Makita HM1205C Manual

P 1/ 17
Specification
Impacts per min.: min.ˉ¹ = ipm
Shank type
Variable speed control by dial
Soft start
950 - 1,900
Adapted for SDS-MAX bits
18 (11/16)
Model No.
Voltage (V)
110
120
220
230
240
15
14
7.8
7.8
7.8
50/60 1,510
---
1,510
1,510
1,510
50/60
50/60
50/60
50/60
700
700
750
750
750
1,600
1,600
1,800
1,800
1,800
Current (A) Cycle (Hz) Input Output Max. Output (W)
Continuous Rating (W)
HM1205C
Yes
Yes
Yes
Double insulation
Europe: 4.0 (13.1)
Chile, Brazil: 2.0 (6.6)
Other countries: 5.0 (16.4)
9.7 (21.4)
Shank diameter: mm (")
Vibration
absorption
Electronic
control
Vibration absorbing handle
AVT (Anti-Vibration Technology using
Active dynamic vibration absorber)
Weight according to
EPTA-Procedure 01/2003*: kg (lbs)
Constant speed control
Suppression of motor speed
during no-load
Power supply cord: m (ft)
Protection from electric shock
No
No
No
* With Side handle
Note: The standard equipment for the tool
shown above may vary by country.
PRODUCT
CONCEPT AND MAIN APPLICATIONS
HM1205C
Demolition Hammer
Model HM1205C is a demolition hammer developed from model HM1203C.
Its main features are:
• Enhanced chipping sensation to soft materials
• Unrivalled high efficiency and durability as well as model HM1203C
• No changes for exterior design from model HM1203C
Models No.
Description H
TECHNICAL INFORMATION
Dimensions: mm (")
Width (W)
Length (L) 576 (22-3/4)
128 (5)
265 (10-3/8)Height (H)
Standard equipment Optional accessories
Side handle (D-shaped) ......................1
Bit grease ...........................................1
Bull-Point 18-280 ..............................1
Cleaning cloth ....................................1
Plastic carrying case ...........................1
Assorted Bull points Assorted Cold chisels
Assorted Scaling chisels Scaling chisel (for Tile)
Grooving chisel Scoop
Bushing tool Rammer
Shank (for Bushing tool and Rammer) Bit Grease
Side handle assembly (D-shaped) Hammer grease
Plastic case Syringe
Safety Goggle Hammer Service Kit
W
L

P 2/ 17
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the Hammer bit from the machine for safety before repair/ maintenance
in accordance with the instruction manual!
[2] LUBRICATIONS
Apply lubricants to the portions designated by triangles to protect parts and product from unusual abrasion.
Code No. Description Use for
1R003 Retaining Ring S Pliers ST-2N removing / assembling Ring spring
1R045 Gear Extractor (large) removing Armature from Gear housing
1R212 Tip for Retaining Ring Pliers removing / assembling Ring spring (attach it to 1R003)
1R214 Taper Sleeve fitting Fluoride ring to Impact bolt
1R229 1/4” Hex. Shank Bit for M5 unscrewing M5 Hex bolts and M6 H.S. Button head screw
1R231 1/4” Hex. Shank Bit for M8 unscrewing M8 Hex bolts when disassembling Barrel
1R232 Pipe 30 assembling Helical gear
1R258 V Block accepting Helical gear 57 when removing Crank shaft
1R263 Bearing Extractor separating Motor section from Crank housing
1R269 Bearing Extractor removing Ball bearing 6000DDW from Commutator end of Armature
1R346 Center Attachment for 1R045 when removing Armature from Gear housing
1R363 Ring Spring Removing Tool removing Ring spring 26 from Tool holder
Fig. 1
Item No.
Ring spring 26
Flat washer 30
Chuck cover
Description
Tool holder cap
Portion to lubricate for Tool holder section Amount
a little
Lubricant
Makita grease N No.2
Makita grease R No.00
1
6
6
24
23
24
Rubber ring 30
Release cover
Spring guide
Change ring
Lock ring
8
a
b
8
Chuck ring Inner wall where 8 Tool retainer contacts
O ring 35.5 Whole portion for smooth action of 24 Tool holder
in Barrel complete
Tool holder
Tool retainer Belly side where shank of Hammer bit contacts
Lip portion
8
1
23
a Portion where Rubber ring 30 contacts
b Portion where Lock ring contacts

P 3/ 17
Repair
[2] LUBRICATIONS (cont.)
Makita grease R
No. 00
Item No. Description Portion to lubricate for Impact bolt section and Crank section AmountLubricant
36 37
38
34
62
66
77
37
36
34
38
Pin 12
Cylinder 40
O ring 44
O ring 31.5
Crank housing
Crank shaft
Armature
Whole portion
Space between Piston and Striker
Space between Impact bolt and Striker
Whole portion for smooth action of Striker in 36 Cylinder 40
Whole portion for smooth action of Impact bolt in 24 Tool holder
Whole portion for smooth action of Piston in 36 Cylinder 40
Space where Helical gear 57 and Crank shaft rotate
Pin portion where Connecting rod accepts
Drive end (Gear portion)
62
66
77
25
26 Impact bolt
Helical gear 57
Gear housing
Rubber ring 24
Ball bearing 6206LLU
Shoulder sleeve Piston
Striker
25
26
X ring 21
Fluoride ring 28
40g
10g
a little
a little
a little
10g
10g
Connecting rod
Fig. 2

P 4/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -1. Chuck
DISASSEMBLING
(1) Remove Handle section as drawn in Fig. 3.
(2) After removing Ring spring 26, disassemble the components of Chuck mechanism.
And, remove Tool retainers from Tool holders as drawn in Fig. 4.
Fig. 3
Fig. 4
1. Remove six 5x25 Tapping screws.
Disconnect Connector of Switch from Controller.
Separate Handle section (Handle base, Switch,
Power supply cord, Handle, Handle cover.)
1. Attach 1R212 to 1R003 as shown
below. Press down Flat washer 30
with 1R363 and remove
Ring spring 26 with 1R003/212.
Note: For easy and safety disassembling,
stand the machine on Work bench
as drawn below. And remove Tool holder
cap with a slotted screwdriver.
2. Remove Flat washer 30, Chuck cover
Rubber ring 30, Chuck ring and
Release cover.
3. While pressing down Spring
guide with your fingers,
remove two Tool retainers.
1R363
1R003
Flat washer 30
Chuck cover
Rubber ring 30
Chuck ring
Chuck cover
Ring
spring 26
Flat washer 30
1R212
Release
cover
Spring guide
Tool retainer (2pcs.)
Change
ring cover
Controller
Handle section
5x25 Tapping
screw (6pcs.)
Connector Slotted screwdriver
Tool holder cap
Chuck cover

P 5/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -1. Chuck (cont.)
DISASSEMBLING
(3) Remove the components of Chuck mechanism form Tool holder as drawn in Fig. 5.
Fig. 5
2. Change ring is fixed to Change ring cover with
Retaining ring WR-45.
Remove Retaining ring WR-45 with 1R003/212.
Change ring can be removed from Change ring cover.
1. Remove Spring guide, Compression spring 56,
Change ring cover.
Chuck mechanism can be removed in this step.
Spring guide
Compression
spring 56
Change ring
cover
Retaining ring
WR-45
Change ring
Change ring
Retaining ring
WR-45
Change ring
cover
ASSEMBLING
(1) Assemble Chuck mechanism by reversing the disassembly procedure. (Refer to Figs. 3, 4 and 5.)
Note for Assembling:
It is difficult to set Tool holder cap in place by hand.
Put Tool holder cap on floor, and push Tool holder to Tool holder cap while making use of the machine weight
as drawn in Fig. 6.
Fig. 6
Tool holder capTool holder

(2) If Fluoride ring 28 is worn, O ring 23 (orange) appears. In this case,
replace all the rings (X ring 21, Fluoride ring 28 and O ring 23) with new ones. X ring 21
O ring 23
Fluoride ring 28
Impact bolt
Fig. 8
P 6/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -2. Impact bolt, Cylinder, Striker
DISASSEMBLING
(1) Impact bolt can be disassembled as drawn in Fig. 7.
Fig. 7
1. Remove four M8x35 Hex socket head bolts with 1R231
and M5x25 Hex socket head bolt with 1R229.
Housing cover and Barrel section can be separated from
Crank housing without disassembling Chuck mechanism.
Barrel section
Crank housing
Shoulder
sleeve
Impact bolt
Tool holder cap
Rubber
ring 24
Housing cover
M8x35 Hex
socket head
bolt (4pcs.)
M5x25 Hex
socket head
bolt
Screwdriver
2. Insert a screwdriver and tap Impact bolt
with the screwdriver to remove Impact bolt,
two Shoulder sleeves and Rubber ring 24.
1. Tap Crank housing as shown below to remove
Cylinder 40 from Crank housing.
2. Remove Striker from Cylinder 40. Then,
O ring 31.5 can be removed from Striker.
Fig. 9
(3) Disassemble Cylinder 40 from Crank housing, and take out Striker from Cylinder 40 as drawn in Fig. 9.
O ring 31.5
Cylinder 40 Cylinder 40 Crank housing
Striker

P 7/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -2. Impact bolt, Cylinder, Striker (cont.)
Shoulder
sleeve
Shoulder
sleeve
Impact bolt
(3) Mount Shoulder sleeves and Rubber ring 24 to Impact bolt as drawn in Fig. 13.
(4) Assemble components by reversing the disassembly steps (3) to (1). (Refer to Figs. 9 and 7.)
Note: Be careful of the directions of Shoulder sleeves.
See the drawings below.
Rubber
ring 24
Fig. 13
Cylinder 40
Striker
Crank housing side Impact bolt side
(1) Insert Striker with O ring 31.5 into Cylinder 40 so that O ring 31.5 faces to Crank housing side as drawn in Fig. 10.
(2) Assemble X ring 21, O ring 23 and Fluoride ring 28 to Impact bolt as drawn in Fig. 12.
Note:1) If Fluoride ring 28 is worn, O ring 23 (orange) appears through Fluoride ring 28 on Impact bolt.
If so, be sure to replace O ring 23 together with Fluoride ring 28 and X ring 21 with new ones.
2) If there is dust in Tool holder, wash it off.
3) Once Fluoride ring 28 deforms, it does not shrink by itself. If installing it into Impact bolt
without the proper step, it may result in its breakage. So insert Impact bolt into Taper Sleeve (1R214)
for about 60 seconds to fit Fluoride ring 28 into the groove on Impact bolt.
One way
valve guide O ring 31.5
Cylinder 40
Fig. 10 Fig. 11
Correct Wrong
Taper sleeve
(No.1R214)
Insert Impact bolt into
the HR5001C side of
Taper Sleeve. And keep
it approx. 60 seconds
in Taper sleeve.
Impact bolt
Assemble of Rings to Impact bolt
Before Correction:
Rings' edges are protruding from
the top edge of the groove on
Impact bolt.
groove on Impact bolt
Fluoride ring 28
X ring 21 O ring 23
After Correction:
Rings' edges are positioned
under the top edge of the
groove on Impact bolt.
Corrected
Fig. 12
O ring 31.5
ASSEMBLING
One way
valve guide Striker
Crank housing side Impact bolt side

P 8/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -3. Tool holder section
DISASSEMBLING
(1) Remove Chuck section. (Refer to Figs 3 to 5.)
(2) Remove Housing cover and Impact bolt. (Refer to Fig. 7.)
(3) Remove Tool holder section as drawn in Fig. 14.
Fig. 14
Ring spring 35
Tool holder
Tool holder
Tool holder
Rubber ring 39
Flat washer 39
O ring 35.5
Barrel complete
O ring 35.5
1R003/212
Assemble Tool holder section by reversing the disassembly procedure. (Refer to Fig. 14.)
2. Tap the top end on Tool holder to remove it
from Barrel complete.
1. Remove Ring spring 35 with 1R003/212.
3. Remove O ring 35.5 from Tool holder. Note: The components of Tool holder are shown below.
ASSEMBLING

P 9/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -4. Crank section
DISASSEMBLING
(1) Remove Handle section. (Refer to Fig. 3.)
(2) Remove Controller as drawn in Fig. 15.
(3) Remove Housing cover and Barrel section. (Refer to Fig. 7.)
Note: No need to disassemble Chuck section.
(4) Remove Rear cover and disconnect Carbon brushes from the commutator of Armature as drawn in Fig. 16.
Note: This is a necessary step to remove Armature from machine.
Fig. 16
Fig. 15
Controller
Slotted screwdriver
4x14 Tapping
screw (2pcs.)
1. Loosen two 4x14 Tapping screws.
And pry off Controller with two slotted screwdrivers.
3. Detach Spiral spring
from Carbon brush.
1. Remove three 5x25 Tapping screws
and remove Rear cover from Motor
housing.
Carbon brush
Spiral spring
Carbon brush
Carbon brush
Spiral spring
Armature shaft of
commutator end
Rear cover
5x25 Tapping screw (3pcs.)
Motor housing 2. Carbon brush is pressed
with Spiral spring to
maintain its contact with
commutator of Armature.
4. Disconnect Carbon brush.

P 10/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -4. Crank section (cont.)
DISASSEMBLING
(5) Separate Motor housing from Crank section as drawn in Fig. 17.
Fig. 17
1R263
Motor housing
Flat washer 15
Crank housing
Crank housing
1. Remove six M6x40 Hex
socket button head screws.
2. Pry off Crank housing from
Motor housing with two 1R263.
Note: Flat washer 15 may come off.
So, be careful not to lose it.
Fig. 18
(6) Disassemble Crank section as drawn in Figs. 18, 19 and 20.
1. Disassemble Gear housing complete
with Armature from Crank housing.
3. Filter can be removed
from Crank cap.
Gear housing
complete
Armature
Crank cap cover
Crank cap
Seal ring
M4x18 Pan head screw (4pcs.)
Crank cap
Filter
2. Loosen four M4x18 Pan head screws
and remove Crank cap cover,
Crank cap and Seal ring.
Crank housing

P 11/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -4. Crank section (cont.)
DISASSEMBLING
Fig. 19
Fig. 20
1. Replace O ring 35 and O ring 31.5 with new ones in the following cases.
* When there is damage or wear.
* When Carbon brush is replaced.
O ring 31.5
O ring 35
Piston
1. Turn and set Connecting rod in the position
(at the upper dead point) shown below.
Connecting rod
Crank pin at the upper dead point
of Connecting rod
Crank shaft
Ball bearing 6206LLU
Helical gear 57
Connecting rod
Crank housing
Piston
Flat washer 12
2. Tap Crank housing as drawn below.
Crank shaft is removed together with Ball bearing 6206LLU,
Helical gear 57 and Flat washer 12.
Piston can be removed together with Connecting rod.
(7) Disassemble Crank shaft from Helical gear 57 as drawn in Fig. 21.
Fig. 21
3. Crank shaft can be removed
together with Ball bearing 6206LLU.
2. Put 1R029 on Crank shaft,
and press 1R029 with
Arbor press.
Crank shaft
Ball bearing
6206LLU
Helical gear 57
Arbor press
1R029
Ball bearing
6206LLU
Crank shaft
1R258
1. Set Helical gear 57 into two 1R258.

P 12/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -4. Crank section (cont.)
ASSEMBLING
(1) Assemble Ball bearing 6206LLU and Helical gear 57 to Crank shaft as drawn in Fig. 22.
Fig. 22
1. Set Helical gear 57 with the high stepped rim of Helical gear 57 facing to Ball bearing side.
And assemble Helical gear 57 with the bearing to Crank shaft as drawn in Fig. 23,
or an incomplete engaging with Armature’s Gear may occur as drawn in Fig. 24.
Correct
1R258
1R029
Arbor press
Helical gear 57
Crank shaft
Wrong
High stepped
rim of
Helical gear 57
Ball bearing
6206LLU
Armature’s gear Armature’s gear
Helical gear 57
Fig. 23 Fig. 24
(2) Assemble Crank shaft section to Crank housing as drawn in Figs. 25 and 26.
(3) Assemble components by reversing the disassembly steps (6) to (1). (Refer to Figs. 18, 17, 16 and 15.)
Fig. 25
Cylinder 40
Cylinder 40
Crank
Housing
Piston
1. Insert Piston into Cylinder 40. 2. Assemble Cylinder 40 to Crank housing.
1. Move Connecting rod of piston to the upper dead point
on Handle assembling side. And then, align the pin of
Crank shaft with the hole of Connecting rod, and tap
Helical gear 57 with a plastic hammer.
The pin of Crank shaft
Helical gear 57
Connecting rod
of Piston
Connecting rod
The hole of Connecting rod
Flat washer 12
Crank shaft
2. Crank shaft is fitted into Connecting rod.
Note: Do not forget to assemble Flat washer 12
to Crank shaft.
Fig. 26

P 13/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -5. Armature
(1) Separate Motor housing from Crank section. (Refer to Figs. 16 and 17.)
(2) Separate Gear housing complete from Crank section. (Refer to Fig. 18.)
(3) Remove Armature as drawn in Fig. 27.
Assemble Armature by reversing the disassembly procedure.
Note: Make sure that Flat washer 15 is set in place. (Refer to Fig. 17.)
Fig. 27
2. Remove Ball bearing 6000DDW with 1R269.
1. Remove Armature from Gear housing complete
with 1R045 and 1R346.
1R045 1R346 Armature
Armature
Insulation
washer
Ball bearing
6000DDW
Gear housing
complete 1R269
DISASSEMBLING
ASSEMBLING

P 14/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -6. Electrical parts in Handle section
(1) Disassemble Handle section. (Refer to Fig. 3.)
(2) Remove electrical parts as drawn in Fig. 28.
Fig. 28
1. Remove two 4x18 Tapping screws and
remove Handle cover.
DISASSEMBLING
Power supply cord
Switch lever
Lever stopper
4x18 Tapping
screw (2pcs.) Terminal block
Switch
Handle cover
Sponge sheet
Rubber pin 4 (green)
2. Electrical parts (Switch, Power supply cord and Terminal block, etc.)
can be replaced.
Note: Be careful not to lose Rubber pin 4 when disassembling Switch.
Pliers
3. Remove Lever stopper with pliers and also remove Switch lever.

P 15/ 17
Repair
[3] ASSEMBLY/ DISASSEMBLY
[3] -7. Fastening torque
(1) Tighten the specific bolts and screws to the appropriate points. (Refer to Fig. 29.)
Fig. 29
Crank housing cover
Barrel complete
Crank housing
Gear housing
Motor housing
Item No. Fastening torqueQ’tyDescription
13 - 3.5 N.mM5x25 Hex socket head bolt
430 - 40 N.mM8x35 Hex socket head bolt
64.0- 4.5 N.mM6x40 H. S. button head screw
15
19
63
[4] MAINTENANCE PROGRAM
(1) When replacing carbon brushes, it is recommended to replace the following parts at the same time for longer service life
of the machine. (Refer to Fig. 30.)
(2) Be sure to apply the appropriate greases to the specific portions. (Refer to Figs. 1 and 2.)
Fig. 30
1
21
23
Flat washer 39
Chuck cover
Barrel complete
Tool holder
Impact bolt
25
Item No. Item No.Descriptions Descriptions
26 27
33 38
40
30
Striker
Shoulder sleeve
Piston
1
21
23
25
Tool holder cap
Rubber ring 39
O ring 35.5 on Tool holder
X ring 21 on Impact bolt
Fluoride ring 28 on Impact bolt
26
27
30
33
38
O ring 23 on Impact bolt
Rubber ring 24
O ring 31.5 on Striker
O ring 31.5 on Piston
O ring 35 on Piston
40
15
19
63

P 16/ 17
Fig. D-1
Fig. D-2
White
Color index of lead wires' sheath
Black
Controller
Pig tail Pig tailBrush holder unitBrush holder unit
Connector Switch
Terminal block
Power supply cord
Correct
Motor housing’s
brim side
Rear cover
side
Wrong
Motor housing Motor housing
Wiring of Carbon brush
Insert Carbon brush into Brush holder as drawn in Fig. D-2.
Note: The pig tail should not be faced to
Rear cover side.
This Lead wire is brown
for some countries
instead of black.
This Lead wire is blue
for some countries
instead of white.
1. Insert Carbon brush into Brush holder
so that the pig tail is facing to
Motor housing’s brim side.
Wiring diagram
Circuit diagram

P 17/ 17
Fig. D-3
Wiring in Handle
Wiring to Switch
Fix Lead wires with
Sponge sheet and
Lead wire holder.
Connect the insulated connectors so that
the clamped portions are set inside the
width of Switch as shown below.
If the clamped portions of insulated connectors
are out of the width of Switch, they interfere with
installing Switch.
Connector
for connecting
to Controller
Lead wire holder
Terminal block
Lead wire holder
covered with Sponge
sheet
Switch
Switch
The following Lead wires have to be
routed over Lead wire (thin, black)
and to be routed through Lead wire holder.
* Lead wire (thick, black) connected to
Switch and Terminal block
* Lead wire (thick, white) connected to
Switch and Controller
Insulated connectors
Fig. D-4
The clamped
portions
The clamped
portions
the width of
Switch
the width of
Switch
Route Lead wires through
these lead wire holders.
Lead wires must be tightened
in this position.
Wiring diagram
Switch