Hitachi Koki DV 13SS F403 Bedienungsanleitung

REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 1

1. Precautions on disassembly and reassembly ----------------------------------------------------------- 1

STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------13

CONTENTS

Page

PRODUCT NAMES

Hitachi 13 mm Impact Drill

Models DV 13SS, DV 13VSS

Hitachi 16 mm Impact Drill

Models

DV 16SS, DV 16VSS

LIST Nos.

DV 13SS: F403

DV 13VSS: F404

DV 16SS: F405

DV 16VSS: F406

Mar. 2009

International Sales Division

DV16SS/DV16VSS

- 1 -

1. Precautions on Disassembly and Reassembly

The [Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded

view assembly diagram for the Models DV 13SS and DV 16SS, and the <Bold> numbers to those in the

Parts List and exploded view assembly diagram for Models DV 13VSS and DV 16VSS.

Note on disassembly: Before starting disassembly, be sure to disconnect the power plug from the power

supply.

1. Removal of the handle cover

Loosen the Tapping Screw (W/Flange) D4 X 20 (Black) [32] <32> and remove the Handle Cover [31] <31>.

2. Removal of the carbon brush

Use a small flat-blade screwdriver to slightly lift the Brush Holders [36] <36>. Then, while pushing the

Carbon Brush [37] <37> to the bottom of the Brush Holders [36] <36>, gently pull out and disconnect the

internal wire terminals. (Figs. 1 and 2)

3. Removal of the gear cover from the housing

Loosen the Tapping Screw (W/Flange) D4 x 60 (Black) [11] <11> and Tapping Screw (W/Flange) D4 x 45

[15] <15>, and then separate the Gear Cover [12] <12> from the Housing [34] <34>. Then remove the

Inner Cover [21] <21> together with the Armature [26] <26> from the Housing [34] <34>.

REPAIR GUIDE

Disassembl

Fig. 1 Terminal Carbon brush stop piece

Bush Holder [36] <36>

Push

Carbon brush [37] <37>

Carbon brush stop piece

Terminal

Projection

Fig. 2

- 2 -

4. Removal of the armature ass'y from the inner cover

As illustrated in Fig. 3, support the Inner Cover [21] <21> with a tubular jig, and then push down on the top

of the pinion of the Armature [26] <26>.

5. Removal of the stator from the housing

[For DV 13SS, DV 16SS]

First insert a flat-blade screwdriver into the longitudinal cut of a sponge at the rear end of the switch, loosen

both of the upper two setscrews, and then remove the internal wires. Remove the Tapping Screws D4 x 45

[28], and then slightly tap the end surface of the Housing [34] with a wooden hammer. The stator [29] can

then be removed from the Housing.

[For DV 13VSS, DV 16VSS]

First, disconnect the internal wires from the upper side of the Switch <41> by pulling the faston terminal. To

disconnect the internal wires from the switch, insert a small flat-blade screwdriver into the windows near the

terminals and pull out the internal wires. Remove the Tapping Screws D4 x 45 <28> and slightly tap the end

surface of the Housing <34> with a wooden hammer. The stator <29> can then be removed from the

Housing <34>.

Fig. 3

Pinion

60 mm dia. to 70 mm in dia.

Push

Inner Cover [21]<21>

rmature

[

]

<26>

Tubular jig

- 3 -

6. Removal of the drill chuck

[For DV 13SS, DV 16SS]

The Drill Chuck 13VLRC-D [3] is secured to the Spindle [6] with 1/2"-20 UNF (right hand) and Flat Hd.

Screw (A) (Left Hand) M6 x 25 [1]. At first, open the chuck jaw as far as possible and loosen Flat Hd. Screw

(A) (Left Hand) M6 x 25 [1] by turning it clockwise.

(a) Hold the drill so that only the Drill Chuck 13VLRC-D [3] rests firmly and squarely on the edge of a solid

bench. Insert the hex. bar wrench into the drill chuck. Turn the drill chuck until the wrench is at about a

30° angle to the bench top, and then sharply strike the wrench with a hammer so the drill chuck turns in

the counterclockwise direction. (Fig. 4)

[For DV 13VSS, DV 16VSS]

The Drill Chuck 13VLRC-D (or The Drill Chuck 13VLRJ-N (W/O Chuck Wrench)) <3> is secured to the

Spindle <6> with 1/2"-20 UNF (right hand) and Flat Hd. Screw (A) (Left Hand) M6 x 25 <1>. First, open the

chuck jaw as far as possible and loosen Flat Hd. Screw (A) (Left Hand) M6 x 25 <1> by turning it clockwise.

(a) Hold the drill so that only the Drill Chuck 13VLRC-D (or The Drill Chuck 13VLRJ-N (W/O Chuck

Wrench)) <3> rests firmly and squarely on the edge of a solid bench. Insert the hex. bar wrench into the

drill chuck. Turn the drill chuck until the wrench is at about a 30° angle to the bench top, and then

sharply strike the wrench with a hammer so the drill chuck turns in the counterclockwise direction. (Fig.

If the drill chuck cannot be removed by striking the wrench, do not forcibly strike the wrench forcibly and

try another way as follows.

(b) Hold the Spindle [6] <6> with an open end wrench secured to the vise as shown in Fig. 5.

Mount the pipe onto the hex. bar wrench. Turn the hex. bar wrench counterclockwise to loosen the drill

chuck. (Fig. 5)

Fig. 5

Open end wrench

Vise

Turn it counterclockwise.

Pipe

Hex. bar

wrench

Fig. 4

Hex. bar

wrench

Flat Hd. Screw (A)

(Left Hand) M6 x 25 [1] <1>

Loosen

- 4 -

Secure the drill chuck with a disassembly tool: Ring (J-78) to the drill chuck, which in proper sequence

should be secured with a vise. Then fit a disassembly tool: Wrench Ass'y (J-140) to the spindle, and turn

it counterclockwise to loosen the drill chuck. (Fig. 6)

7. Removal of the spindle

Remove the Retaining Ring for D32 Hole [4] <4> and Dust Seal [5] <5>. Place the end surface of the Gear

Cover [12] <12> on the tubular jig and press down on the Spindle [6] <6> with a hand press. The spindle

can then be removed together with the Ball Bearing 6002VVCMPS2L [9] <9>, Distance Ring [8] <8>,

Spring [7] <7> and the Retaining Ring for D15 Shaft [10] <10>. The Gear [13] <13> can then be removed

from the spindle. (Fig. 7)

CAUTION:

• Be sure to replace both the spindle and gear with new ones.

Fig. 6

Wrench Ass'y (J-140)

Ring Ass'y and Ring (J-78) Turn it counterclockwise.

Vise Drill chuck

Fig. 7

Gear [13] <13> Spindle [6] <6>

Push

Distance Ring [8] <8>

Dia. of 32 mm

Tubular jig

- 5 -

8. Removal of the ratchet

Insert the tip of a flat-blade screwdriver between the Ratchet [17] <17> and Change Lever [22] <22>, and

then pry out the Change Lever [22] <22> to remove it. (Fig. 8) Remove the Tapping Screw (w/SP Washer)

D4 X 20 [16] <16> that mounts the Ratchet [17] <17> on the Inner Cover [21] <21>.

Place the end of the Inner Cover [21] <21> on the cylinder and push the end of the Bushing [18] <18> on

the rear of the ratchet with a hand press. The Ratchet [17] <17> then comes out together with the Change

Plate [20] <20>. (Fig. 9)

Perform reassembly by reversing the order of the disassembly procedure. However, special attention

should be given to the following items.

1. Internal wire arrangement

(1) Arrange the internal wires according to "7. Internal Wire Arrangement and Wiring Work."

(2) Be careful not to catch the internal wires when mounting the handle cover.

Change Lever [22] <22>

Change Plate [20] <20>

Bushing [18] <18>

Fig. 9

Inner Cover [21] <21>

Change Plate [20] <20> Bushing [18] <18>

Ratchet [17] <17>

Ø67 to Ø80

Push

Reassembl

Fig. 8

Insert the tip of the flat-blade

screwdriver here.

Cylinder

- 6 -

2. Lubrication

(1) Apply ATTOLUB MS No. 2 Grease (Code No. 309922) to the following parts:

•Teeth of the Armature [25] <25> and the Gear [13] <13> (with a brush)

•On the Spindle [6] <6>

Ground portion for fitting the Ball Bearing 6002VVCMPS2L [9] <9>, splined portion and hole on the

rear side

•Surface of Steel Ball D6.35 [14] <14>

•Lip portion of the Dust Seal [5] <5>

•On the Ratchet [17] <17>

Inside the Needle Bearing, teeth of ratchet

•Inside the Gear Cover [12] <12>: 5 g

3. Tightening torque

(1) Tapping Screw D4 -------------------------------------------------1.5 to 2.5 N•m (13.3 to 22.1 in-lbs.)

(2) Drill Chuck-----------------------------------------------------------30 to 50 N•m (266 to 443 in-lbs.)

(3) Machine Screw M3 (Switch [41] <40>)-----------------------0.4 to 0.8 N•m (3.5 to 7.1 in-lbs.)

(4) Flat HD. Screw (A) (Left Hand) M6 X 25 [1] <1> ----------4.4 to 5.4 N•m (38.9 to 47.8 in-lbs.)

(5) Bolt M3 [19] <19> -------------------------------------------------1.2 to 1.8 N•m (10.6 to 15.9 in-lbs.)

4. Change Plate

Place the Change Plate [20] <20> between the Ratchet [17] <17> and Bushing [18] <18> before

assembling in the Inner Cover [21] <21>. (Fig. 10)

5. Change Lever

Push the Change Lever [22] <22> forward until the front end of the Change Plate [20] <20> protrudes

about 1.5 mm. (Fig. 11)

Fig. 10

Change Lever [22] <22>

Fig. 11

1.5

Change Plate [20] <20>

Bushing [18] <18>

Ratchet

[17] <17>

Change Plate

[20] <20>

Place the Change Plate [20] <20> between the Ratchet [17]

<17> and Bushing [18] <18> before assembling.

- 7 -

6. Wiring Diagrams

[For DV 13SS, DV 16SS]

(1) For products with noise suppressor

(2) For products without noise suppressor

[For DV 13VSS, DV 16VSS]

(1) For products with noise suppressor

(2) For products without noise suppressor

Blue

Brown

Choke Coil Connector

White

Gray

Stator

1a 1

2a 2

Black

Red

Choke Coil Connector Stator

Switch

Noise

Suppressor

White or Blue

Black or Brown

Cord Ass’y

Blue

Brown

Connector

White

Gray

Stator

1a 1

2a 2

Black Red

Connector Stator White or Blue

Black or Brown

Cord Ass’y

Switch

Blue

Brown

Choke Coil

Whit

Gray

Stator

1a 1

2a 2

Black

Red

Choke Coil Stator

Speed Control Switch

Noise

Suppressor

White or Blue

Black or Brown

Cord Ass’y

Reversing Switch

Blue

Brown

Whit

Gray

Stator

1a 1

2a 2

Black

Red

Stator

Speed Control Switch

White or Blue

Black or Brown

Cord Ass’y

Reversing Switch

- 8 -

7. Internal Wire Arrangement and Wiring Work

A. Internal wire arrangement

[For DV 13SS, DV 16SS]

Stator: Red

Choke Coil: Brown

Choke Coil: Blue

Stator: White

Connector

Stator: Gray

Cord:

White or Blue

Cord [45]

Cord Clip [38]

5 +5

Noise Suppressor

Cord:

Black or Brown

Stator: Red

Stator: Gray

Stator: White

Stator: Black

Connector

Choke Coil:

Brown

Stator: White

Connector

Stator: Gray

Cord:

White or Blue

Cord [45]

Cord Clip [38]

5 +5

Cord:

Black or Brown

Stator: Red

(a)

(b)

Mounting the cord clip

(1) For products with noise suppressor (2) For products without noise suppressor

Stator: Gray

Stator: White

Stator: Black

Connector

Earth Terminal 46]

Insert the Earth Terminal [46] between

the Stator [29] and Housing [34].

Thread the lead wire under the

Brush Holder [36].

Neutral wire of capacitor

Neutral wire

of capacitor

Put the carbon terminal

between (a) and (b).

Thread the lead wire under the

Brush Holder [36].

Lead wire:

Blue

Thread the lead wire

under the Brush

Holder [36].

Thread the lead wire

under the Brush

Holder [36].

- 9 -

[For DV 13VSS, DV 16VSS]

Choke Coil: Brown

Choke Coil: Blue

Stator: Black

Stator: Gray

Cord:

White or Blue

Cord <45>

Cord Clip <39>

5 +5

Noise Suppressor

Cord:

Black or Brown

Stator: Red

Stator: Gray

Stator: White

Stator: Black

Earth Terminal <46>

Stator: Black

Stator: Gray

Cord:

White or Blue

Cord <45>

Cord Clip <39>

5 +5

Cord:

Black or Brown

Stator: Red

(a)

(b)

(1) For products with noise suppressor (2) For products without noise suppressor

Stator: Gray

Stator: Black

Stator: White

Stator: Red

Thread the lead wire under the

Brush Holder [36].

Neutral wire of capacitor

pply silicon

grease to

prevent these

from falling

Thread the lead wire under the

Brush Holder [36].

Lead wire:

Blue

Thread the lead wire

under the Brush

Holder [36].

Thread the lead wire

under the Brush

Holder [36].

Lead wire:

Brown

Insert the Earth Terminal <46> between

the Stator <29> and Housing <34>.

Mounting the cord clip

Put the carbon terminal

between (a) and (b).

pply silicon

grease to prevent

these from falling

Stator: Red

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