Makita HM002G Repair Manual
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Makita HM002G Repair Manual

Makita HM002G Repair Manual

Cordless demolition hammer
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OFFICIAL USE
For ASC
CORDLESS DEMOLITION HAMMER
HM002G
REPAIR MANUAL
June 2021
Ver.1

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Summary of Contents for Makita HM002G

  • Page 1 OFFICIAL USE For ASC CORDLESS DEMOLITION HAMMER HM002G REPAIR MANUAL June 2021 Ver.1...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................4 TIGHTENING TORQUE SPECIFICATIONS ..........................5 REPAIR ......................................6 Disassembling ..................................6 6-1-1 Housing section ................................6 6-1-2 Chuck section ................................8 6-1-3 Motor section................................

  • Page 3: Caution

    CAUTION Repair the machine in accordance with "Instruction manual" or "Safety instructions". Follow the instructions described below in advance before repairing:  Wear gloves.  In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what the parts are. ...

  • Page 4: Lubricant And Adhesive Application

    LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease FA. No.2 a little Makita grease R. No.00 Apply a little unless specified in the figure. Molybdenum disulfide a little Fig. 1 4 / 39...

  • Page 5: Tightening Torque Specifications

    TIGHTENING TORQUE SPECIFICATIONS Tightening torque Parts to fasten Fastener (N∙m) ↔ Barrel Hex socket head bolt M8x35 29.4 - 39.2 ↔ Crank housing Crank cap cover Pan head screw M4x18 0.88 - 1.5 ↔ Motor housing H.S.H.bolt M6x40 with WR 3.9 - 4.3 5 / 39...

  • Page 6: Repair

    REPAIR Disassembling 6-1-1 Housing section Fig. 2 Remove Tapping screws 4x18 [1] (10 pcs), then remove Housing R [2]. Fig. 3 Remove the following parts from Housing [1]:  Trigger lock [2]  Leaf spring [3]  Switch lever [4] ...
  • Page 7 Fig. 5 Remove the following parts from Housing [1]:  Switch [2]  Terminal units [3] (2 pcs)  LED circuit [4]  Controller [5] Fig. 6 Remove Housing [1] and Compression spring 8 [2]. Note Be careful not to pop out Compression spring 8 [2]. Fig.

  • Page 8: Chuck Section

    6-1-2 Chuck section Fig. 9 Remove Hex socket head bolts M8x35 [1] (4 pcs). Tips Remove each Hex socket head bolt M8x35 [1] after loosening it with Hex wrench and Pipe, because Hex socket head bolt M8x35 [1] is firmly tightened. Fig.
  • Page 9 Fig. 12 Hold the machine with 1R312 and remove Tool holder cap [2] with a slotted screwdriver [1]. Tips Support Barrel with a grip of plastic hammer to prevent it from falling out. 1R312 Fig. 13 Insert SDS max shank [1] of 1R363 and fix it in the same way as a bit.
  • Page 10 Fig. 15 Remove 1R363, then remove Ring spring 26 [1] with 1R003 and 1R212. 1R003 1R212 Fig. 16 Remove the following parts from Tool holder [1]:  Flat washer 30 [2]  Chuck cover [3]  Rubber ring 30 [4] ...
  • Page 11 Fig. 19 Remove Retaining ring WR-45 [1] with 1R003 and 1R212-A. 1R363 1R212-A Fig. 20 Remove Change ring cover [1] and Change ring [2]. Fig. 21 Remove Ring spring 35 [1] with 1R003 and 1R212, then remove Lock ring [2]. Tips Widen Ring spring 35 [1] with 1R003 and 1R212-A, then remove it with 1R003 and 1R212.

  • Page 12: Motor Section

    Fig. 23 Push out Tool holder [2] from Barrel [1]. Fig. 24 Remove Rubber ring 39 [2], O-ring 35.5 [3] and Flat washer 39 [4] from Tool holder [1]. [2] [4] 6-1-3 Motor section Fig. 25 Remove Compression springs 12 [2] (2 pcs) and Compression spring 10 [3] from Crank housing [1].
  • Page 13 Fig. 27 Remove H.S.H.bolts M6x40 with WR [1] (6 pcs), then remove Motor housing section [2]. Note Lay a waste cloth or the like because the grease will leak. Fig. 28 Remove Seal ring B [1] and Flat washer 12 [2]. Fig.

  • Page 14: Gear And Crank Section

    Fig. 31 Remove Tapping screws 4x18 [1] (4 pcs), then remove Baffle plate [2]. Fig. 32 Tap Motor housing [1] with a plastic hammer to remove Stator [2]. Note Do not tap the thin portion of Motor housing [1] because it is fragile. 6-1-4 Gear and Crank section Fig.
  • Page 15 Fig. 35 Pull Cylinder [2] out of Crank housing [1]. Fig. 36 Insert a grip of Plastic hammer into Cylinder [1], then push out Striker [2] from Cylinder [1]. Fig. 37 Remove One way valve guide [2] and O-ring 44 [3] from Cylinder [1].
  • Page 16 Fig. 40 Remove Seal ring A [1]. Fig. 41 Support Crank housing [1] with 1R218, then push out Crank shaft section [2] with 1R213 and Arbor 1R213 press. Remove Connecting rod [3]. Note  Position Connecting rod [3] at the escape portion in Crank housing [1].

  • Page 17: Assembling

    Fig. 44 Push out Crank shaft [1] with Arbor press to remove Ball bearing 6206LLB [2]. Assembling 6-2-1 Gear and Crank section Fig. 45 Assemble Ball bearing 6302DDW [2] to Gear housing [1], then press-fit them. Fig. 46 Assemble Flat washer 15 [2] and Rotor [3] to Gear housing [1], then press-fit them.
  • Page 18 Fig. 48 Assemble Ball bearing 6206LLB [2] and Helical gear 57 [3] to Crank shaft [1], then press-fit them with an appropriate Pipe jig. Fig. 49 Place Crank housing [1] on 1R258, then align the crank pin of Crank shaft [2] with the escape portion of Crank housing [1].
  • Page 19 Fig. 51 Assemble Cylinder [1] to Crank housing [2]. Tips Assemble Cylinder [1] with Piston moved forward and fully. Note Apply the specified grease to the outer and inner surface of Cylinder [1]. Fig. 52 Assemble One way valve guide [2] and O-ring 44 [3] to Cylinder [1].

  • Page 20: Motor Section

    6-2-2 Motor section Fig. 56 Assemble Stator [2] to Motor housing [1], then tap the bottom of Motor housing [1] with a plastic hammer and insert Stator [2] fully. Fig. 57 Assemble Baffle plate [2] to Motor housing [1] with Tapping screws 4x18 [3] (4 pcs). Fig.

  • Page 21: Chuck Section

    Fig. 60 Assemble the following parts to Crank housing [1]:  Compression springs 12 [2] (4 pcs)  Spring plates [3] (2 pcs)  Counter weights [4] (2 pcs)  Holder completes [5] (2 pcs) Note Apply the specified grease to O ring portions of Holder complete [5] and Counter weight [4].
  • Page 22 Fig. 64 Assemble Flat washer 39 [2], Rubber ring 39 [3] and O-ring 35.5 [4] to Tool holder [1]. [3] [2] Fig. 65 Insert Impact bolt [2] into Tool holder [1]. Fig. 66 Insert Tool holder [2] into Barrel [1]. Note Apply the specified grease to the outer surface of Tool holder [2] and O-ring 35.5 [3].
  • Page 23 Fig. 68 Assemble Barrel [2] to Crank housing [1] with Hex socket head bolts M8x35 [3] (4 pcs). Note Apply the specified grease to the inside and outer surface of Cylinder [4]. Fig. 69 Assemble Housing cover [1] Fig. 70 Assemble Lock ring [1], then assemble Ring spring 35 [2] with 1R003, 1R212-A and 1R212-B.
  • Page 24 Fig. 71 Assemble Change ring [1] and Change ring cover [2], then assemble Retaining ring WR-45 [3] with 1R003, 1R212-A and 1R212-B. 1R212-A 1R003 1R212-B Fig. 72 Assemble Compression spring 56 [2] and Spring guide [3] to Tool holder [1], then assemble Tool retainers [4] (2 pcs).
  • Page 25 Fig. 75 Insert SDS max shank [1] of 1R363 and fix it in the same way as a bit. While lowering Chuck cover, tighten the nut of 1R363 with Socket wrench 13 [2] to push down Flat washer 30 [3]. 1R363 Fig.

  • Page 26: Housing Section

    6-2-4 Housing section Fig. 78 Assemble Base section [2], Dial circuit [3] and Shoulder pins 4-6 [4] (2 pcs) to Motor housing [1], then tighten Tapping screws 4x18 [5] (2 pcs). Fig. 79 Assemble Motor housing cover [1] with Tapping screws 5x25 [2] (4 pcs).
  • Page 27 Fig. 82 Assemble the electrical parts in accordance with Circuit diagram and Wiring diagram. Assemble the following parts to Housing [1], then fix Lead wires with 1R411.  Controller [2]  Terminal units [3] (2 pcs)  LED circuit [4] ...
  • Page 28 Fig. 85 Assemble Tool holder cap [1]. Note Apply the specified grease to the inner surface seal portion of Tool holder cap [1]. 28 / 39...

  • Page 29: Circuit Diagram

    CIRCUIT DIAGRAM Fig. 86 AWG14 LED circuit AWG16 Controller B AWG22 Line filter (if used) Connector Lead unit Closed end splice Stator Flag receptacle (#250, t=0.8) Dial circuit Switch Sensor circuit Terminal unit Controller Capacitor Circuit diagram of Switch Connector for Wireless unit 29 / 39...

  • Page 30: Wiring Diagram

    WIRING DIAGRAM Motor housing section Fig. 87 Motor housing The end of Tape Controller B Tape Stator Handle side View from “A” in the right drawing of Fig. 87 Lead unit Rib A Pass Controller B lead wires through this opening of Motor housing. Pass Lead unit lead wires through this opening of Motor housing.

  • Page 31: Motor Housing Section

    Motor housing section Fig. 88 Sensor circuit Rib B Dial circuit Rib C Fix Sensor circuit lead wires in these grooves. Route the following lead wires between Rib B and Rib C:  Lead unit lead wires  Controller B lead wires ...

  • Page 32: Motor Housing Section

    Motor housing section Fig. 89 Controller Terminal unit (The front side of the machine) The rugged portion of Controller case Connector Connector for Wireless unit The storage portion for Connector LED circuit Cross section A-A Terminal unit (The rear side of the machine) Fix the following lead wires in this groove: ...

  • Page 33: Motor Housing Section

    Motor housing section Fig. 90 Switch Line filter (if used) Capacitor Rib A Groove A Inner wall of Housing Rib B Closed end splice Controller Terminal unit (The rear side of the machine) Fix Lead wires to Switch in this groove. ...

  • Page 34: Troubleshooting

    TROUBLESHOOTING Whenever you find any trouble in your machine, first, see this list to check the machine for solution. Note for Repairing The content may vary depending on the model. Use full charged batteries. When Housing is disassembled, check the conditions of each part (Mechanical lock, Adherence of iron powder to Rotor and Stator, Disconnection of Connectors, Lead wires, Assembling of Stator, Connection of Terminal unit and Battery, etc.).

  • Page 35: Flowchart For Troubleshooting

    Flowchart for Troubleshooting Check the items in the following flowchart in order from the top to bottom. Description of the item is referred to CIRCUIT DIAGRAM. After corrective action, return to the start of Troubleshooting and re-check again. Symptom Cause Corrective action Tester indicates proper figure.
  • Page 36 (Continued from previous page.) Connect Connectors firmly. Connectors are poorly connected. LED Job light Lead wires are broken. Check Lead wires or replace lights up. them. Switch is broken. Replace Switch. LED circuit is broken. Replace LED circuit. Rub marks are on Controller is broken.

  • Page 37: Wireless Activation

    Wireless activation  Be sure to prepare non-defective AWS-supported tool and vacuum cleaner for efficient defect inspection.  Check Step 1 (9-4-1) to Step 3 (9-4-3) in order and if some troubles happen, see 9-4-4.  During the inspection, do not use microwave oven nearby. AWS-supported tool AWS-supported vacuum cleaner Wireless activation lamp...

  • Page 38: Step 2: Tool Registration

    9-4-2 Step 2: Tool registration AWS-supported tool AWS-supported vacuum cleaner Press and hold down Wireless activation button, Press and hold down Wireless activation button, then make sure that Wireless activation lamp blinks then make sure that Wireless activation lamp blinks in green.

  • Page 39: Step 3: Checking Wireless Activation

    9-4-3 Step 3: Checking wireless activation The tool and cleaner should be about 5m apart from each other. AWS-supported tool AWS-supported vacuum cleaner Make sure that, when the tool is activated, Wireless Make sure that, when the tool is activated, Wireless activation lamp lights up in blue.

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