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