HR5211C | User manual | Makita Repair

T

ECHNICAL INFORMATION

Models No.

HR5211C, HR5210C, HR5201C

Description

Rotary Hammer 52mm (2")

C

ONCEPT AND MAIN APPLICATIONS

These Rotary hammers are successor models of the current

HR5001C series models, featuring the same engineering concept of "Low vibration and High efficiency" as applied to Model HR4001C series models.

L

PRODUCT

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H

Listed below are specification differences among the three models.

Model No.

Active dynamic vibration absorber

Vibration absorbing handle

Selectable two on-off switches

HR5211C

Yes

Yes

No

HR5210C

Yes

No

Yes

HR5201C

No

No

Yes

W

(The image illustrated above is Model HR5211C.)

Dimensions: mm (")

Length (L)

HR5210C

HR5211C

HR5201C

599 (23-1/2)

Width (W)

Height (H)

149 (5-7/8) 130 (5-1/8)

287 (11-1/4)

S pecification

Voltage (V)

110

120

220

230

240

Current (A)

15

15

8

8

8

Cycle (Hz)

50/60

50/60

50/60

50/60

50/60

Continuous Rating (W)

Input Output

1,500

---

750

800

1,500

1,500

1,500

950

950

950

Specification

Model

HR5210C/ HR5211C HR5201C

No load speed: min

-1

= rpm

Impacts per minute: min

-1

= ipm

Shank

Shank type

Shank diameter: mm (")

Capacity :

mm (")

Concrete

Torque limiter

TCT bit

Core bit

Electronic control

Variable speed control by dial

Soft start

Constant speed control

LED power light* 1

LED service light* 2

Double insulation

Power supply cord: m (ft)

Net weight: kg (lbs)

130 - 260

1,075 - 2,150

SDS-Max

18 (11/16)

52 (2)

160 (6-1/4)

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Europe: 4.0 (13.1), Other countries: 5.0 (16.4)

11.6 (25.6) 10.8 (23.8)

*1 indicates trouble with the electric circuit. *2 indicates when to replace carbon brush.

S tandard equipment

Side handle assembly (D-shaped) .......... 1 pc

Side handle (Bar-shaped) ....................... 1 pc

Depth gauge ........................................... 1 pc

Bit grease ................................. 1 pc

Plastic carrying case................. 1 pc

Cleaning cloth .......................... 1 pc

Note: The standard equipment for the tool shown may differ from country to country.

O ptional accessories

TCT bits

Core bits

Bull points

Cold chisels

Scaling chisels

Tile chisels

Grooving chisel

Clay spade

Bushing tool

Rammer

Shank for Bushing tool/Rammer

Chemical anchor adapter

Bit grease

Hammer grease

Blow-out bulb

Safety goggle

Hammer service kit

Max. Output (W)

1,600

1,800

2,100

2,100

2,100

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CAUTION: Remove the bit from the machine for safety before repair/ maintenance

in accordance with the instruction manual!

[1] NECESSARY REPAIRING TOOLS

Code No.

1R003

1R040

1R045

1R212

1R213

1R214

1R228

1R231

1R232

1R258

1R269

1R346

1R350

Description Use for

Retaining ring S pliers ST-2N Removal of Ring springs

Armature holder 50 set for Vise Supporting Jig for 1R213 when removing Cylinder from Barrel complete

Gear extractor

Tip for Retaining pliers

Cylinder extractor

Taper sleeve

Removal of Armature from Gear housing complete

Attachment for 1R003 when removing Ring springs

Removal of Cylinder from Barrel complete

Fitting Fluoride ring to Impact bolt

1/4" Hex shank bit for M4

1/4" Hex shank bit for M8

Pipe 30

V block (2 pcs.)

Bearing extractor

Removal of Hex socket head bolt M4

Removal of Hex socket head bolt M8

Assembling Spur gear 24

Supporting Jig for assembling / disassembling Spur gear 24

Assembling / Disassembling Ball bearings

Center attachment

Ring 60

Attachment for 1R045 when removing Armature

Supporting Jig for 1R213, when removing Cylinder from Barrel complete

Stabilizing the machine

[2] LUBRICATION

Apply Makita grease to the following portions designated with the black triangle to protect parts and product from unusual abrasion.

Item No.

1

9

17

21

22

24

29

34

Description Portion to lubricate

Tool holder cap a Apply Makita grease N No.2 to the rip portion.

Tool retainer b Apply Makita grease N No.2 to the portion where Bit shank contacts.

Tool Holder A c To the portion where Oil seal in Barrel complete contacts

O Ring 18 To the whole portion

Fluoride Ring 25 To the whole portion

Impact Bolt

Ring 47

To the whole portion

Tool Holder B d To the portion where Plane bearing 52 contacts.

e Apply approx. 15g to the portion where Ring 20 hits, when it is pushed

by Slide sleeve.

f To the portion where Plane bearing 57 contacts g To the Inside where Ring 20, Rubber ring 24, Collar sleeve 20 contact

Fig. 1

Barrel complete

Oil seal

9 c d e f g

O ring 20

Slide Sleeve

Rubber ring 24 a

1 b

Plane bearing 52

Plane bearing 57

Plane Bearings 52 and 57 are factory-assembled parts.

9

17

29 34

21

22 24 Ring 20 Collar sleeve 20

Oil index

Makita grease N No.2

Makita grease N No.00

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[2] LUBRICATION (Cont)

Item No.

45

46

47

49

48

51

54 67

56 65

59 61

60

74

76

86

97

Description

Pin 12

O ring 34

O ring 36: 3 pcs.

Cylinder 40

Straight bevel gear 46

O ring 12

O ring 12

O ring 24

Pipe 22

O ring 36

Link lever

Crank housing complete

Gear housing complete

Portion to lubricate

Drum portion for smooth moving of Connecting rod and Piston

Whole portion

Whole portion

Inside where Striker and Piston move. Apply approx. 5g. a Drum portion where Plane bearing 67 in Crank housing complete contacts.

b Teeth portion which engages with the Spiral bevel gear of Torque limiter.

Whole portion

Whole portion

Whole portion

Inside where counter weight moves.

Whole portion

Whole portion c Crank room where Crank shaft rotates. Apply approx. 40g.

d Gear room where Helical gears 24 and 47, Torque limiter's gear

and the drive end of Armature engage. Apply approx. 40g.

Fig. 1A Crank cap cover a

Striker

Connecting rod

Plane bearing 67

Crank lever c

Torsion spring 16

Crank cap

45

74

76

51 b

49 48

86

47 46

Piston

Crank shaft d

Retainer plate

Helical gear 47

Spur gear 24

97

Active dynamic vibration absorber of HR5210C and HR5211C

Fig. 1B

Spring

guide

Counter

weight

Spring

guide

Pipe holder

54 56

Spring

guide

59 60 61

65 67

Pipe holder

Counter

weight

Spring

guide

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[3] DISASSEMBLY/ASSEMBLY

[3] -1. Chuck Section

DISASSEMBLY

Chuck section can be disassembled in the order from Fig. 2 to 6.

Fig. 2

Handle section

Lead unit

Fig. 3

Tool holder cap

Chuck cover

Controller

Cord clamp base

Power supply cord

Tapping

screw 5x25: 6pcs.

Remove six 5x25 Tapping screws, and disconnect Lead unit from

Controller. Now Handle section can be separated from the Machine.

And remove Power supply cord with Cord clamp base.

1R350

Remove Tool holder cap with a slotted screwdriver.

Fig. 4

Put Ring spring 25 out of the ring installation groove on Tool holder using 1R003 and 1R212. Then remove the Ring spring 25 from

Tool holder. Now Flat washer 28, Chuck cover and Spacer can be removed.

Ring Spring 25

Fig. 5

Remove the other Ring spring 25 using

1R003 and 1R212. Now Chuck ring and

Release cover can be removed.

Ring Spring 25

1R212

1R003

Flat Washer 28

Chuck Cover

Spacer

Chuck Ring

Release

Cover

Fig. 6

Remove two Tool retainers while pushing down Spring guide toward Barrel cover side.

Spring guide and Compression spring 49 can be removed from Tool holder A.

Spring Guide

Tool Retainer: 2psc.

Compression

Spring 49

Spring Guide

Tool

Holder A

Spring Guide

ASSEMBLY

Do the reverse of disassembling steps.

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[3] -2. Parts in Tool Holder and Cylinder 40

DISASSEMBLY

The Parts in Tool holder can be removed, without disassembling Chuck section.

1) Separate Chuck and Barrel section and Gear housing cover from Crank housing complete. (Fig. 7)

2) From Tool holder B, the Parts can be removed as illustrated in Fig. 8 and Fig. 9.

3) From Cylinder 40, the Parts can be removed as illustrated in Fig. 10.

Fig. 7 Fig. 8

Hex Socket

Head Bolt M8x35: 4 pcs.

Crank Housing

Complete

Chuck and Barrel section

Hex socket head bolt M4x25: 1 pc.

Gear housing cover

Unscrew a M4x25 Hex socket head bolt using 1R228 or the like.

Unscrew four M8x25 Hex socket head bolts using 1R231 or the like.

Now Chuck and Barrel section and Gear housing cover can be separated from Crank housing cover.

Fig. 9

Tool

Holder B

Remove Impact bolt, Slide sleeve, etc. from Tool holder B by pushing with screwdriver or the like.

Rubber ring 24

Slide sleeve

The inner Parts removed in Fig. 8 are disassembled as illustrated to right.

O ring 20 is installed under Fluoride ring 25.

If Fluoride ring 25 is worn out, the orange color of

O ring 20 will be visible. (Fig. 9)

In this case, replace Fluoride ring 25 together with

O ring 20 and O ring 18.

Do not replace the Fluoride ring alone.

Impact bolt

O ring 18

Ring 20

Impact bolt

Collar sleeve 20

O ring 20 Fluoride

ring 25

Fig. 10

Ring 45

Compression

spring 46 Striker

Cylinder 40

Striker O ring 34

Ring 45, Compression spring 46 and Striker can be removed from

Cylinder 40.

Then O ring 34 can be disassembled from Striker.

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[3] -2. Parts in Tool Holder and Cylinder 40

ASSEMBLY

Do the reverse of the disassembling steps. Be sure to remember the following notes.

Note 1) When assembling Fluoride ring to Impact bolt;

After installing Fluoride ring 25 on the groove of Impact bolt, the Ring is stretched and its edges are

protruding from the groove. In order to correct the deformation, insert the Ring into the repairing tool,

Taper Sleeve (Tool No.1R214), and leave it in the tool about one minute. (Fig. 11)

Fig. 11

Before Correction :

Rings' edges are protruding from the top edge of the groove on

Impact bolt.

Fluoride Ring 25

O Ring 18

Correction

Impact Bolt

Taper Sleeve

(No.1R214)

After Correction :

Rings' edges are positioned under the top edge of the groove on Impact bolt.

corrected

O ring 20

Insert Impact bolt from the HR4000C side of the Taper Sleeve.

groove on Impact bolt

Note 2) When assembling Parts to Tool holder (B) and Cylinder 40;

Pay attention to the matters in Fig. 12 and Fig.13.

Fig. 12

Ring 20 and Collar sleeve 20 are not reversible.

They have to be assembled as illustrated below.

Fig. 13

Insert Striker into Cylinder 40, facing the O ring installation end to Crank housing side.

Tool holder B

Impact Bolt Ring 20

Rubber ring 24

Collar sleeve 20

Slide

sleeve

O ring installation end

Cylinder 40

Striker O ring 34

Crank housing side

O ring 18

Fluoride ring 24 and O ring 20

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[3] -3. Tool Holder Section and Barrel Complete

DISASSEMBLY

1) To come to the Stage of Fig. 14, do the following steps.

1. Separate Chuck and Barrel section and Gear housing cover from Crank housing complete. (Fig. 7)

2. Remove Impact bolt, Slide sleeve, etc. from Tool holder B by pushing with screwdriver or the like. (Fig. 8)

3. Disassemble Chuck section. (Figs. 3, 4, 5 and 6)

2) Disassemble Tool holder section from Barrel complete. (Fig. 14)

3) Separate Tool holder B from Tool holder A in the order from Fig. 15 to 17.

Fig. 14

Barrel

complete

Tool

holder A

Ring spring 44

Ring 47

Barrel

complete

Tool

holder B

Tool

holder A

Tool Holder

Section

Disassemble Tool holder section by striking the tip of Tool holder A.

Fig. 15 Fig. 16

Ring 47

Ring spring 44

1R212

1R003

Tool Holder A

Flat washer 57

Urethane ring 57

Flat washer 57

Tool Holder B

Pin 10: 4 pcs.

Remove Ring spring 44 using 1R003 and 1R212, and then remove Ring 47.

Remove Pin 10 which works as a jointer for

Tool holders A and B.

Remove Flat washers and Urethane ring from Tool holder B.

Fig. 17

Tool holder A Tool holder A

O ring 32

Tool holder B

Tool holder B

O ring 32

Strike the Tool holder B at the illustrated portion.

Now Tool holder B can be separated from Tool holder A.

O ring 32 can be removed from Tool holder A.

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[3] -3. Tool Holder Section and Barrel Complete

DISASSEMBLY

4) Remove Oil seal from Barrel complete by striking a Slotted screwdriver which is applied to Oil seal from the Crank

housing side. (Fig. 18)

Fig. 18

Barrel complete

Oil seal

ASSEMBLY

1) Mount O ring 32 to Tool holder A. Refer to right Fig. 17.

2) Mount Tool holder A to Tool holder B. (Fig. 19)

Fig. 19

Section of the correctly joined Tool holders A and B

Accepting hole for Pin 10

Tool holder A

O Ring 32

Tool Holder B

Accepting hole for Pin 10

Pin 10

Insertion hole for Pin 10

Tool holder B

Tool holder A

O Ring 32

Pin 10

Insertion hole for Pin 10

Strike Tool holder A while watching the

Accepting hole's Position against insertion hole.

And stop to strike Tool holder A when accepting hole of Tool holder A fits to insertion hole of Tool holder B.

Now assemble Pin 10 for joining two Tool holders.

< Note >

O ring 32 is broken by the edge of Insertion hole of Tool holder B, if Tool holder A is inserted too deeply into Tool holder B.

3) Mount Flat washer 57 and Urethane ring 57 to Tool holder B in the following Order. Refer to Fig. 16.

1. Flat washer 57

2. Urethane ring 57

Fig. 20

3. Flat washer 57

4) Facing the Rip portion to the Front side

Rip portion of Oil seal

(Opposite side of Crank housing), assemble Oil seal to

Barrel complete. (Fig. 20)

5) Do the reverse of Disassembling Steps.

Refer to Figs. 15 and 14.

Oil seal

Crank housing side

Barrel complete

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[3] -4. Crank Section

DISASSEMBLY

1) Do the following steps.

1. Separate Chuck and Barrel section and Gear housing cover from Crank housing complete. (Fig. 7) And remove

Crank housing cover.

2. Remove Ring 45, Compression spring 46 and Striker from Cylinder 40. (Fig. 10)

2) Disassemble the following Parts by unscrewing three 4x14 Tapping screws.

* HR5211C: Change lever, Crank cap cover, Spring guide, Compression spring 11 (Fig. 21A)

* HR5210C and HR5201C; Change lever, Crank cap cover, Control plate (Figs. 21B and 21C)

3) Disassemble in the order of Fig. 22 to 24.

Fig. 21A Fig. 21B Fig. 21C

HR5211C HR5210C HR5201C

Tapping screw

4x14: 2 pcs.

Tapping screw 4x14

Change lever

Tapping screw

4x14: 2 pcs.

Tapping screw 4x14

Change lever

Tapping screw

4x14: 2 pcs.

Tapping screw 4x14

Change lever

Crank cap cover

Crank cap cover

Crank cap cover

Spring guide

Control plate

Control plate

Crank lever Crank lever

Compression spring 11

Fig. 22

Pan head screw M4x18: 6 pcs.

Crank lever

Crank cap

Fig. 23 Fig. 24

Straight bevel gear 33

Link plate

Link plate guide

Tail of Link arm

Lock sleeve

O ring 60

Link arm

Seal ring

Remove Crank cap by unscrewing six M4x18 Pan head screws.

Seal ring between Crank cap and

Crank housing complete can be removed in this step.

Remove Link plate with Link plate guide by dislinking from tail of

Link arm.

Driving sleeve

Remove Driving sleeve to which

Lock sleeve, O Ring 60 and Link arm are mounted. Then remove

Straight bevel gear 33.

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DISASSEMBLY

4) Set 1R213, 1R350 and 1R040 on Cylinder 40 and Crank housing complete as illustrated in Fig. 25. And pull off

the Cylinder by turning the handle of the 1R213 clockwise.

Use two Phillips screwdrivers as illustrated in Fig. 26 if 1R213 and 1R350 are not available.

5) Remove Piston and Connecting rod as illustrated in Fig. 27.

6) Now O Ring 34 can be replaced. (Fig. 28)

Fig. 25 Fig. 26

No.1R213

Turn the handle clockwise to remove

Cylinder 40.

Insert two Phillips screwdrivers into the side holes of Cylinder 40 and lever up the Cylinder.

Phillips Screwdriver Cylinder 40

Grasp Cylinder 40 by inserting the pins of

No.1R213 into the side holes of the Cylinder.

No.1R350

No.1R040

Crank housing comp.

Cylinder 40

Put pieces of wood or the like to protect the machined surface of Crank housing complete from damages and scratches.

Crank housing comp.

Fig. 27

Crank Housing Complete viewed from Crank Cap Cover Side

Cylinder assembling side Cylinder assembling side Cylinder assembling side

Piston

Connecting rod

Crank shaft

Crank pin

Turn Crank shaft to position it at the Dead point of Cylinder assembling side.

Fig. 28

O ring 34

Crank pin

Disconnect Connecting rod from Crank pin by lifting it up.

Piston

Connecting rod

Pull out Piston from the Cylinder assembling side.

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ASSEMBLY

1) Assemble Piston by connecting Connecting rod with Crank shaft which is at the Dead point of Cylinder assembling side.

Refer to Fig. 27.

2) Inserting over Piston, mount Cylinder 40 to Crank housing complete by pressing with Arbor press until it stops. (Fig. 29)

And mount Straight bevel gear 33. Refer to Fig. 24.

3) Assemble Lock and Driving sleeve Section. (Fig. 30)

4) Insert Lock and Driving sleeve section into Crank housing complete until the tail of Link arm comes into your sight in

Crank room. (Fig. 31)

Fig. 29

Fig. 30

Assembling of Lock and Driving Sleeve Section

O ring 60

Lock sleeve

Link arm guide

Cylinder 40

O ring 60

Lock sleeve

Driving sleeve

Link arm guide

Link Arm

Link arm O ring 36: 3 pcs.

Make sure that three O rings 36 are assembled to Cylinder 40 before assembling it.


Driving sleeve

Mount Driving sleeve to O ring 60, Lock sleeve and Link arm with Link arm guide.

Fig. 31

Link Arm

Lock and Driving

Sleeve Section

Crank Housing

Complete

Crank Shaft

Tail of Link Arm has to come into your Sight at this Portion.

5) Assemble Link plate with Link plate guide to Crank housing complete, while linking the End of Link plate to the tail

of Link arm. Refer to Fig. 23.

6) Assemble Crank cap with Crank lever and Seal ring to Crank housing complete. Refer to Fig. 22.

7A) HR5211C: Assemble Spring guide with Compression spring 11 to Crank housing complete. And then mount

Crank cap cover and Change lever. Refer to Fig. 21A.

7B) HR5210C: Assemble Control plate to Crank lever on Crank cap. And then mount Crank cap cover and Change lever.

Refer to Fig. 21B.

7C) HR5201C: Do the same step as HR5210C. Refer to Fig. 21C.

8) As for the further Assembling, do the reverse of Disassembling steps.

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[3] -5. Active Dynamic Vibration Absorber of HR5210C and HR5211C

DISASSEMBLY

1) Do the following Steps.

1. Remove Handle section. (Fig. 2)

2. Separate Chuck and Barrel section and Gear housing cover from Crank housing complete. (Fig. 7)

And remove Crank housing cover.

2) Separate Active Dynamic Vibration Absorber from Crank housing complete. (Figs. 32 and 33)

3) The removed Active Dynamic Vibration Absorber is disassembled as illustrated in Fig. 34.

Fig. 32 Fig. 33

Slotted screwdriver

Absorber holder

Compression spring 15

Absorber holder of


Pipe holder Spring guide

Inserting Phillips screwdriver through the

Absorber holder's hole, push Spring guide with the Screwdriver.

The Spring guide will tilt to be locked inside the Absorber, and this end of the

Absorber is now released from Crank housing complete. Then do the same on the other end of the Absorber.

Fig. 34

Pipe holders can now be separated by turning them while pushing strong toward each other.

Now it can be disassembled as illustrated below.

Pipe holder

Pipe 22 Counter weight

Now the Absorber can be levered off from Crank housing complete using a slotted screwdriver

Pipe holder

O ring 12

Spring guide

O ring 24

ASSEMBLY

1) Push Spring guide again. So it is set in Place. (Fig. 35)

2) Attach Active Dynamic Vibration Absorber to Crank housing complete

while keeping it parallel to Crank housing complete. (Fig. 36)

Fig. 36

Fig. 35

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[3] -6. Controller and Power Supply Cord

DISASSEMBLY

1) Remove Handle section. And disconnect Lead unit from Controller. (Fig. 2) Disconnect Lead wire of Power

supply cord from Controller by unscrewing two 4x14 Tapping screws. Now Power supply cord can be replaced. (Fig. 37)

2) Remove Controller as illustrated in Fig. 38.

Fig. 37 Fig. 38

Controller

Tapping

Screw 4x14

Controller

Lead Wire of

Power Supply Cord

Tapping

Screw 4x14

Cord clamp base

Tapping Screw 4x14

Cord Clamp

Power Supply Cord

Cord clamp base and Controller is fastened to Motor housing with this Tapping screw 4x14.

Unscrew a 4x14 Tapping screw and then insert two Slotted-screwdrivers between Motor housing's rib and Controller frame's tab.

And remove Controller by levering up with the Drivers.

ASSEMBLY

Do the reverse of Disassembling steps .

[3] -7. Armature

DISASSEMBLY

Fan 90 interferes with the Application of Finger or Tools for disconnecting the Contact of carbon brush with Commutator.

Therefore, Fan 90 has to be disassembled.

1) Disassemble Rear cover from Motor housing by unscrewing two

5x25 Tapping screws. (Fig. 39)

2) Remove Fan 90 by unscrewing M8-12 Hex nut . (Fig. 40)

Note: Before disassembling Fan 90, make sure that your Impact

driver is preset to Clockwise rotation. Otherwise, the Fan

can not be removed any more because of the Deformation

of its Insertion hole for Armature shaft.

Fig. 39

Rear cover

Tapping screw 5x25: 2 pcs.

Fig. 40

Impact driver

Socket bit, hex 12mm

Hex nut M8-12

Fan 90

Flat washer 8

Motor housing

While holding Fan 90 with your gloved Hand, remove the Fan with

Impact driver which is

[Motor housing complete] viewed from the Rear cover side preset to clockwise

Rotation.

Fan guide

Fan 90

Flat washer 8

Hex nut M8-12

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DISASSEMBLY

3) Disconnect the Contact of Carbon brush with commutator as illustrated in Fig. 41.

Fig. 41

Disconnection of the Contact of Carbon brush with Commutator

Carbon brush

Spiral spring

Carbon brush is pressed with

Spiral spring to maintain its contact with Armature's commutator.

Armature shaft of commutator end

Detach Spiral spring from Carbon brush.

By pulling Carbon brush, disconnect its contact with

Armature's commutator.

Now Armature is ready to be disassembled.

Spiral spring

Carbon brush


Carbon brush


Motor housing

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4) Separate Crank housing complete from Motor housing as illustrated in Figs. 42, 43 and 44.

Fig. 42 Fig. 43 Fig. 44

Crank housing cover

Hex socket head bolt M6x40: 4 pcs.



Active dynamic vibration absorber

(HR5210C, HR5211C)

Disassemble Crank housing cover.

And remove Active Dynamic

Vibration Absorber, as illustrated in Fig. 32.

Armature

Motor housing

Remove four M6x40 Hex socket head bolts.

Strike Armature shaft with Plastic hammer.

Crank housing complete with Gear housing can be separated from Motor housing.

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DISASSEMBLY

5) Separate Gear housing complete from Crank housing complete as illustrated in Fig. 45.

6) Disassemble Armature with 1R045 and 1R346 as illustrated in Fig. 46.

Fig. 45 Fig. 46



Armature

Handle of 1R045

1R346

Hex socket head bolt M6x25: 2 pcs.

Separate Gear housing complete from

Crank housing complete by removing two

M6x25 Hex socket head bolts.

Armature

Set 1R045 and 1R346 on Armature, and turn the Handle of 1R045 clockwise as illustrated above.

ASSEMBLY

Do the reverse of Disassembling steps.

Note in assembling Fan 90: Before assembling Fan 90, make sure that your Impact driver is preset to

counterclockwise rotation.

[3] -8. Torque Limiter

1) Separate Gear housing complete. And disassemble armature. (from Fig. 39 to 46)

2) Remove Torque limiter assembly from Gear housing complete by tapping the edge of Gear housing complete with

plastic hammer. (Fig. 47A) If Torque limiter assembly remains on Crank housing complete, remove by tapping the edge

of Crank housing complete. (Fig. 47B)

Fig. 47A Fig. 47B

Torque limiter assembly

Torque limiter assembly

Gear housing complete Crank housing complete

< Note >

Torque limiter assembly is factory-adjusted. Therefore, do not disassemble it.

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[3] -9. Crank Shaft and Gears

DISASSEMBLY

1) Disassemble the following Parts from Crank housing complete.

* HR5211C: Change lever, Crank cap cover, Spring guide, Compression spring 11 (Fig. 21A)

* HR5210C and HR5201C; Change lever, Crank cap cover, Control plate (Fig.21B, Fig. 21C)

2) Remove the following Parts from Crank housing complete.

* Crank Cap with Crank Lever (Fig. 22) * Link Plate with Link Plate Guide (Fig. 23)

* Lock and Driving Sleeve Section (Fig. 24) * Straight Bevel Gear 33 (Fig. 24)

3) Separate Crank housing complete together with Gear housing complete from Motor housing. And disassemble Gear

housing from Crank housing complete. (from Fig. 39 to 45)

4) Now Crank shaft section can be disassembled as illustrated in Figs. 48, 49, 50 and 51.

5) Piston can be also removed, if it is necessary to replace O Ring 34. (Fig. 52)

Fig. 48 Fig. 49


Crank shaft

section

Crank shaft Crank pin

Handle assembling side Handle assembling side

Turn Crank shaft to position it at the dead point of Handle assembling side.

Fig. 50 Fig. 51

Flat washer 12

1R003

Retaining ring S-22

1R258: 2 pcs.

While keeping the Crank pin's Position at the dead point in Fig. 48, strike the Edge of Crank housing complete.

Now Crank shaft section can be removed from Crank housing complete.

Spur gear 24

Remove Flat washer 12.

And then disassemble Retaining ring S-22 using 1R003.

(Flat washer 12 may remain in Gear housing.)

Fig. 52

Set Crank shaft section on

1R258, and then press

Spindle with arbor press.

Helical gear 47

Key 5: 2 pcs.

Crank shaft

Ball bearing 6006LLU

Now the Crank shaft section can be disassembled as illustrated above.

Piston can be removed by striking the edge of

Crank housing complete.

Piston

O ring 34

Connecting rod

P 17 / 24

R epair

[[3] DISASSEMBLY/ASSEMBLY

[3] -9. Crank Shaft and Gears

ASSEMBLY

1) Set Helical gear 47 to Crank shaft as illustrated in Figs. 53 and 54.

Note: Helical gear 47 is not reversible. Pay attention to the position of its Drum portion. (Fig. 54)

2) Assemble Crank shaft section by pressing Spur gear 24 with arbor press. And mount Retaining ring S-22

for securing Spur gear 24. (Figs. 55 and 56)

3) Assemble the Crank shaft section to Crank housing complete. Refer to Figs. 49 and 48.

And assemble Piston into by connecting Connecting rod with Crank shaft which is at the dead point of

Cylinder assembling side.

4) As for the further step, do the reverse of disassembling steps.

Fig. 53 Fig. 54

Insert Key 5 into the groove of Crank shaft.

Key 5: 2 pcs.

Fig. 55

Spur gear 24

1R258: 1pc.

Crank shaft

Set the Helical gear 47 to

Crank shaft while fitting this groove portion to the assembled Key 5.

Crank shaft

Key 5

Helical

gear 47

Face this Drum portion to Ball bearing Side when assembling.

Ball bearing

6006LLU

Fig. 56

1R232

1R003

Flat washer 12

Retaining ring S-22

Ball bearing

6006LLU

Accepting Crank shaft with

1R258, assemble Spur gear 24 by pressing with arbor press.

Crank shaft

Mount Retaining ring S-22 and Flat washer 12.

(Flat washer 12 may remain in Gear housing.)

P 18 / 24

R epair


[3] -10. Handle Section

HR5201C and HR5210C

(models with two selectable on-off switches)

DISASSEMBLING

1) After removing one 4x18 Tapping screw, Handle cover can be separated from Handle by levering off with a slotted

screwdriver inserted between Handle and Handle cover- the portion designated by the circle in Fig. 57.

Main switch can now be replaced. (Fig. 57)

2) Separate Handle from Motor housing by removing six 5x25 Tapping screws.

By unscrewing two 4x14 Tapping screws, Controller and Power supply cord can now be replaced.

(Fig. 58; Refer to Figs. 37 and 38)

Fig. 57 Fig. 58

Handle

Handle cover

Tapping screw 4x18

Controller

Cord clamp base

Power supply cord

Slotted screwdriver

3) Slide lever complete, Switch box and Slide switch can be

removed from Handle by unscrewing one 4x14 Tapping screw.

(Fig. 59)

Note: Be careful not to lose Leaf spring.

Fig. 59

Handle

4) Remove Change lever and Crank cap cover from Crank

housing. Control plate can now be removed. (Fig. 60)

Tapping screw 4x14 (2pcs)

Handle

Tapping screw

5x25 (6pcs)

Slide lever complete

Slide switch Switch box

Leaf spring

Tapping screw

4x14

Fig. 60

Tapping screw

4x14: 2 pcs.

Tapping screw 4x14

Change lever

Control plate

Crank cap cover

Crank lever

Control plate

P 19 / 24

R epair



HR5201C and HR5210C

(models with two selectable on-off switches)

ASSEMBLING

Do the reverse of the disassembling steps.

Note 1: Control plate is not reversible when fit on Crank lever. Be sure to install so that the side having embossed

part number and Projection is placed on the Crank cap cover side. (Fig. 61)

Note 2: Do not forget to mount Leaf spring between Slide lever complete and Slide switch when assembling them

to Handle. (Fig. 59)

Fig. 61

Crank cap cover

Control plate

Projection

Embossed part number

HR4011C

(model without two selectable on-off switches)

DISASSEMBLING

1) After removing one 4x18 Tapping screw, Handle cover can be separated from Handle by levering off with a slotted

screwdriver inserted between Handle and Handle cover- the portion designated by the circle in Fig. 62.

Main switch can now be replaced. (Fig. 62)

2) Separate the assembly of Handle and Handle base from Motor housing by removing six 5x25 Tapping screws.

By unscrewing two 4x14 Tapping screws, Controller and Power supply cord can now be replaced. (Fig. 63)

Fig. 62

Handle

Handle cover

Tapping screw 4x18

Fig. 63

Controller

Compression spring 11 with Spring guide

Tapping screw 4x14 (2pcs)

Handle base

Handle

Tapping screw

5x25 (6 pcs)

Handle base

Slotted screwdriver

Cord clamp base

Power supply cord

R epair



HR5211C

(model without two selectable on-off switches)

DISASSEMBLY

3) Separate Handle from Handle base by unscrewing two 5x40 Tapping screws and two 5x25 tapping screws.

Now Dust cover support and Dust cover can be removed. (Fig. 64)

Fig. 64

P 20/24


Flat washer 5: 2 pcs.

Handle base

Dust cover support

Dust Cover

Handle


Shoulder sleeve 6: 2 pcs.

ASSEMBLY

Do the reverse of the disassembling steps.

Note: Dust cover support is not reversible when fit on Dust cover. Be sure to install so that the side having

embossed triangle mark is placed on the Dust cover side. (Fig. 65)

Fig. 65

Handle base

Dust cover support

Embossed triangle mark

Dust cover

Handle

R epair


[3] -11. Fastening Torque of Screw and Bolt

Fasten the Bolts illustrated in Fig. 66 with the fastening torque listed below.

Fig. 66

15

Position

No.

Size of Hex Socket

Head Bolt

15

68

131

M8 x 35

M6 x 40

Hex Nut M8 - 12

Used

Q'ty

Fastening

Torque

4 20 - 29 N.m

4 4.9 - 7.8 N.m

1 1.8 - 3.5 N.m

Barrel cover

Barrel complete



68

P 21 / 24

Motor housing

Fan 90

Flat washer 8

131

[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.

1. Tool holder cap

21. O ring 18 on Impact bolt

22. Fluoride ring 25 on Impact bolt

Fig. 67

23. O ring 20 on Impact bolt

46. O ring 34 on Piston

49. O ring 34 on Striker

1

Barrel complete

21

22

23 Impact bolt 49 46

Chuck cover Barrel cover

Release cover

Tool holder B

Cylinder 40

Striker

Piston

2) Additionally apply approx. 100cc of Makita grease R No.00 to the inside of Crank housing complete.

C ircuit diagram

Fig. D-1

HR5211C without Selectable Two On/Off Switches

Color index of lead wires' sheath

Black

White

Blue

Brown

Speed control dial

Field

Lead unit

Main Switch

Brush holder unit

In stead of blue, white Lead wire is used for some Countries.

In stead of brown, black Lead wire is used for some Countries.

Power supply cord

Fig. D-2

HR5201C and HR5210C with Selectable Two On/Off Switches

Color index of lead wires' sheath

Black

White

Red

Blue

Brown

Speed control dial

Slide switch for lock ON

Main Switch

Field

Lead unit

P 22 / 24

Brush holder unit

In stead of brown, black Lead wire is used for some Countries.

Power supply cord

In stead of blue, white Lead wire is used for some Countries.

P 23 / 24

W iring diagram

[1] In Handle

Lead Wires from Main switch

Fix with the lead wire holders of Handle and Switch holder. (Fig. D-3)

Fig. D-3

Handle

Main switch

Lead wire holder of Switch holder

Lead wire holder of Handle

Lead wire (white) to Controller

HR5211C:

Lead wire (black) to Controller

HR5201C and HR5210C:

Lead wire (red) to Lock-on slide switch

Lead Wires to Lock-On Slide Switch (HR5201C and HR5210C)

Fix with the lead wire holders on the inside surface of Handle. (Fig. D-4)

Fig. D-4

Handle viewed from the Motor housing side

Switch box

Switch box viewed from the Handle cover side

Lock-on slide switch

Lead wire (black) from lock-on slide switch

Connector

Lead wire (white) from Main switch

Fix with this lead wire holder.

Handle

Fix with these lead wire holders.

Lead wire (red) between Main switch and Lock-on slide switch

W iring diagram

[2] In Motor Housing

Lead Wires of Power Supply Cord

When assembling Handle to Motor housing, be careful not to pinch at the circled portion in Fig. D-5.

Fig. D-5

Motor housing

P 24 /24

Controller

Controller

Lead wires of power supply cord

Be careful not to pinch the lead wires of Power supply cord.

HR5211C | User manual | Makita Repair

Models No.

Description

ONCEPT AND MAIN APPLICATIONS

Lead Wires from Main switch

Lead Wires to Lock-On Slide Switch (HR5201C and HR5210C)

Lead Wires of Power Supply Cord

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