Makita HR4002 Manual

Model No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Note: The standard equipment for the tool shown may differ from country to country.
P 1 / 20
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 458 (18)
114 (4-1/2)
256 (10-1/8)
Shank type: mm (")
Yes
Yes
680
2,500
18 (11/16) SDS-Max
6.2 (13.7)
Impacts per minute: min -1= ipm
No load speed: min -1= rpm
HR4002
Rotary Hammer 40mm (1-9/16")
Model HR4002 has been developed as a 40mm (1-9/16")
SDS-Max Rotary Hammer cost-competitive with competitor B's model.
Features high cost-competitiveness obtained by reducing functions
to the minimum required for a rotary hammer, but still ensuring
work efficiency higher than the competing models.
Double insulation
Net weight: kg (lbs)
Power supply cord: m (ft)
40 (1-9/16)Max TCT bit diameter
105 (4-1/8)Max Core bit diameter
Capacities:
mm (")
Optional accessories
* TCT bits
* Core bits
* Bull points
* Cold chisels
* Scaling chisels
* Scaling chisel (for tile)
* Grooving chisels
TECHNICAL INFORMATION
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
110
120
220
230
240
10
10
5
4.8
4.6
50/ 60
50/ 60
50/ 60
50/ 60
50/ 60
1,050
---
1,050
1,050
1,050
570
650
570
570
570
1,200
1,200
1,200
1,200
1,200
Current (A)
Torque limiter
W
L
H
Side handle (Bar-shaped) ......... 1 pc
Bit grease ................................. 1 pc
Depth gauge ............................. 1 pc
Plastic carrying case................. 1 pc
North America: 3.0 (9.8)
Europe: 4.0 (13.1)
Other countries: 5.0 (16.4)
* Clay spade
* Bushing tool
* Rammer
* Shank (for Rammer and Bushing tool),
* Chemical anchor adapter
* Bit grease
* Grease vessel (containing Hammer grease)
* Side handle (D-shaped)
* Plastic carrying case
* Blow-out bulb
* Safety goggle,
* Hammer service kit
* Depth gauge

P 2 / 20
[2] LUBRICATION
Apply Makita grease R. No.00 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion, and apply Makita grease N No.2 to the portions designated with white triangle.
Fig. 1
[1] NECESSARY REPAIRING TOOLS
CAUTION: Remove the bit from the machine and disconnect for safety
before repair/ maintenance, in accordance with the instruction manual!
Code No. Description Use for
Item No. Description Lubricant Portion to lubricate
Repair
1R003 Retaining Ring S Pliers ST-2N Disassembling / assembling Ring spring
Disassembling / assembling Ring spring1R022 Bearing Plate(for arbor press)
1R212
Tip for Retaining Ring Pliers Attachment to 1R003, for Disassembling / assembling Ring spring
1R213 Disassembling Cylinder from Crank housing
Disassembling Motor housing from Crank housing
Cylinder Extractor
1R214 Taper Sleeve Fitting Fluoride rings on Impact bolt of Rotary hammers
1R230 1/4” Hex. Shank Bit M6 Disassembling Barrel complete from Crank housing
1R263 Bearing Extractor
Removing Ball bearings1R269 Bearing Extractor (small)
Stabilizing the machine, when removing Cylinder1R350 Ring 60 (3 pcs.)
Tool retainer
Impact bolt
Ring 17
Striker
Piston
Helical gear 46
Torque limiter
Change Plate
Compression spring 5
Compression spring 5
Rubber ring 17
Tool retainer
Its inside where Impact bolt contacts
Its inside where Striker and Piston reciprocate
Inside of Tool holder-Hole for Hammer bits insertion
Tool Holder
Connecting rod
19
Tool Holder
34
Its inside where Helical gear 46 and armature rotate
Its Pin portion for accepting Change plate
Crank Housing Comp.
57
Its inside where Torque limiter engages with Helical gear 46
and Armature
Gear Housing Comp.
70
Makita grease N. No.2
Makita grease R.
No.00
Makita grease R.
No.00

P 3 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Chuck Section
Repair
DISASSEMBLE
1R350 for stabilizing
the Machine
Tool holder cap
1. Disassemble Handle section
from the machine.
1. Chuck section can be disassembled in the order from Fig. 2 to Fig. 9.
Putting the machine on 1R350,
remove Tool holder cap with
Slotted head screwdriver.
Pan head
screw M5x20: 4 pcs.
2. Disconnect Lead unit
from Brush holder unit.
Ring spring 25
Remove Ring spring 25 from
Tool holder.
Remove Tool retainer, while
pressing down Spring guide.
Disassemble Spring guide
(2 pcs.) and Compression
spring 48 from Tool holder.
Remove Flat
washer 28, Chuck
cover, and Spacer
from Tool holder.
Remove Chuck
ring and Release
cover.
Remove Ring
spring 25 from
Tool holder.
Ring
spring 25
Flat washer 28
Flat
washer 28
Chuck
cover
Chuck ring
Chuck
ring
Spacer
Chuck Cover
Ring spring 25
(another one)
Spring
guide
Spring guide
Tool retainer: 2 pcs.
Release
cover Compression
spring 48
Spring guide
Tool holder
Spring guide
Fig. 2 Fig. 3
Fig. 6
Fig. 7 Fig.8 Fig. 9
Fig. 5Fig. 4
1R003 1R003
1R212
Handle section

P 4 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Chuck Section
Repair
DISASSEMBLE
ASSEMBLE
Do the reverse step of disassembling. Refer to the illustrations from Fig. 2 to Fig. 9.
[3] -2. Tool Holder Section and Barrel Complete
Pull off Barrel complete, while pushing Impact bolt
with Screwdriver toward Piston in Slide sleeve
so that the Impact bolt remains in the Slide sleeve.
1) In case of HR4002, it is not necessary to disassemble Chuck section, when repairing inside of Tool holder section.
Remove Barrel complete together with Chuck section. (Fig. 10) Now Impact bolt comes into your sight.
2) Check whether Fluoride ring 25 is worn out.
When O ring 20 (orange color) under Fluoro carbon resin ring 25 can be seen, Fluoride ring 25 is worn out. (Fig. 11)
Be sure to replace not only Fluoride ring 25 but also O ring 20 and X ring 18.
3) Check whether there has been dust in the Tool holder. If yes, be sure to clean up Tool holder.
4) For removing Flat washer 45 and Urethane ring 45 from Tool holder, chuck section has to be disassembled as
illustrated in page 3.
5) Disassemble Tool holder from Barrel complete, by striking it with plastic hammer. (Fig. 12)
6) Remove Urethane ring 45 and Flat washer 45 by pushing them toward the Bit installing side of Tool holder. (Fig. 13)
Screwdriver
Hex socket head
bolt M6x30: 4 pcs.
Urethane ring 45
Flat washer 45
Tool holder
Barrel
Impact bolt
Impact bolt
Slide sleeve
Fig. 10 Fig. 11
O ring 20
(orange color) X ring 18
Worn Fluoride ring 25
Flat washer 45
Flat washer 45
Urethane ring 45
Urethane ring 45 Tool holder
Tool holder Barrel complete
Fig. 12 Fig. 13

P 5 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Tool Holder Section and Barrel Complete
Repair
DISASSEMBLE
6) Oil seal 32 is assembled to Barrel complete on the Release cover side. Remove the Oil seal by pushing with
Slotted head screwdriver from the Crank housing complete side. (Fig. 14)
1) Mount fresh O Ring 20 to Impact bolt. And then, mount Fluoride ring 25 onto the O ring 20. (Fig. 15)
The assembled Fluoride ring 25 does not fit on Impact bolt by itself. To fit it on Impact bolt, insert
into 1R214 as illustrated in Fig. 15.
2) After about 60 seconds, pull off Impact bolt from 1R214. Now the Fluoride ring fits on Impact bolt. (Fig. 16)
3) Assemble X ring 18 to Impact bolt. (Fig. 17) Now the assemble of Impact bolt is finished.
ASSEMBLE
Oil seal 32
Release
cover side Crank housing
complete side
Slotted head
screwdriver
Barrel complete
Fig. 14
Fig. 15
Fluoride ring 25
Before fitting to Impact bolt
O ring 20
1R214
1R214
Indication of
"HR4000C"
Note: Do not use the HR5001C marked side.
Impact bolt
Fig. 16
Fig. 17
Fluoride ring 25 after fitting
to Impact bolt
O ring 20 Impact bolt
X ring 18Fluoride ring 25

P 6 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Tool Holder Section and Barrel Complete
Repair
ASSEMBLE
Urethane ring 45
Urethane ring 45
Insert Tool holder into Barrel complete until Urethane ring 45
contacts to Plane bearing 32 of Barrel complete.
Flat washer 45
Tool holder
4) From the Bit installing side, assemble Flat washer 45 to Tool holder. (Fig. 18)
5) And then, assemble Urethane ring 45 to Tool holder from its Bit installing side. (Fig. 18)
Fig. 18
Fig. 19
6) Assemble Oil seal 32 to Barrel complete on the Release cover side. (Refer to Fig. 14.)
7) Mount Tool holder to Barrel complete. And insert Impact bolt into Tool holder. (Fig. 19)
8) Assemble the Tool holder section to Crank housing. (Refer to Fig. 10.)
9) Assemble the Chuck section, by doing the reverse step of disassembling in Page 3.
Plane bearing 32
(Integral part of Barrel complete)
Tool holder
Tool holder
Assembling of Tool holder
section is completed by
inserting Impact bolt.
Impact bolt

P 7 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Cylinder Section
Repair
DISASSEMBLE
ASSEMBLE
1) Disassemble Chuck section, Barrel and Tool holder section from Crank housing, as illustrated in Fig. 10.
2) Remove the parts from Cylinder 28.5 in the following order. (Fig. 20)
1. Impact bolt 2. Ring 17 3. Rubber ring 17 4. Slide sleeve 5. Ring 33 6. Compression spring 37
3) Take out Striker from Cylinder 28.5. (Fig. 21) Now O ring 22 can be removed from Striker.
1) Insert Striker with fresh O ring 22 into Cylinder 28.5. (Fig. 22)
2) Assemble the parts for cylinder section as illustrated in Fig. 23.
Ring 17
Ring 17
Ring 17
Ring 33
Impact bolt
Impact bolt Ring 33
Face the Brim portion to Rubber ring 17 side
to accept Compression spring with its Brim.
Face the Metal portion
to Crank housing Side.
In this case, impossible to
accept Impact bolt with
Ring 17 exactly.
Because the small hole
side faces to Impact bolt .
Rubber ring 17
Slide sleeve
Slide sleeve
Compression spring 37
Compression
spring 37
Cylinder 28.5
Cylinder 28.5
Striker
O ring 22
Fig. 20 Fig. 21
Striker
Cylinder 28.5
Striker
Cylinder 28.5
Crank housing
O ring 22
O ring 22
Insert Striker into Cylinder 28.5,
facing O ring 22 side to Crank housing.
Fig. 22
Fig. 23
Rubber Ring 17
Crank housing
Crank housing
3) Assemble the Chuck section, Barrel complete and Tool holder to Crank housing. (Fig. 10)

P 8 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Crank Section
Repair
DISASSEMBLE
1) Disassemble Tool holder and Barrel section. (Fig. 10)
2) Disassemble Cylinder section. (Fig. 20 and Fig. 21)
3) Take out Link plate and Link plate guide from Crank housing complete. (Fig. 24)
4) Disassemble Link plate and Compression spring 7 from Link plate guide. (Fig. 25)
5) Take out Lock sleeve with Lock sleeve guide and Straight bevel gear 25. (Fig. 26)
Fig. 24
Fig. 25
Fig. 26
Set Change lever
to Hammer mode.
Pan head
screw M5x20: 4 pcs.
Change
lever
Crank cap
cover compete
Hammer mode Link plate guide
Link plate
Seal ring comes with Crank
cap cover complete, which is
fitted to the Bottom of Crank
cap cover complete.
Link plate
Link plate guide
Bottom View
(View from
Eye mark side)
Compression
spring 7: 2 pcs.
Push out the tail
of Lock sleeve.
Top View of Crank Housing
Straight bevel gear 25
Lock sleeve Lock sleeve
guide
Crank housing Crank housing
Tail of Lock sleeve
Tail of Lock sleeve
Link plate guide
This Plate portion is fitted to the Rail portion
of Link plate guide.
By expanding the Rail portion, de-fit the Plate
portion from the Rail of Link plate guide.
Now Link plate and
Compression spring 7
can be removed from
Link plate guide.
Link plate guide
Link plate
Link plate
Rail portion

P 9 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Crank Section
Repair
DISASSEMBLE
Ring spring 31
6) Disassemble Ring spring 31 from Cylinder 28.5. (Fig. 27)
7) Remove Ring 33 from Cylinder 28.5. (Fig. 28)
8) Setting 1R213 and 1R350 to Crank housing complete, disassemble Cylinder 28.5 from Crank housing complete.
(Fig. 29)
9) Disconnecting Connecting rod from Crank shaft, Piston can be disassembled from Crank housing complete.
(Fig. 29)
Ring spring 31
Ring 33
Cylinder 28.5
Cylinder 28.5
Ring 33
1R213
Cylinder 28.5
Cylinder 28.5
1R350
1R350
Grip Cylinder 28.5 by fitting these Pin portions
with the Holes of Cylinder 28.5, passing the Legs
of 1R213 through 2 pcs. of 1R350.
The gripped Cylinder 28.5 is lifted up, by turning the
Handle, and the Cylinder is disassembled from Crank
housing complete.
Inserting thin Screwdriver
into any of these Slits, remove
Ring spring 31. Remove ring 33 from Cylinder
28.5.
Ring
spring 32
O ring 30
Fig. 27 Fig. 28
Fig. 29
O Ring 22
Crank Shaft
Ring 33, removed in the Step of Fig. 28
Piston
Connecting Rod

P 10 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Crank Section
Repair
DISASSEMBLE
ASSEMBLE
Fig. 29A
Wood piece to protect
the edge of Crank housing
from cracking.
Cylinder 28.5 can be removed
from Crank housing complete
by levering up it with a pair of
Screwdriver.
Cylinder 28.5
1) Pass Ring 33 through Connecting rod. And connect the Connecting rod with Crank shaft in the Crank housing
complete. (Refer to below Fig. 29.)
2) Mount O ring 30 (2 pcs.) and Ring spring 32 to Cylinder 28.5. (Refer to right Fig.29)
< Note > Ring spring 32 functions as a stopper to set Cylinder 28.5 to the correct Position in the Crank housing
complete. Therefore, do not forget to reassemble it to Cylinder 28.5, if it has been removed.
3) Apply Grease to O ring 30 ( 2 pcs.) for smooth assembling. Strike the Cylinder with Plastic hammer to assemble it
to Crank housing complete. At the same time, Piston has to be inside of the assembled Cylinder. (Fig. 30)
4) Insert Straight bevel gear 25 over Cylinder 28.5, and engage it with Straight bevel gear 7 of Torque limiter
assembly. Bring the Concave of the Straight bevel gear to the Side of Crank housing complete (Fig. 31)
5) Assemble Ring 33 to Cylinder 28.5. (Refer to Fig. 28.)
6) Assemble Ring spring 31 to Cylinder 28.5. (Refer to Fig. 27.)
Note: Remove Cylinder 28.5 with a pair of Screwdriver when you do not have 1R213. (Fig. 29A)
Ring spring 32
Fig. 30 Fig. 31
Piston
O Ring 30
Cylinder
28.5
Cylinder 28.5
Piston
Piston
Cylinder 28.5
You can turn Straight bevel gear 25,
by turning Crank shaft by hand, if
it engages with Straight bevel gear 7
exactly.
Straight
bevel gear 25
Bring the concave of the Straight bevel gear 25
to the side of Crank housing complete, by turning
Crank shaft, for easy assemble of mode change
mechanism in the next step.
Straight bevel gear 25

P 11 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Crank Section (cont.)
Repair
ASSEMBLE
Notch of Lock
sleeves's tail
Indication for
Lock sleeve insertion
Insert Lock sleeve with Lock sleeve guide into
Crank housing complete along the concave of
Straight bevel gear 25.
Push Lock sleeve until the notch of the
tail reaches the indication.
Concave of Straight
bevel gear 25
Lock sleeve with
Lock sleeve guide
Lock sleeves's tail
Fig. 32
Fig. 33
7) Insert Lock sleeve with Lock sleeve guide into Crank housing complete. (Fig. 32)
8) Assemble Compression spring 7 and Link plate to Link plate guide. (Refer to Fig. 25.)
9) Assemble Link plate with Link plate guide while fitting Link plate to the notch of Lock sleeves's tail.
(Fig. 33)
10) Before assembling Crank cap cover complete, make sure that Seal ring is installed on the Bottom side of
Crank cap complete.
Assemble Crank cap complete to Crank housing complete. (Refer to Fig. 24.)
Link plate guide Link plate guide
Link plate
Link plate

P 12 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Armature
Repair
DISASSEMBLE
1) Disassemble Handle section from Motor housing. (Fig. 2)
2) After removing Rear cover, disconnect Carbon brush from Commutator by pulling out it.
3) Remove Pan head screw M5x35. (Fig. 35)
4) Disassemble Motor housing from Gear housing complete. (Fig. 36)
5) After disassembling Motor housing, Armature stays in Gear housing complete.
Remove the Armature as illustrated in Fig. 37.
Spiral spring Carbon brush
Rear cover
1R263
Motor housing
Tapping screw 4x18: 2 pcs.
Remove the Spring
from Carbon brush.
And pull out carbon brush to
disconnect it from Commutator.
No need to remove Carbon brush
from Brush holder unit.
Fig. 34
Fig. 35
Fig. 37
Fig. 36
Pan head
screw M5x35: 4 pcs.
Flat
washer 5: 4 pcs.
1R263
Inserting 1R263 between Gear housing complete
and Motor housing, disassemble Motor housing
from Gear housing complete, by levering up
with 1R263.
Gear housing
complete
Gear housing
complete
Strike the Gear housing complete with
Plastic hammer.
Now Armature is disassembled from
Gear housing complete.
Armature
Gear housing
complete
Remove Baffle plate.
Armature
Baffle Plate

P 13 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Armature
Repair
DISASSEMBLE
ASSEMBLE
1) Do the reverse Step of Disassembling..
1) Disassemble Motor section as per Illustrations from Fig. 34 to Fig. 37.
2) Disassemble Gear housing complete from Crank housing complete. (Fig. 38)
3) Remove Torque limiter section together with Change plate from Gear housing complete. (Fig. 39)
4) Remove Ball bearing 6904LLU and 608DDW. Now Cup washer 8, Conical compression spring 19-2 and Driving
flange are removed from Torque limiter complete. (Fig. 40)
Note: Do not forget to assemble Baffle plate. (Refer to left Fig. 37.)
[3] -6. Torque Limiter Section
Gear housing complete
Gear housing complete is
removed together with Seal
ring.
Torque limiter
section
Change plate
Change plate
Compression spring 5: 2 pcs.
Ball bearing
6904LLU
1R269
Ball bearing 608DDW
Cup washer 8
Conical compression spring 19-2
Driving flange
Note: Do not remove this Flat washer.
It is factory assembled as an integral
part of Torque Limiter Complete.
Torque limiter complete
Fig. 38 Fig. 39
Fig. 40
Strike the edge of Crank housing complete to remove it when
Torque limiter section is left in Crank housing complete side.

P 14 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -6. Torque Limiter Section
Repair
ASSEMBLE
1. Assemble Ball bearing
6904LLU to the Straight
bevel gear 7 side.
1) After mounting Ball bearing 6904LLU, assemble the parts to Torque limiter complete in the order of Driving flange,
Conical compression spring 19-2 and Cup washer 8. (Fig. 41)
2) Fix the Cup washer 8 provisionally by turning it approx. 90 degree. And assemble Ball bearing 608DDW.
(Fig. 42)
3) Assemble Change plate. (Fig. 43)
4) Do the reverse step of disassembling.
5. Turn Cup washer 8 approx. 90 degree,
while pressing it toward the Driving
flange. Now Cup washer 8 is fixed
provisionally on the shaft of Torque
limiter complete.
Ball bearing
6904LLU
Conical
compression
spring 19-2
2. Mount Driving flange,
while fitting these projections
with the Groove of Torque
limiter 's Shaft.
3. Face small Loop side to
Driving flange.
6. Assemble Ball bearing
608DDW.
Projection
Cup washer 8
Torque limiter
complete
Assemble Change plate by inserting between Driving flange and Torque limiter's helical gear.
Groove
Driving flange
4. While aligning this notch to
the groove of Torque limiter,
assemble Cap washer 8 to
the Shaft.
90
degree
Fig. 41 Fig. 42
Fig. 43
Torque limiter's
helical gear
Driving flange
Change plate
Note: 1) Do not forget to mount Compression spring 5 (2 pcs.) to the Pins of Gear housing complete before
mounting Torque limiter section. (Refer to Fig. 39.)
2) Make sure that Seal ring is mounted to Gear housing complete. (Refer to Fig. 38.)

P 15 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Crank Shaft
Repair
DISASSEMBLE
Align Crank shaft to its Insertion hole. Strike Gear housing complete with Plastic hammer.
Now Crank shaft is disassembled.
Insertion hole for Crank shaft
1R022
Ball bearing
6004LLU
Ball bearing
6004LLU
Ball bearing
6004LLU
Remove Retaining ring S-20 from Crank shaft.
And set a pair of 1R022 under Ball bearing
6004LLU.
Retaining
ring S-20
1R269
Crank shaft
1) Disassemble Crank shaft as per the illustration from Fig. 44 to Fig. 49.
Flat washer 10
Remove Flat washer 10 from Crank shaft.
And set a pair of 1R022 between
Helical gear 46 and Ball bearing 6004LLU.
Remove Crank shaft from Ball bearing 6004LLU,
by pressing with Arbor press.
Remove Crank shaft from
Helical gear 46, by pressing
with Arbor press.
Crank Shaft
Helical
gear 46
Helical gear 46
Gear housing complete
Crank shaft
Crank shaft
Fig. 44 Fig. 45
Fig. 46 Fig. 47
Fig. 48 Fig. 49

P 16 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -7. Crank Shaft
[3] -8. Electrical Parts in Handle Section
[3] -9. Field and Brush Holder Unit
Repair
DISASSEMBLE
ASSEMBLE
DISASSEMBLE
Do the reverse step of Disassembling.
Note: Mount the assembled Crank shaft, while aligning it to the Insertion hole. (Refer to Fig. 44.)
And connect Connecting rod with the Pin of Crank shaft.
Fig. 50
Fig. 51 Fig. 52
Tapping screw
bind 4x18: 1 pc.
Tapping screw
bind 4x18: 2 pcs.
Tapping screw
bind 5x55: 2 pcs.
Handle cover
1) Handle cover is tightened by one 4x18 Tapping screw bind. Remove this screw, So Handle cover is separated
from Handle. (Fig. 50)
2) Now Power supply cord and Switch can be replaced. (Fig. 50)
After removing Tapping screw bind 4x18 (1 pc.),
insert a slotted screwdriver into the Gap between
Handle and Handle cover at the Cord guard insertion,
and remove the Handle cover, by levering it up.
Switch
Cord guard
Power supply cord
Cord clamp
1) Remove Motor housing from Crank housing complete, while referring to "3-5. Armature" in page 12.
2) Remove Baffle plate, and take off Brush holder unit from the bottom of Motor housing after unscrewing Tapping
screw Bind 4x18.
Unscrew Tapping screw bind 5x55 with which Field is fixed to Motor housing. (Fig. 51)
3) Remove Field from Motor housing, by striking the Edge of Motor housing. (Fig. 52)
Brush holder
unit
Baffle plate
Motor housing Motor housing
Field
Field
Tapping screw
Bind 4x18: 4 pcs.

P 17 / 20
[3] DISASSEMBLY/ASSEMBLY
[3] -9. Field and Brush Holder Unit
Repair
ASSEMBLE
Insert a pair of Bar into the
Screw hole for Tapping screw
bind 5x55.
Assemble Field, by
striking the bottom of
Motor housing.
Along the Bar, push Field
halfway into Motor housing.
After taking off 1R063 or a pair of Bar,
tighten Field with Tapping screw bind
5x55.
Field
Note: 1) The wrong order will causes Breakage or Deform of the Terminals of Field to assemble Brush holder
unit. Be sure to follow the above assembling step.
2) Use 1R063 or a pair of Bar to assemble Field exactly to Motor housing. (Fig. 53) It is easy to connect
the Receptacles of Brush holder unit to the Terminals of Field without their Deform or Breakage.
1) First assemble Field to Motor housing and then assemble Brush holder unit to Motor housing. Refer to Figs. 53, 54,
55, 56, 57 and 58.
Tapping screw
bind 5x55: 2 pcs.
Tapping screw bind 4x18: 4 pcs.
Face the Connector
portion to the Handle
assembling side.
With these four Receptacles,
connect to terminals of Field.
Guiding line on the inside surface of Motor housing
Bottom View of the Assembled
Brush Holder Unit
1) Align the top surface line of the base portion of Brush holder unit with
the guiding line on the inside surface of Motor housing.
2) Keeping the base portion of Brush holder unit parallel to the guiding
line, push straight into Motor housing.
Now Brush holder unit is connected to Field exactly.
3) Tighten Tapping screw bind 4x18.
Fig. 53 Fig. 54 Fig. 55
Fig. 56 Fig. 57
Fig. 58
2) After mounting of Baffle plate, assemble Motor housing to Gear housing complete.
(Refer to Fig. 36 and Fig. 35.)
3) Connect Carbon brush to the commutator of Armature. And mount Rear cover to the Motor housing.
(Refer to Fig. 34.)
1R063 Field
Brush holder unit

P 18 / 20
[4] Maintenance
Repair
When replacing carbon brush, it is recommended to do the following maintenance at the same time
for longer service life of the machine.
2) Additionally apply approx. 60cc of Makita grease R No.00 to the inside of Crank housing complete.
1) Replace the following parts.
[3] DISASSEMBLY/ASSEMBLY
[3] -10. Fastening Torque of Screw and Bolt
Fasten the specific bolts to the appropriate fastening Torque as shown below.
Crank housing
complete
Barrel complete
Gear housing
complete
Motor housing
Item No. Fastening torque
Q'ty
Size of Hex socket
head bolt
14 4 7.8 - 12.0 N.mM6 x 30
85 4 2.9 - 4.9 N.mM5 x 35
Fig. 59
Fig. 60
1
1. Tool holder cap
20. O ring 20
21. Fluoride ring 25
20 21 22
Impact bolt
Tool holder
Striker Piston
28 40
22. X ring 18
28. O ring 22 on Impact bolt
40. O ring 22 on Piston

Circuit diagram
P 19 / 20
Color index of lead wires' sheath
Noise Suppressor and Sponge are not used for some Countries.
This Lead wire is white for some Countries.
This Lead wire is black
for some Countries.
Black
Power Supply Cord
Brush Holder Unit
Lead Unit
Noise Suppressor
Switch
White
Blue
Brown
Sponge
Fig. D-1

Wiring diagram
P 20 / 20
Pull the Lead wire (white) through
the Hole for guiding to connect it
to Switch.
Connect Lead unit, facing the
Wire-connecting Portion
toward Top.
Wire-connecting Portion
Handle
Fig. D-2
Fig. D-3
Handle
Lead Unit
Connecting Lead Unit
Wiring in Handle
Switch
The Lead wires for connecting to Switch,
have to be guided between Rib A and Rib B.
The Lead wires for connecting to Switch,
have to be fixed with this Lead wire holder.
Noise suppressor,
covered with Sponge
Switch
holder Lead Wire Holder of Switch Holder
Rib A Rib B
If Noise suppressor is used, cover it with Sponge,
and put into the Hole for Lead wires (white) of
Lead unit.
Hole for Lead wires
(white) of Lead unit
Hole