeve
(Tool Name)
Repair
2.5 up to 3.0 N.m
Motor housing 2.5 up to 3.0 N.m
4x18 Tapping screws
Strain relief 1.3 up to 1.8 N.m
Rear cover 1.3 up to 1.8 N.m
Brush holder cover 1.3 up to 1.8 N.m
Switch box 1.3 up to 1.8 N.m
Crank housing coverM5x25 Hex. socket head bolt 4.9 up to 7.4 N.m
BarrelM6x30 Hex. socket head bolt 7.8 up to 12.0 N.m
FanM6 Hex. nut 1.8 up to 3.7 N.m
Inside lip of tool holder cap
: 0.5g The remaining Makita grease R. No.00 (25.0g):
In the crank room
Contact area of tool retainer
and bull point installed: 0.5g
Contact area of urethane ring 28
and Flat washer 29: 0.1g
Surface of tool holder: 0.2g
Surface of
pin 8: 0.2g Contact area of piston and
crank shaft complete: 0.2g
Contact area of crank shaft
complete and flat washer 14: 0.1g
Surface of
o-ring 38: 0.2g
Surface of
o-ring 24: 0.5g
Surface of
o-ring 24: 0.2g
Surface of
o-ring 26: 0.2g
Contact area of rubber ring 20
and cup washer 23: 0.2g
P 2 /14
Surface of urethane ring
and tool holder: 0.1g
Surface of striker: 3.0g
Inside of sleeve: 0.1g
Contact area of flat washer 14 and
crank housing complete: 0.1g
Engaging area of gears of armature and
crank shaft complete: 0.2g
Surface of steel ball 4.8: 1.0g
Surface of o-ring 23 and
fluoride ring 28: 1.0g
Contact area of slide sleeve
and cylinder 32: 0.2g
Contact area of cup washer
and guide ring: 0.2g

<4> Disassembling/Reassembling Chuck Portion
<4>-1. Disassembling Chuck Section
(1) Slide Chuck cover in the direction of Gear housing,
and remove Tool holder cap from the machine.
(Fig. 1)
(2) Remove Chuck cover from Tool holder.
<4>-2. Reassembling Chuck Section
(1) Pressing Spring guide in the direction of Gear housing, insert two Tool retainers to the oval holes
on Tool holder. (Fig. 3)
Note: 1) Be sure to insert Tool retainers.
2) As soon as Tool retainers are set in place, release Spring guide so that Tool retainers
can be set in place.
P 3 /14
(3) Remove Ring spring 25 from tool holder using Retaining ring pliers ST-2N (1R003).
And then remove Flat washer 28, Urethane ring 28 and Chuck ring from Tool holder.
(4) Remove two Tool retainers from Tool holder by pulling them out with long nose pliers etc.
while pressing Spring guide in the direction of Gear housing. (Fig. 2)
Note: Be sure to release Spring guide slowly as soon as the two Tool retainers are removed,
or Spring guide and Compression spring 52 will pop out.
Fig. 1
Fig. 3
Fig. 2
Tool holder cap
Chuck cover
Tool retainer (2 pcs.)
Tool holder
Tool retainer
Tool retainer
Spring guide Compression spring 52
Spring guide
Compression spring 52
Ring spring 25
Flat washer 28 Urethane ring 28
Chuck ring
(to the machine)
(Image of inside
of the spring)

P 4 /14
Fig. 5
Fig. 7
Fig. 6
Chuck ring
Urethane ring 28 (reversible when assembled to Tool holder)
(2) Install Chuck ring, Urethane ring 28 and Flat washer 28 on Tool holder as in Fig. 4,
and then set Ring spring 25 with Retaining ring pliers ST-2N (1R003).
<5> Disassembling/reassembling Change Ring
<6> Disassembling/reassembling Armature Assembly
<5>-1. Disassembling Change Ring
<5>-2. Reassembling Change Ring
<6>-1. Disassembling Armature Assembly
(1) Remove Crank housing cover after disassembling Chuck section.
(1) Remove Ring spring 50 from Change ring with slotted screwdriver.
Note: Be careful not to let Ring spring 50 pop out.
(2) Remove Plate.
(3) Remove Steel ball 4.8 (4 pcs.) by moving Change ring back and forward,
and you will find Steel balls stuck to the grease on the four grooves of Tool holder.
(4) Now Lock ring and Change ring can be removed.
(1) Fix Lock ring to Change ring as in Fig. 5 so that the depressions of Lock ring can face the direction of
bit side.
(2) Put Steel ball 4.8 (4 pcs.) in the four grooves of Tool holder and depressions of Lock ring.
Note: Lock ring is not reversible.
(3) Put Plate in place, and then put Ring spring 50 in the groove of Change ring using slotted driver, etc.
Ring spring 25 Flat washer 28
Slotted screwdriver
Inserting space for
slotted driver
(2) Remove Handle by removing M5x20 Pan head screws (2 pcs.) and 5x25 Tapping screw (2 pcs.).
and then disconnect Connectors.
(3) Remove 4x18 Tapping screws on both sides of Motor housing with Phillips screwdriver. (Fig. 6)
Plate
Ring spring 50 View of Lock ring from bit side
Lock ring
Change ring
Change ring
assembled
to Lock ring
Tool holder
Steel ball 4.8
Fig. 4
Four depressions
for Steel ball 4.8
cannot be seen.
Four depressions
for Steel ball 4.8
can be seen.
Phillips Screwdriver
4x18 Tapping screw
(4) Remove Brush holder covers with slotted screwdriver inserted into the inserting spaces as in Fig. 7.
Bit side [wrong] [correct]

P 5 /14
Fig. 8
Fig. 9
(6) Remove Fan 76 as described below;
Holding Fan by hand, turn M6 Hex. nut located under
Fan 76 counterclockwise with an M10 hex socket attached
to Makita impact driver.
Caution: Be sure to wear gloves when you hold Fan 76
on removing M6 Hex. nut, or Fan 76 could
injure your hand.
(5) Separate Rear cover from Motor housing by removing
four M4x18 Tapping screws as in Fig. 8.
(8) Remove Ball bearing 6201LLU and Sleeve 12 from Armature assembly at the same time using Bearing
extractor (1R269).
(9) Remove Ball bearing 608DDW and Insulation washer from Armature assembly at the same time using Bearing
extractor (1R269).
(1) After setting Flat washer 12 in place, press-fit Ball bearing 6201LLU to the drive-end of armature shaft using
Bearing setting plate 12.2 (1R034) and arbor press. (Fig. 9)
(7) Armature assembly can be separated from Motor housing complete by removing four 5x25 Tapping screws that
fasten Crank housing to Motor housing complete.
Armature assembly will be removed from Motor housing complete together with Crank housing. So remove
Armature assembly from the Crank housing by knocking on the end of Crank housing with wooden or plastic
hammer.
Note: Don't forget to set Flat washer 12.
Rear cover
Motor housing
4x18 tapping screw
(4 pcs.)
ø12.2mm
(1/2")
Bearing Setting
Plate 12.2
(1R034)
Bearing Setting
Plate 12.2
(1R034)
<6>-2. Reassembling Armature Assembly
Ball bearing 6201LLU
Flat washer 12
Ram of arbor press
Table of arbor press
(2) Gently press-fit Sleeve 12 to the drive-end of armature shaft using Bearing setting plate 12.2 (1R034) and arbor
press. (Fig. 9)
(3) Gently press-fit Insulation washer and Ball bearing 608DDW to the commutator end of armature shaft
using Bearing setting plate (1R034). (Fig. 10)
Fig. 10
Ball bearing 608DDW
Insulation washer: The end with smaller periphery
must face the direction of Ball
bearing 608DDW as illustrated.
(4) And then fix Armature assembly to Crank housing.
Do the reverse of the procedure described in "Disassembling Armature Assembly" in page 4 to 5.
Sleeve 12

P 6 /14
<7> Disassembling/reassembling Tool Holder
<7>-1. Disassembling Tool Holder
<7>-2. Reassembling Tool Holder
(1) Remove Retaining ring R-42 from Barrel using Retaining R pliers RT-2N (1R005).
(2) Take Flat washer 29 and Urethane ring 28 out of Barrel.
(3) Take Tool holder out of Barrel.
(4) Remove Impact bolt from Tool holder by striking Impact bolt with a proper round bar as illustrated in Fig. 11.
(1) Put Impact bolt into Tool holder.
Be sure to place Impact bolt as illustrated in Fig. 12,
because it is not reversible when assembled to
Tool holder.
(2) Set Flat washer 29, Urethane ring 28 and Retaining
ring R-42 in place by doing the reverse of the
disassembling procedure described in <7>-1.
Urethane ring 28 and Flat washer 29 are reversible
when assembled to Barrel.
Fig. 11
Fig. 12
Flat washer 29
Retaining ring R-42
Urethane ring 28
Impact bolt
Barrel
Tool holder
Impact bolt
Tool holder
shorter end longer end

P 7 /14
<9> Removing /Installing Oil Seal 15
<9>-1. Removing Oil Seal 15
Fig. 14
Oil Seal 15
Bearing extractor
(1R225)
Fit a washer onto Oil seal 15, and
push it using Bearing extractor
and arbor press.
As illustrated in Fig. 14, push Oil seal 15 out of Crank housing complete using following tools;
Bearing extractor (1R225), arbor press, *washer of proper size, **Bearing setting plate
*The ram diameter of the Bearing extractor is too small to push the oil seal. So a washer of proper size is
necessary as an auxiliary tool.
** Any one of the six Bearing setting plates can be used.
<9>-2. Installing Oil Seal 15
Oil seal 15 can be press-fitted into Crank housing complete using arbor press and washer as follows;
(1) Put Crank housing complete on Bearing setting plate so that its motor side of Crank housing faces
the ram of arbor press.
(2) Carefully press-fit Oil seal 15 to Crank housing complete.
Caution: The groove of Oil seal 15 must face the side of Crank housing cover.
Wrong installation will result in damages to the machine.
Ram of arbor press
Motor side of
Crank housing complete
Crank housing cover side of
Crank housing complete
Bearing setting plate
table of arbor press
Fluoride ring 28 can be removed from Impact bolt using slotted driver.
When installing Fluoride ring 28 on Impact bolt, use a Taper sleeve (1R214). (Fig. 13)
<8> Removing/Installing Fluoride Ring 28
Insert Impact bolt
into Taper sleeve
from the end on
which "HR5001C"
is stamped.
Fig. 13
Note:
Do not fail to place
an O ring 23 under
Fluoride ring 28.
Fluoride Ring and Taper Sleeve
Use Taper sleeve for fitting fluoride ring to impact bolt of Rotary Hammers.
Once expanded, fluoride ring does not shrink to its initial size by itself. So, after you install fluoride ring
on the groove of impact bolt, insert the impact bolt into Taper sleeve to the full. And hold them on at least
for 15 seconds till the fluoride ring fits completely to the impact bolt.
Note: Do not reuse the fluoride ring removed from impact bolt. Always use fresh one for replacement.
If you find difficulty in pulling out Impact bolt after
installation of Fluoride ring 28, remove Impact bolt
by hitting around bar inserted from the opposite end.
120mm
ø45mm
ø20mm
ø30mm
HR5001C HR4000C
[cross section of Taper Sleeve]
Impact bolt
Taper sleeve
Washer of
proper size
Crank housing complete
round bar

P 8 /14
<10> Disassembling/reassembling Cylinder Section
<10>-1. Disassembling Cylinder Section
(1) Separate Barrel from Crank housing comp. by removing M6x30 Hex. socket head bolts (4 pcs.) as in Fig. 15.
(2) Cylinder section can be removed from Barrel by hitting the end of Barrel with wooden or plastic hammer
as illustrated in Fig. 16.
(3) Remove Cylinder guide by removing Ring spring 34 from Cylinder
using Retaining ring S pliers (1R003). (Fig. 17)
(4) Remove Compression spring 37 and Ring 36 by removing Ring spring 34 from Cylinder using
Retaining ring S pliers (1R003). (Fig. 18)
M6x30 hex. socket
head bolts
Crank housing complete
Barrel
Fig. 15 Fig. 16
Fig. 17
Retaining ring S pliers
ST-2N (1R003)
Cylinder guide
Ring spring 34
Fig. 18
Retaining ring S pliers
ST-2N (1R003)
Ring 36
Compression spring 37
Ring spring 34
(5) Take Rubber ring 20 and Cup washer 23 out of Guide ring.
Now Guide ring and Slide sleeve can be removed from Cylinder. (Fig. 19)
Fig. 19
Rubber ring 20
Cup washer 23
Guide ring
Guide ring Slide sleeve
Cylinder
Plastic (or wooden)
hammer
Cylinder section

P 9 /14
Do the reverse of the disassembling procedure described in <10>-1.
<10>-2. Reassembling Cylinder Section
Note: When reassembling Cylinder section, be sure to follow the instructions below;
1) Rubber ring is not reversible when installed on Cup washer 23 in Guide ring.
The metal portion of Rubber ring 20 must face the direction of Bit side. (Fig. 20)
(4) Striker is not reversible when put into Cylinder.
Be sure to place Striker so that the end where O ring 24 is installed faces the direction of
Crank housing. (Fig. 23)
Fig. 23
Barrel Cylinder section
Fig. 20
[Cross section of Rubber ring 20
illustrated to right]
Metal portion
Plastic portion
Rubber ring 20 Cup washer 23
Guide ring
Cylinder
(Bit side)
(Crank housing side)
(Bit side)
(Crank housing side)
(Bit side) (Crank housing
side)
3) Insert the assembled Cylinder section to the full from Crank housing side till Cylinder guide is
completely hidden by Barrel. (Fig. 22) At this time, Rubber ring 20 could fall off Cylinder section.
However, it can be reinstalled on Cylinder section from the bit side of Barrel.
Fig. 22
(Crank housing side)
2) Cylinder guide is not reversible when installed
on Cylinder.
The end where O ring 46 is installed must face
the direction of Crank housing side. (Fig. 21)
Fig. 21
O ring 46
Cylinder guide
(Bit side)
Cylinder guide Cylinder guide
Cylinder
Striker
(Crank housing side)
(Bit side)
Place Striker as illustrated below.
O ring 24
(Crank housing side)
(Bit side)

P 10 /14
<11> Disassembling/reassembling Piston
<11>-1. Disassembling Piston
<11>-2. Reassembling Piston
(1) Separate crank cap from crank housing complete by removing M5x20 pan head screws (4 pcs.) with
screwdriver. (Fig. 24)
(2) Set the Crank shaft complete to the position of the nearest to cylinder, then Piston and Connecting rod can be
removed. (Fig. 25)
(3) Take O-ring 26 out, and remove Pin 28 from Piston.
(1) Insert Pin 28 into Piston and Connecting rod, and then set O-ring 26 onto the groove of Piston.
Fig. 24
Fig. 25
M5x20 pan head screws (4 pcs.)
Crank cap
Bit side
Bit side
Bit side
Crank housing complete
Crank shaft complete
Connecting rodPiston
Fig. 26
Crank shaft complete
Connecting rod
Pin 28O-ring 26
O-ring 24
Piston
(4) Take O-ring 24 out from Piston.
(2) Set O-ring 24 into the another groove (close to Bit side) of Piston.
(3) Once moving crank shaft complete to the position as Fig. 26, install the assembled Piston portion.

P 11 /14
<12> Disassembling/reassembling Switch Portion
<12>-1. Disassembling Switch Portion
(1) Separate Handle from machine by removing two M5x20 pan head screws on the upper side and two 5x25
tapping screws on the lower side. (Fig. 20) And then disconnect the terminal from the Controller as
illustrated in Fig. 27.
<12>-2. Reassembling Switch Portion
See Fig. 30 for the details.
(1) Put switch between ribs of Switch box, and then insert Rubber pin 4 into the place designated by allow.
Note: ON-OFF indication of Switch must face upward.
(2) Separate two 4x18 tapping screws of Switch box from the reverse side of Handle, and remove the Switch
box. (Fig. 29)
Note: Take care not to lose Leaf spring in the Switch box.
(3) Remove Switch from Switch box.
(2) Install Switch box with Switch into Switch lever in Handle.
Note: Do this step while moving Switch lever to right and left by fingers, and you can fit toggle of
Switch to groove of Switch lever.
(3) Secure Switch box to Handle by two 4x18 tapping screws, and connect the terminals to the controller, then
put lead wires with connecters to ribs.
After checking the all assembling work, fix Handle to machine by screwing two M5x20 pan head screws
on the upper side and two 5x25 tapping screws on the lower side.
4x18 tapping screw
Ribs of switch box
Switch box
4x18 tapping screw
Handle
Switch
Leaf spring
M5x20 Pan head screw (2 pcs.)
Fig. 27
Fig. 29
Fig. 28
5x25 Tapping screw (2 pcs.) Connectors
Fig. 30
Handle
Groove of switch lever
Toggle of Switch
Rubber pin 4

Wiring
Put the lead wires to three lead holders of Handle as Fig. 31.
Do not slack the lead wires at this place.
Put the lead wires in each lead holder of Motor housing as Fig. 33.
Handle
Motor housing
Motor housing
Brush holders
Pass the lead wire (red) for connecting with Brush holder between bosses and wall of Motor housing as Fig. 32.
Lead holders of Motor housing
P 12 /14
Bosses of Motor housing
Lead wire (red) for connecting with Brush holder
Lead holders
Fig. 33
Fig. 32
Fig. 31

Circuit Diagram Switch
black
white
Lead wire (blue) of Controller
(for 220-240V)
(white: for 115-127V)
Lead wire (black) of controller
Clamping lead wires of Field
Terminal for carbon brush detection
Controller
Connector
Terminal block
Power supply cord
Pick-up coil
white
black
black
black
black
red
P 13 /14

Maintenance program
P 14 /14
The service life of Makita genuine Carbon brushes is approximate 120 hours.
When replacing the Carbon brushes, we recommend you of replacement of the following parts at the same time.
How to change Grease:
(1) Remove Crank cap from Crank housing complete. Refer to Fig. 17 of page 10.
(2) Rest the machine on the table with the bit end pointing upwards as Fig. 34. This will allow the old grease
coming down to the Crank housing.
(3) Wipe up the old grease gathered in Crank housing with cloth.
(4) Put the fresh grease into the Crank housing and other portions in accordance with the step in page 2,
"Lubrication".
Grease 30cc (See note below.)
Tool holder cap
2pcs. of Tool retainers
O ring 23
Fluoride ring 28
2pcs. of O ring 24
Description Part No.
181573-3 (In a vessel)
286269-2
310108-5 / 1pc. (Order 2 pcs. from Makita service center.)
213394-6
213431-6
213958-6 / 1pc. (Order 2 pcs. from Makita service center.)
Fig. 34