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Use this guide to service the piston in a Makita Jack Hammer HM1203C 2010.
Wherever there’s grease, make sure to clean it off and replace it with new grease. The recommended grease is Makita 181490-7.
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Unscrew the knob securing the side handle.
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Remove the bolt securing the side handle.
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Remove the side handle.
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Use a Phillips #2 screwdriver to remove the six screws securing the handle assembly.
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Pull the handle assembly away from the hammer, but do not completely remove it yet. It's still connected to the hammer by a power cable.
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Pull the power connector straight off of its plug.
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Remove the handle assembly.
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Use a small pry bar or flathead screwdriver to pry the rubber front cap off of the hammer.
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Use a pair of snap ring pliers to expand the snap ring on the front of the hammer.
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Remove the snap ring.
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Remove the washer on the front of the hammer.
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Lift the front cover off of the front of the hammer.
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Lift the rubber ring off of the front of the hammer.
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Compress the spring and hold it down while you pull the two retainers out of their slots and remove them.
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Remove the spring guide.
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Remove the spring.
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Remove the front barrel cover.
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Remove the 4 mm hex bolt securing the barrel cover.
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Lift the barrel cover straight up and remove it.
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Use a pair of snap ring pliers to expand the snap ring securing the bolt holder.
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Remove the snap ring.
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Lift the washer off of the bolt holder and remove it.
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Remove four 6 mm hex bolts securing the barrel.
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Lift the barrel straight up and remove it.
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Use an angled pick to pull the washer and rubber ring 39 out of the barrel.
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Lift the upper-most rubber ring straight up and remove it from the bolt holder.
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Lift the upper-most washer straight up and off of the bolt holder.
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Grasp the bolt holder, rubber ring 24, and the two metal sleeves below it, and lift it off of the cylinder.
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Separate the rubber ring 24 and the two metal sleeves from the bolt holder.
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Separate the rubber ring 24 from the two metal sleeves.
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Remove the rubber ring 24.
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Use an angled pick to lift the O-ring 35.5 out of its groove on the bolt holder.
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Remove the O-ring 35.5.
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Use a long punch, long flathead screwdriver, or a thin, long bar to push the bolt out of the bolt holder.
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Remove the bolt.
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Lift the cylinder straight out of the aluminum housing.
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Pull the striker out of the cylinder.
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Use a pick to pry the striker O-ring 31.5 out of its groove on the striker.
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Remove the striker O-ring 31.5.
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Use a 5 mm hex key to remove the six screws securing the aluminum housing.
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Separate the aluminum housing from the rest of the hammer.
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Slide the fix guides and the rubber plate out of their slots on the housing and remove them.
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Use a Phillips #2 screwdriver to remove the four screws securing the piston cover.
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Rotate the crank shaft and the connecting rod so that the rod is vertical and the end is at the very bottom of the housing.
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Use an arbor press and a custom punch to carefully press the crank shaft, bearing, and gear assembly out of the housing.
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If you don't have access to a press or custom tool, use a punch and a hammer to tap the crank shaft until the whole crank shaft, bearing, and gear assembly starts to slide out.
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Pull the connecting rod and the piston out of the housing.
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Use a pick to pry the piston O-ring 31.5 out of its groove in the piston.
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Remove the piston O-ring 31.5.
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Use a pick to pry the O-ring 35 out of its groove in the piston.
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Remove the O-ring 35.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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