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HM1810-TE


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T     ECHNICAL INFORMATION
   Models No.               HM1810
                                                                                                             PRODUCT
                                                                                                               P 1 / 21
                                                                                                                  H
   Description              Electric Breaker

CONCEPT AND MAIN APPLICATIONS
   Model HM1810 has been developed as 28.6mm hex shank electric breaker                      W
   conforming to the permissible noise level limit of 2006 stage of European                                          L
   Noise Directive for Outdoor Equipment.
   Despite such low noise level, features highest-in-class chipping efficiency.
   Also features unique Makita AVT (Anti-Vibration Technology), ensuring             Dimensions: mm (")
   incredibly low vibration.
                                                                                   Length (L) 824 (32-1/2)
                                                                                   Width (W) 146 (5-3/4)
                                                                                   Height (H)   633 (25)

 Specification
                                                                    Continuous Rating (W)
      Voltage (V)          Current (A)       Cycle (Hz)                                              Max. Output(W)
                                                                   Input           Output
          110                  16.0             50/60              1,700             950                  2,300
          120                  15.0            AC/DC               1,700*1           950                  2,300
          220                   9.6             50/60              2,000            1,240                 2,500
          230                   9.2             50/60              2,000            1,240                 2,500
          240                   8.8             50/60              2,000            1,240                 2,500
   *1: Continuous Rating Input: Taiwan=1,570W, UK (low voltage)=1,700W, Saudi Arabia (low voltage)=1,650W

    Specification                         Model                           HM1810
    Blows per min.: bpm=min-1                                              1,100
    Shank: mm (")                                                     Hex 28.6 (1-1/8)
    Impact energy: J (catalog value)                                         63
    Anti-vibration Vibration absorbing handle                               No
    technology       Counterweight mechanism                                No
               Permissible noise level limit*3                              111
    Noise*2:
               Guaranteed noise level on the
    dB(A)                                                                    107
               catalog for European countries
    Vibration*4: m/s2                                                          8
    Protection from electric shock                                   Double insulation
    Power supply cord: m (ft)                               5.0 (16.4) [brazil only: 2.0m (6.6ft)]
    Net weight: Kg (lbs)                                                  32 (70.6)

   *2: Noise indicates sound power level.
   *3: This is the permissible noise level limit of 2006 stage of the "European Noise Directive for Outdoor
       Equipment" (2000/14/EC). And in and after 2006, it will be prohibited in Europe to sell the products
       with the sound power level exceeding this noise level limit.
       The values of the permissible noise level limit listed above are calculated by us in accordance with the
       directive. (The calculation is based on the weight of product.)
   *4: Vibration level on the catalog for European countries

 Standard equipment
   Hex wrench 5 ................ 1 pc
   Note: The standard equipment for the tool shown above may differ by country.

 Optional       accessories
   Bull point              Clay spade
   Cold chisel             Rammer
   Scaling chisel
                                                                                                                                 P 2 / 21
Features      and benefits

  Conforming to the permissible noise level limit of 2006 stage                                              Highest-in-Class
  of European Noise Directive for Outdoor Equipment                                                          Chipping efficiency
                                                                                1
AC/DC Switch *                                                                                Optimum for Rental Use
For North American                                                              2
                                                                                              with the following features
countries only
                                                                                      1. Auto cut-off brushes for protecting
                                                                                         commutator *
             AVT                             5
                                                                                      2. Name plate placed in the position almost
 (Anti-Vibration Technology)                                                 3           free from damages and scratches *
                                                                                      3. Flat surface for ownership engraving or sticker
 Counterweight mechanism ensures
                                                                                      4. Cylindrical tool holder with high reparability;
 extra-low vibration i chiseling jobs.
                                                                                         new bolt holes can be drilled when the original
              Rugged One                                                                 bolt hole is clogged with broken bolt.
                                                                            4
                                                                                      5. Warning lamp indicates trouble with cord.
Provides longer service life compared
with Makita HM1800 and Competitor's model A.                                                  *The same advantage as Model HM1800

Comparison         of products
Specification Comparison Competitor's model A is the model for North American countries.
                                   Model No.                       Makita                        Competitor A
 Specifications                                        HM1810            HM1800                    Model A
 Continuous rating input: W                            2,000*1             1,700                    1,900
 Rated amperage for North America: A                      15                 15                       15
 Blow per min.: min-1=bpm                               1,100              1,000                    1,030
                        Great Britain                                   31.7(1-1/4)
 Hex shank: mm (")                                 28.6(1-1/8)                                    28.6(1-1/8)
                        Other countries                                 28.6(1-1/8)
 Angle settings of bit                                     6                  6                         6
 Impact energy: J (catalog value)                         63                36.4                       60
            Permissible noise level limit*3              111                108                       108
 Noise*2:
            Guaranteed noise level on the
 dB(A)                                                   107                        109               110
            catalog for European countries
 Vibration*4: m/s2                                        8                         24                13
 Anti-vibration Vibration absorbing handle               No                         Yes               Yes
 technology      Counterweight mechanism                 Yes                        No                No
 Warning lamp that indicates trouble with cord           Yes                        No                No
 Auto cut-off brush                                      Yes                        Yes               Yes
 Double insulation                                       Yes                        Yes               Yes
                              Length              824 (32-1/2)          818 (32-3/8)              753 (29-3/4)
 Dimensions: mm (")           Width                146 (5-3/4)          137 (5-3/8)               138 (5-7/16)
                              Height                   633 (25)         624 (24-1/2)              596 (23-1/2)
 Power supply cord: m (ft)                         5.0 (16.4)               5.0 (16.4)             4.0 (13.1)
                                                                                                                       *1, *2, *3, *4:
 Net weight: Kg (lbs)                                  32 (70.6)             29 (64)                 29 (64)              See page 1.
Performance Comparison
Note: Numbers in the chart on right are relative values when the capacity of Competitor's model A is indexed at 100.
                                      [High Voltage (230V)]                                      [Low Voltage (120V)]

 Makita HM1810                                   114                                                             127
 Competitor's                                    100                                                             100
 model A
 Makita HM1800                            78                                                                87
                                                                                                                P 3 / 21
Repair
 CAUTION: Disconnect the machine from the power source for safety before repair/maintenance!
 [1] NECESSARY REPAIRING TOOLS
  Code No.                Description                                               Use for
   1R005      Retaining Ring R Pliers RT-2N           Removing Retaining ring R-80 from Crank box
   1R023      Pipe Ring (for arbor press)             Removing Helical gear 47
   1R045      Gear extractor, large
   1R346      Center Attachment for 1R045             Disassembling Tool retainer section
   1R347      Jig for Tool Retainer Disassembling
   1R348      Spring Pin Extractor                    Removing Spring pin 8-40 from Tool retainer shaft
   1R231      1/4" Hex Shank Bit for M8               Loosening/ tightening Hex socket head bolt M8x75
   1R263      Bearing Extractor
                                                      Removing Ball bearings
   1R269      Bearing Extractor
   1R291      Retaining Ring S and R Pliers           Removing Retaining ring S-20 from Crank shaft
  784408-3    Socket Bit 13-55                        Loosening/ tightening Hex nut M8 that secures Fan 100

 [2] ADHESIVE APPLICATION AND LUBRICATION
 [2] -1. Adhesive Application
 Apply an appropriate amount of adhesive to the following parts in order to lock them against vibration loosening or
 leakage. Be sure to wipe off grease or oil from the parts before adhesive application.

  Item No.                Description                                     Portion to apply adhesive
     10      Brush holder cap (2pcs)                 Threaded portion
     12      Hex socket head bolt M6x22 (4pcs)       Threaded portion
     16      Hex bolt M5x85 (2pcs)                   Threaded portion
     22      Gear housing complete                   Figure 8 inlaid portion that contacts Gear housing cover
     76      Hex socket head bolt M5x16 (2pcs)       Threaded portion
     83      Hex socket head bolt M12x55 (4pcs)      Threaded portion
     94      Hex socket head bolt M12x45 (4pcs)      Threaded portion

   Fig. 1
                                                                                                Bearing box
                               Crank housing                             76
                                                                                   Motor housing B
       : ThreeBond 1215
                                                                          Plate
       : ThreeBond 1321B or 1324,                                                 Field
         or Loctite 242                                                                                                12

                                                                                                                10
                                                                                                        16

                          22
                                                                                      Motor housing A
                                                              83
     Gear housing cover
                                                                Barrel

                                                                Tool holder




                                                               94
                                                                                                                  P 4 / 21
Repair
 [2] LUBRICATION
 Apply Makita grease to the following portions designated with the black triangle and gray triangle to protect
 parts and product from unusual abrasion.

 Item No.           Description                                       Portion to lubricate
    22      Gear housing complete approx. 80g of Makita grease N No.1 in the gear chambers
    24      Spur gear 22                appropriate amount of Makita grease N No.1 to the teeth portion
    31      Crank housing               approx. 110g of Makita grease R No.00 in the crank room
    35      Helical gear 50             appropriate amount of Makita grease N No.1 to the teeth portion
    43      Spur gear 47                appropriate amount of Makita grease N No.1 to the teeth portion
    52      Connecting rod              appropriate amount of Makita grease R No.00 to the inside surface of the two holes
    53      O ring 55                   appropriate amount of Makita grease R No.00 to the whole portion
   56, 58   O ring 52                   appropriate amount of Makita grease R No.00 to the whole portion
    57      Cylinder liner 62           approx. 10g of Makita grease R No.00 to the inside
    61      Balancer complete           appropriate amount of Makita grease R No.00 to the inside surface
    64      Connecting rod              appropriate amount of Makita grease R No.00 to the inside surface of the two holes
    66      Crank box                   approx. 20g of Makita grease R No.00 to the rollers of Needle bearing
    85      Cylinder B                  appropriate amount of Makita grease R No.00 to the inside surface
     98     X ring 40                   appropriate amount of Makita grease R No.00 to the whole portion
    100     O ring 60                   appropriate amount of Makita grease R No.00 to the whole portion

   Fig. 2
                                                                           Crank complete                 66
      : Makita grease N No.1                         Crank complete
      : Makita grease R No.00              31                              52
                                                                                                           64

                                22


                                                                                                     61
                      24




                                                                  Pin 15
               35
                           43          Piston
                                          53                                                 85
                                          56
                                                                                             Impact bolt holder
                                                                                             100


                                                                                             Impact bolt


                                                                                              98
                                        57

                                                                                             Tool holder
                                         58
                                     Striker
                                                                                                              P 5 / 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -1. Disassembling/Assembling Motor Section
 REMOVING FIELD
 1) Remove Motor housing cover set. Fan 100 secured with Hex nut M8 will be now visible.
 2) Remove the assembly of Rear cover and Handle (switch side), then Brush holder caps and Carbon brushes.
 Important:
 When unscrewing Brush holder caps, be careful not to break the screwdriver insertion slot because the adhesive-applied
 Brush holder caps are secured tight.
 3) Remove hex nut M8 by turning counterclockwise with Socket bit 13-55 (No.784408-3) and Impact driver.
    Now Fan 100 can be separated from Armature shaft. (Fig. 3)
 4) After unscrewing four M6x22 Hex socket had bolts, remove Bearing box from Crank housing using
    Gear extractor, large (No.1R045). (Fig. 4)
 Fig. 3                                           Fig. 4

                                                                                              Gear extractor, large
                             Socket Bit 13-55
                                                                                              (No.1R045)
                             (No.784408-3)

                                                                                              Hex socket head bolt
                                   Fan 100                                                    M6x22 (4pcs)


                                                                                              Bearing box



                                                                                              Crank housing
                                    Bearing box




 5) Pull off Motor housing B from Crank housing. Then remove Motor housing A from Crank housing by tapping the
    edge of Crank housing with plastic hammer. (Fig. 5) Sometimes, when tapping Crank housing, Armature may be
    removed from Crank housing before Motor housing A.
 6) After unscrewing two M5x85 Hex bolts, remove Field by tapping the edge of Motor housing A with plastic hammer.
   (Fig. 6)

 Fig. 5                                                                 Fig. 6

                                          Motor housing A                                 Field      Hex bolt M5x85


      Crank housing                                Motor housing B




                                                                          Motor housing A




                               Armature
                                                                                                                P 6 / 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -1. Disassembling/Assembling Motor Section (cont.)
 INSTALLING FIELD
 Do the reverse of the disassembling steps.
 Important:
 Field is not reversible when assembled into Motor housing A. Be sure to assemble so that the Lead wire side of the Field
 is placed on the Motor housing B side as illustrated to left in Fig. 7.
 It will be impossible to route the lead wires to Motor housing B if assembled as illustrated to right in Fig. 7.
 Fig. 7

                        [Correct]                                               [Wrong]
                                        Motor housing B side                                  Motor housing B side
                       Field
   Motor housing A



                                       Lead wire side                                        Field lead wires
                                        Field lead wires
                                                                                        Lead wire side

 REMOVING ARMATURE                                                          Fig. 8
 If Armature is not removed in removal of Field as described in 5)                   Gear housing cover
 of "Removing Field", remove by following the steps described below:
 1) Remove the parts of Fan 100 side (Fan 100, Bearing box and
    Motor housing B). (See Figs. 3, 4, 5)
    Note: It is not necessary to remove Motor housing A and Field.
    Remove four M8x75 Hex socket head bolts with 1R231.
 2) Remove Gear housing cover by raising with Slotted screwdriver and
    Bearing extractor (No.1R263) as in Fig. 8.
    Note: The two tools are necessary because Gear housing cover is
    securely fastened to Gear housing using adhesive.
 3) After removing the assembly of Helical gear 50 and Spur gear 22,
    insert the arms of 1R045 through the opening of Gear housing.
    Then grip the bearing chamber of Gear housing with the jaws of 1R045.
    Now, by turning the handle of 1R045 clockwise, Armature can be
    removed form Gear housing. (Fig. 9)                                                                   Gear housing

 Fig. 9

    Assembly of
    Helical gear 50                         No.1R045
    and Spur gear 22




    Bearing chamber
    of Gear housing                    Armature shaft                                          Armature
                                                                                                                  P 7 / 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -2. Disassembling/Assembling Gear Section
 DISASSEMBLING
 1) After separating Gear housing from Crank housing, remove Ball bearing 6302LLB with Gear extractor, large
    (No.1R045). At this time, be careful not to lose Pin 5. Then using Retaining ring S and R pliers (No.1R291)
    remove Retaining ring S-20. (Fig. 10)
 2) Put Gear housing on Pipe Ring (No.1R023), and press down Crank shaft using arbor press. (Fig. 11)
 3) Now Crank shaft complete, Spur gear 47 and Sleeve 25 can be removed from Gear housing. (Fig. 12)
    Note: Be careful not to lose two woodruff keys.
 Fig. 10                                Fig. 11                                Fig. 12

                                                                                                     Spur gear 47
                     Ball bearing
                     6302LLB                              Arbor press                                Sleeve 25
                     Retaining
                     ring S-20                               Crank shaft
                                                             complete
                       Gear housing

                                                                                                        Woodruff key 4
                                                               Pipe Ring
                                                               (No.1R023)
                                                                                                   Crank shaft complete


 4) Two 6202 Ball bearings can be removed from the assembly        Fig. 13
    of Helical gear 50 and Spur gear 22 using Bearing extractors
                                                                    Ball bearing 6202              Ball bearing 6202
    (No.1R263) as illustrated in Fig. 13.
                                                                    (on Helical gear 50 side)      (on Spur gear 22 side)
 5) As illustrated in Fig. 15, the assembly of Helical gear 50 and
    Spur gear 22 can be disassembled using Pipe ring (No.1R023),
    Round Bar for Arbor 14-100 (No.1R243), arbor press and
    two appropriate steel plates.
    Note: Be careful not to lose two Woodruff keys.

                                                                                 Helical gear 50          Spur gear 22
                                                                        Bearing Extractor
                                                                        (No.1R263)

 Fig. 14

                              Arbor press                                                          Helical gear 50

                              Round bar
                              for arbor 14-100
                              (No.1R243 )



                                                                                                   Spur gear 22
                                    Metal plates
                                    for supporting Gear
                                                                                                   Woodruff key 4
                               Pipe Ring (No.1R023)
                                                                                                               P 8 / 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -2. Disassembling/Assembling Gear Section (cont.)
 ASSEMBLING
 1) After setting O ring 40, O ring 90 and Pin 4 in place on Gear housing complete, press-fit Crank shaft complete and
    Armature onto Gear housing using arbor press as illustrated in Fig. 15.
 2) Put Sleeve 25 through Crank shaft complete. Set woodruff keys onto the concaves of Crank shaft complete.
    Mount Spur gear 47 to Crank shaft complete. After fixing Spur gear 47 with Retaining ring S-20, assemble Ball
    bearing 6302LLB to Crank shaft complete. (Fig. 16)
 Fig. 15                                                         Fig. 16

    Apply Makita grease N No.1 to the gear portion
                                                                   Ball bearing 6302LLB
    of Armature before press-fitting Armature onto
    Gear housing.                                                  Retaining ring S-20
                                                                      Spur gear 47
                                 Clean this bearing chamber
                                 of Gear housing complete          Woodruff key 4
                                 before mounting O ring 40                (2 pcs)
                                 and Armature to protect
                                 O ring 40.                        Crank shaft complete

   O ring 40
                                        Crank shaft complete
                                                                   Gear housing complete
   Pin 5
                                                                                 Sleeve 25
                                        O ring 90
                                                                                                  Pin 4



 3) Assemble Helical gear 50 to Spur gear 22. Mount the assembly to Gear housing complete.
 4) Put Gear housing complete onto Crank housing complete as illustrated in Fig. 18.
 5) Apply an appropriate amount of ThreeBond 1215 to the figure 8 inlaid portion that contacts Gear housing cover.
    Then secure Gear housing cover to Gear housing complete with four M8x75 Hex socket head bolts. (Fig. 19)

 Fig. 17                                               Fig. 18

   Assembly of Helical gear 50
   and Spur gear 22
                                                                                         Hex socket head bolt M8x75


                         Fit Pin 4 on Gear housing                                       Gear housing cover
                         complete in the hole of
                         Crank housing complete.




                                                                                       Before putting Gear housing
                                                                                       cover, apply ThreeBond 1215
                                                                                       to the figure 8 inlaid portion
                                                                                       designated with white arrow.


                          Crank housing comp.
                                                                                                                 P 9 / 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -3. Disassembling/Assembling Crank Section of AVT
 DISASSEMBLING
 1) Stopper and Crank box will be visible by removing Motor housing cover set and the assembly of Rear cover and
    Handle (switch side).
 2) Grasp the projection of Stopper with pliers. While turning Stopper, pull off from Crank box. (Fig. 19)
 3) Unscrew four M12x55 hex socket head bolts with hex wrench. (Fig. 20)
    Note: Use an appropriate steel pipe to extend the grip of hex wrench for easy removal of the bolts securely fastened
          with adhesive.
 4) Move Barrel till the connection portion of Balancer comp. and Connecting rod (for balancer reciprocating) is visible.
    Now Connecting rod can be removed from Balancer complete and Crank complete as illustrated in Fig. 21.
 Fig. 19                             Fig. 20                                  Fig. 21

                                                            Barrel             Crank complete        Connecting rod




                                                 Hex wrench                    Crank box

   Crank box          Stopper                       steel pipe                         Balancer complete

 5) Remove Crank box from Crank housing by unscrewing four M6x20 Hex socket head bolts. (Fig. 22)
 6. Remove Retaining ring R-80 and Flat washer 65 from Crank box. (Fig. 23)
 Fig. 22                                                        Fig. 23
              Hex socket head bolt M6x20 (4pcs)
                                                                                                Retaining ring R-80
                                  Crank housing
                                                                                                Flat washer 65
                                         Connecting rod                                         Crank box
                                         (for Piston reciprocating)


  Crank box                                                                              Note: Remove Retaining R-80
                                                                                         using Retaining Ring R Pliers
                                                                                         (No.R005).


 7) Remove Crank by pressing with arbor press.( Fig. 24)
    The other Flat washer 65 and Needle bearing 7025 still remain in Crank box in this step.
 8) Needle bearing 7025 and the other Flat washer 65 can be removed from Crank box by putting the Crank complete
    removed in the previous step on Flat washer 65, then pressing it with arbor press. (Fig. 25)
 Fig. 24                                                    Fig. 25

                                                                               Put the removed Crank complete
                                          Flat washer 65                       on Flat washer 65.
                                          (the other one)
                                          Needle bearing
                                          7025
                                          Crank box
                                                                                                        Flat washer 65

                                         Crank complete                                                 Needle bearing
                                                                                                        7025
                                                                                                                  P 10/ 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -3. Disassembling/Assembling Crank Section of AVT (cont.)
 ASSEMBLING
 1) Put Flat washer 65 into Crank box.
 2) Then, as illustrated in Fig. 26, press-fit Needle bearing 7025 into Crank box using Crank complete and the other
    Flat washer 65 as jigs,
   Important:
   Needle bearing 7025 is not reversible when assembled into Crank box. Be sure to assemble as illustrated in Fig. 26.
 3) Put Ring 10 through the crank pin on Crank complete. Then apply Makita grease R.No.00 to the roller portion of
    Needle bearing 7025, then assemble Crank complete into the Needle baring. (Fig. 27)
 4) Put the other Flat washer 65 into Crank box. With retaining ring R-80, fix the parts assembled into Crank box.
    Then make sure that Crank complete rotates easily by finger.
 Fig. 26                                                                           Fig. 27
                                         arbor press
                                         Crank complete                                                   crank pin
                                                                                     Ring 10
                                         Flat washer 65
                                         (another one)
                                         Assemble Needle bearing 7025
                                         so that the brim of the needle baring
  Needle bearing                         is placed on the arbor press side.
            7025
                                                                                             Apply Makita grease R.No.00
            Crank box             Flat washer 65
                                                                                             to the roller portion.
                                  (mounted in the previous step)


 5) Move Crank shaft to the rear dead point (or to the front dead point). Then, aligning the elliptic hole of Crank complete
    with the crank pin on Crank shaft, fit Crank box to Crank housing. (Fig. 28)
    If the crank pin is not completely inserted into the elliptic hole or positioned on the wrong hole, a gap of approx. 5mm
    will occur between the brim of Crank box and Crank housing. In this case, turn Crank shaft slowly until the crank pin
    is completely inserted in the elliptic hole to eliminate the gap.
 6) Secure Crank box to Crank housing with four M6x20 hex socket head bolts. (Fig. 29)
 7) Do the reverse of the disassembling steps from 1) to 4).
 Fig. 28                                                                              Fig. 29

                                                          Crank shaft
   Connecting rod                                         at the rear dead point
                                                          crank pin
                                                          on Crank shaft


   Crank housing                                          elliptic hole


                                                                                        Crank box

                                                                                                        Hex socket
                                                                                                        head bolt M6x20
                        Crank complete       Crank box
                                                                                                                                              P 11/ 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -4. Disassembling/Assembling Barrel Section
 DISASSEMBLING
 1) Remove Stopper, Connecting rod (for balancer reciprocating) and Crank box. (See 1) to 5) of [3] -3.)
 2) From Crank housing, separate Barrel then the assembly of Cylinder liner 62 and Balancer complete. (Fig. 30A)
    Note: When replacing Barrel with new one, replace Plate (the guide for Balancer complete) at the same time.
          When reusing two M5x16 Hex socket bolts, apply appropriate amount of adhesive to them. (Fig. 30B)
 3) Take out Striker from Cylinder liner 62, then remove O ring 52 from Striker. (Fig. 30C)
 4) Take out Piston and Connecting rod (for Piston reciprocating) from Crank housing complete, and remove O ring 52
    and O ring 55 from the removed Piston. (Fig. 30D)
 Fig. 30A                                                                        Fig. 30B

                                      Balancer complete Piston                                   Barrel             Hex socket head
                                                                                                                    bolt M5x16




                              Cylinder liner 62 Spacer
   Barrel                             Flat washer 63
                                                         Crank housing comp.                                   Plate
 Fig. 30C                                                         Fig. 30D

                                                                                          Piston and Connecting Rod




    Striker O ring 52                                              O ring 52 O ring 55

 ASSEMBLING
 Do the reverse of the disassembling steps.
 Note:
   Striker and Spacer are not reversible when assembled to Cylinder liner 62. Be sure to install as illustrated in Fig. 31.
 Fig. 31

                                                                      Spacer
                                                 Striker                                        Cylinder liner 62
                                                                      [Cross section]
                                                                                                                           [Crank housing side]
       [Tool retainer side]




                              CORRECT




                              WRONG



   Do not forget to put Flat washer 63 between Cylinder                  Fig. 32
    liner 62 and Crank housing complete.
   When assembling Barrel to Crank housing complete,                           Barrel Gasket                 Crank housing complete
   first fit Pin 5 in the hole on Barrel, and put the pin
   through the hole of Gasket.
   Then fit Barrel to Crank housing complete so that
   Pin 5 is inserted into the hole on Crank housing
   complete. (Fig. 32)


                                                                                Pin 5
                                                                                                                    P 12/ 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -5. Disassembling/Assembling Tool Retainer Section
  DISASSEMBLING
 1) Tool retainer can be removed as illustrated in Fig. 33.
 Fig. 33

      Tool holder 29     Tool retainer                                             Slotted
                                                                                   screwdriver




                                                Spring pin 8-40                      Tool retainer shaft

     Swivel Tool retainer to the                 Remove spring pin 8-40             Tap out Tool retainer shaft
     position illustrated above.                 with Spring pin extractor          using slotted screwdriver.
                                                 (No.1R348).                        Now Tool retainer can be
                                                                                    removed from Tool holder.


 2) For removing Tool retainer poles, first set Gear extractor, large (No.1R045) as illustrated in Fig. 34.
    *Attach Center attachment (No.1R346) to No.1R045.
    *Adjust the pitch of the arms of No.1R045 to minimum for securely holding Retainer ring.
    *Set Tool retainer pole removing tool (No.1R347) between No.1R346 and Tool retainer pole.
 3) Then pull Retainer ring in the direction of Tool retainer pole by turning the handle of 1R045 clockwise, and remove
    Pin 4 from the rod hole of Tool retainer pole by hand. (Fig. 34)
    Be sure to securely hold the arms of No.1R045 not to spread out, or the arms will fall off from retainer ring and
    Compression spring and Retainer ring will fly away.
 4) Slowly loosen the handle of No.1R045 by turning counterclockwise until Retainer ring is released from Compression
    spring 12. Now Tool retainer pole can be removed from Tool holder 29. (Fig. 35)
 Fig. 34                                                                       Fig. 35

   Retainer ring Tool retainer pole No.1R347
                                                                                               Tool retainer pole
                                              No.1R346
                                                                                         Tool holder 29




                                                    No.1R045                                               Compression
    Pin 4         Compression spring 12
                                                    Adjust the pitch between                               spring 12
                                                                                 Retainer ring
                                                    the arms to minimum.
                                                                                                                         P 13/ 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -5. Disassembling/Assembling Tool Retainer Section (cont.)
  ASSEMBLING
 Do the reverse of the disassembling steps.
 Note:
 When assembling Tool retainer to Tool holder 29, follow the instructions described below. (Fig. 36 - 39)
 Fig. 36

               Tool holder 29                     Slotted screwdriver



                                                                 Tool retainer




                                                             Pin 4 insertion hole

                       A                                    Insert tool retainer shaft by tapping with plastic hammer
                            B                               till the Pin 4 insertion hole of Tool retainer shaft is aligned
                                C                           with that of Tool retainer.
               Tool retainer shaft

 A) See Fig. 37. As illustrated to left, when assembled to Tool holder 29, Tool retainer pole is pulled in the direction of
    Barrel by the force of Compression spring 12, and the hole of Tool retainer pole is not aligned with the hole of Tool
    holder 29.
    Therefore, as illustrated to right, while aligning the two holes by sliding Tool retainer pole with slotted screwdriver,
    assemble Tool retainer and Tool retainer shaft to Tool holder 29.
 Fig. 37

                 Tool holder 29       Tool retainer pole                                                   Slotted screwdriver




      Barrel




           Compression spring 12

 B) Insert Tool retainer shaft from the end chamfered more than the other. (Fig. 38)
 C) Tool retainer shaft is not reversible when inserted into Tool retainer. As illustrated in Fig. 39, be sure to insert so that
    the concave portion on Tool retainer shaft is positioned on the bit insertion hole of Tool holder 29.

 Fig. 38                                                     Fig. 39

                      Tool retainer                            Tool holder 29                              Bit insertion hole
                            End chamfered more




                                      Tool retainer shaft                                                      Concave portion
                                                               Tool retainer shaft
                                                                                                                  P 14/ 21
Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -6. Disassembling/Assembling Tool Holder Section
  DISASSEMBLING
 1) Remove Tool retainer section from Tool holder 29. (Figs. 33, 34, 35)
 2) Separate Tool holder 29 from Barrel by unscrewing four M12x45 Hex socket head bolts as illustrated in Fig. 40.
    Note: Use an appropriate steel pipe to extend the grip of hex wrench for easy removal of the bolts securely fastened
           with adhesive.
 3) Remove Impact bolt by tapping the edge of Tool holder 29. (Fig. 41)
 4) Take out X ring 40 from Tool holder 29 using small screwdriver or the like. (Fig. 42)
    Now Tool holder 29 can be replaced. If Cylinder B is contaminated with dust, X ring 40 can be damged.
    In this case, also replace X ring 40, and clean up the inside of Barrel section.
 5) Take out Cylinder B from Barrel by tapping its edge with plastic hammer. (Fig. 43)
 6) Take out Impact bolt holder from Cylinder B by tapping its edge with plastic hammer. Then remove O ring 53
    from Cylinder B. (Fig. 44)
 7) Remove O ring 60 and Rubber ring 54 from Impact bolt holder. (Fig. 45)
 Fig. 40                                      Fig. 41                               Fig. 42

  Hex socket head bolt                                                                                   Barrel
  M12x45 (4pcs)                  Steel pipe
                                                                  Tool bolder 29                         Cylinder B
                                 Hex wrench
                                                                                                               X Ring 40
                                               Impact bolt

   Barrel

                                                                                      Tool bolder 29
                            Tool bolder 29

 Fig. 43                                      Fig. 44                               Fig. 45
                   Barrel
                                                                                                  O ring 60
                                                         Impact bolt holder
                                                                                                       Impact bolt holder
                                                                   Cylinder B




                                                                      O ring 53               Rubber ring 54
           Cylinder B    Impact bolt holder


 ASSEMBLING
 Do the reverse of the disassemblidng steps.
 Note: Do not forget to apply adhesive to M12x45 Hex socket head bolts.
                                                                                                             P 15/ 21

Repair
 [3] DISASSEMBLY/ASSEMBLY
 [3] -7. Assembling Handle
 See Fig. 46.
                                                        Fig. 46
 When mounting Handle and Side handle, be sure to:
 a) Place Handle (on which Switch and Switch lever
                                                                                                   Switch lever
    are installed) on the side where oil gauge cap is
    installed.
 b) Place Side handle on the opposite side.




                                                            Side handle                                   Handle


                                                                                             Oil gauge cap


 [4] Maintenance
 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 following parts (Fig. 47);
     56. O ring 52 mounted to Piston
     58. O ring 52 mounted to Striker
     84. O ring 53 mounted to Cylinder B
     98. X ring 40 mounted to Tool holder 29
   100. O ring 60 mounted to Impact bolt holder
 Fig. 47


           56               58                   84                           100       98




                 Piston            Striker              Cylinder B    Impact bolt holder            Tool holder 29


 2) Additionally apply approx. 60g of Makita grease R No.00 to the inside of Crank housing complete.
                                                                                                                      P 16/ 21
Circuit   diagram
                                                                     Motor housing B
                                                       Side A
  Color index of lead wires' sheath
  Black
  White
  Red
  Orange                                                                           Side B
  Purple
                                                                               Field




 Countries That Require Noise Suppression Circuitry

   Terminal block        Lead unit           Connector            Pilot lamp




                                             Insulated
                                             connector          Insulated      Brush holder         Brush holder   Insulated
                                                                connector      on side B            on side A      connector



                          Switch


                                                                                             Field




   Power supply cord


                                  Noise suppressor                   Line filter


 USA, Canada, Panama, Mexico, Cyprus, Korea

   Terminal block         Lead unit        Connector             Pilot lamp




                                             Insulated     Insulated           Brush holder Brush holder Insulated
                                             connector     connector           on side B    on side A    connector



                         Switch


                                                                                            Field




   Power supply cord
                                                                                                     P 17/ 21
Circuit   diagram
                                                            Motor housing B
                                                Side A
  Color index of lead wires' sheath
  Black
  White
  Red
  Orange                                                               Side B
  Purple
                                                                     Field




 Other Countries

                                Lead unit   Connector        Pilot lamp




                                            Insulated    Insulated        Brush holder Brush holder Insulated
                                            connector    connector        on side B    on side A    connector



                            Switch


                                                                                  Field


                    Insulated
                    connector
   Power supply cord
                                                                                                                         P 18/ 21
Wiring            diagram
We are explaining the wiring in three sections. (Fig. 48)
Fig. 48

                                         Motor housing B

                                                                         Top cover
                                                [3] Cap cover




                                                                                                                                Handle side
  Motor side




                                                                                                           Lead wires




                       [1] Crank housing cap                                Rear case     [2] Handle sub base

[1] Wiring in Crank Housing Cap
Note: Illustrated below in Fig. 49 is Crank housing cap viewed from Cap cover side.
Fig. 49

  Fix the following lead wires with                                                  Route the following six lead wires
  Lead wire holders A, B and C;                                                      through this opening of Motor housing B:
  A Two orange lead wires                                       Motor housing B      *Four Field lead wires
    (Field lead wire, Lead wire from Brush holder)                                    (orange, black, black, purple)
  B Two purple lead wires                                                            *Two lead wires from Brush holder
    (Field lead wire, Lead wire from Brush holder)                                    (orange, purple)
    Two Field lead wires (black)
  C Two Field lead wires (black)



  When fixing Lead wires with
  Lead wire holders A and B,                                                                    If Noise suppressor is used,
  be sure that all the wires are tight                                                          be careful not to move Noise
  between the Lead wire holders and                                                             suppressor out of place when
  the opening of Motor housing B.                                                               connecting its lead wires with
                                                                                                the insulated connector in
                                                                                                Cap cover.

                                                                                        Lead wire holder B
                      Cap cover side
                                                                                        Noise suppressor
                                                                                        If noise suppressor is used, put here
                                                                                        in place after wrapping with Sponge.
                Lead wire holder A
                                                                                     Purple lead wires
   Orange lead wires                                                                 (Field lead wire, Lead wire
   (Field lead wire, Lead wire                                                        from Brush holder)
   from Brush holder)
                                                                                     Insulated connector
                 Insulated connector
                                                                                     Pilot lamp
                     Line filter                                                      Fix Pilot lamp with this holder.
  (See the illustration below.)
                                                                                     Sponge sheet
                Lead wire holder C                                                    If Line filter is used,
               Field lead wire (black)                                                put Sponge sheet under it.

                Line filter
                                                                                            Field lead wire (black)
                Wind Field lead wires (black) around
                Line filter as illustrated to right,
                then cover the Line filter with Sponge.                               Line filter
                                                                                      Sponge
                                                                                                                     P 19/ 21
Wiring     diagram
[2] Wiring in Handle Sub Base
 When Using Terminal Block
1) Before installing Switch, connect the lead wires with Terminal blocks as illustrated in Fig. 52.
Fig. 52

               to Switch                                         Lead wires of Lead unit
                                    opening of the pipe          Before routing, be sure to put through the pipe of
                                                                 Handle sub base from Motor side as illustrated below.


       rib A

                                                                     Motor side                            Handle side
                                                  boss
      boss
                                                  Terminal         Route round the pin, then route between the boss and
 Terminal                                         block            the inside wall of Handle sub base.
    block
                                                                   Route round the pin and the rib B, then route between
                                                  rib C            the boss and the inside wall of Handle sub base.
      rib B                                                      Important: Be careful not to route over the rib A.
                                                  pin
                                                                    Relay wires (white)
                                                                    Route each wire between the boss and the inside wall
                                             Connector of           of Handle sub base.
                                             Lead unit              Lead wires of Power supply cord
                [Handle sub base viewed                             Route each wire between the inside wall of Handle
                   from Handle side]                                sub base and the rib B/ rib C.

2) After installing Switch, connect the lead wires with Switch as illustrated in Fig. 53.
Fig. 53

                                                          Relay wires (red)
                                                Pin       Before routing, be sure to
        Pin
                                                          put through the pipe of
                                                          Handle sub base from
                           Switch
                                                          Motor side as illustrated
                                                          to right.
      rib B
                                                                    Relay wires (white)
      Noise                                                         Route each wire between the pin and the inside wall
 suppressor                                                         of Handle sub base.
   (if used)
                                                                    Lead wires of Noise suppressor
      rib D                                                         Be careful not to route over the ribs B and D.


                                                                   Terminal block                  surface A
     How to Put Noise Suppressor in Place                                                            Noise suppressor
     If Noise suppressor is used, wrap it with sponge,                                                   Sponge
     and put in the space between the rib A and the rib B                                             Bottom of
     so that the surface A of Noise suppressor is parallel                                            Handle Sub Base
     to the bottom of Handle sub base as illustrated to right.

3) After finishing the wiring in Sub handle base, route the      Fig. 54
   following lead wires through the opening of Top cover
   and Rear cover as illustrated in Fig. 54:
    Lead wires of Lead unit                                                                              Handle sub cover
    Relay wires (red)
                                                                    Rear cover
                                                                                                         Top cover
                                                                                                                     P 20/ 21
Wiring     diagram
[2] Wiring in Handle Sub Base
 When Not Using Terminal Block
1) Before installing Switch, connect the lead wires with Insulated connectors as illustrated in Fig. 55.
Fig. 55

               to Switch
                                                                    Lead wires of Lead unit
                                      opening of the pipe           Before routing, be sure to put through the pipe of
                                                                    Handle sub base from Motor side as illustrated below.


                                                boss

      boss                                                           Motor side                            Handle side
                                                Insulated
  Insulated                                     connector
  connector                                                         Route each wire between the inside wall of Handle
                                                                    sub base and the rib B/ rib C.
                                                 rib C
      rib B                                                         Relay wires (white)
                                                                    Route each wire between the boss and the inside wall
                                                                    of Handle sub base.

                                            Connector of            Lead wires of Power supply cord
                                            Lead unit               Route each wire between the inside wall of Handle
                [Handle sub base viewed                             sub base and the rib B/ rib C.
                   from Handle side]

2) After installing Switch, connect the lead wires with Switch as illustrated in Fig. 56.
Fig. 56

                                                         Relay wires (red)
                                              Pin        Before routing, be sure to
        Pin
                                                         put through the pipe of
                                                         Handle sub base from
                           Switch
                                                         Motor side as illustrated
                                                         to right.
      rib B
                                                                    Relay wires (white)
      Noise                                                         Route each wire between the pin and the inside wall
 suppressor                                                         of Handle sub base.
   (if used)
                                                                    Lead wires of Noise suppressor
      rib D                                                         Be careful not to route over the ribs B and D.

                                                                  Insulated connector
                                                                                                   surface A
     How to Put Noise Suppressor in Place                                                            Noise suppressor
     If Noise suppressor is used, wrap it with sponge,                                                   Sponge
     and put in the space between the rib A and the rib B                                             Bottom of
     so that the surface A of Noise suppressor is parallel                                            Handle Sub Base
     to the bottom of Handle sub base as illustrated to right.

3) After finishing the wiring in Sub handle base, route the      Fig. 57
   following lead wires through the opening of Top cover
   and Rear cover as illustrated in Fig. 57:
    Lead wires of Lead unit                                                                              Handle sub cover
    Relay wires (red)
                                                                    Rear cover
                                                                                                         Top cover
                                                                                                               P 21/ 21
Wiring    diagram
[2] Wiring in Cap Cover
1) First, if Noise suppressor is used, in order to protect lead wires, stick Sponge sheet to the surface A of Cap
   cover so that the longer side of Sponge sheet contacts the surface B of Cap cover and the shorter side
   contacts the surface C. (Fig. 58)
Fig. 58

                                                                                               Surface A
                                         Sponge sheet
                      Cap cover
                                                    shorter side         Surface C
   Sponge sheet                                                       Surface B
                                               longer side




2) Then connect the lead wires as illustrated in Fig. 59.
Fig. 59

                                                            Connector


        Noise suppressor




                                                                                                       Handle sub base

               Crank housing cap Cap cover                                                    Rear case

        Field lead wires (black)
                                                                                           Top cover
        Lead w



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