Makita HR4002 Handbuch

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

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

4.8

4.6

50/ 60

1,050

---

1,050

570

650

570

1,200

Current (A)

Torque limiter

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

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

Tool Holder

Its inside where Helical gear 46 and armature rotate

Its Pin portion for accepting Change plate

Crank Housing Comp.

Its inside where Torque limiter engages with Helical gear 46

and Armature

Gear Housing Comp.

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

Slide sleeve

Fig. 10 Fig. 11

O ring 20

(orange color) X ring 18

Worn Fluoride ring 25

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

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

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

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 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

Compression spring 37

Compression

spring 37

Cylinder 28.5

Striker

O ring 22

Fig. 20 Fig. 21

Striker

Cylinder 28.5

Striker

Cylinder 28.5

Crank housing

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

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

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

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

Ring 33

1R213

Cylinder 28.5

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

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

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