Hitachi DH 40MEY Bedienungsanleitung

International Sales Division

LIST No.

DH 40MEY: F425

Dec. 2014

TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------1

1. Troubleshooting and corrective action ---------------------------------------------------------------------1

REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------3

1. Precautions on disassembly and reassembly -----------------------------------------------------------3

STANDARD REPAIR TIME (UNIT) SCHEDULES ------------------------------------------------------------------ 19

CONTENTS Page

PRODUCT NAME

Hitachi Rotary Hammer

Model DH 40MEY

-1-

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

assembly diagram for the Model DH 40MEY.

1. Troubleshooting and corrective action

Perform troubleshooting and take a necessary corrective action according to the table below if there is a

problem that cannot be solved by the corrective action described in the Handling Instructions.

Problem Cause Check Corrective action

All the four LEDs of

the display lamp

are flashing.

• Broken Controller

Set [49] • No check needed. • Replace the Controller

Set [49] with a new

one.

Three LEDs of the

display lamp are

flashing.

• Mix-up of three

internal wires of

Stator Sensor

PCB Set [42] and

Controller Set [49]

• Check the heat-shrink tube

colors (red, black, and white)

of internal wires connecting

the Stator Sensor PCB Set

[42] and Controller Set [49].

• Correctly connect

internal wires of the

Stator Sensor PCB Set

[42] and Controller Set

[49] by their tube colors

(red, black, and white).

• Broken Controller

Set [49] • Check the state of the

Controller Set [49] connector. • Replace the Controller

Set [49] with a new

one.

• Broken Rotor

[134] • Check the built-in magnet of

the fan for breaks. • Replace the Rotor [134]

with a new one.

Two LEDs of the

display lamp are

flashing.

• Broken Controller

Set [49] • No check needed. • Replace the Controller

Set [49] with a new

one.

One LED of the

display lamp is

flashing.

• Improperly

connected

connector cable of

the Stator Sensor

PCB Set [42]

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug the

connector cable.

• Broken Stator

Sensor PCB Set

[42]

• When the connector cable is

not defective

• Replace the Stator

Sensor PCB Set [42]

with a new one.

• Broken Controller

Set [49] • Check the plug-in state of the

Controller Set [49] connector. • Replace the Controller

Set [49] with a new

one.

• Broken Rotor

[134] • Check the built-in magnet of

the fan for breaks. • Replace the Rotor [134]

with a new one.

TROUBLESHOOTING GUIDE

-2-

Problem Cause Check Corrective action

No LED of the

display lamp is ON.

• Improperly

connected

connector cable of

the Panel [112]

PCB

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug the

connector cable.

• Internal wires

loosely plugged

into the Controller

Set [49] and Filter

PCB Set [58]

• Check the plug-in state of the

internal wires.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug the internal

wires into the Controller

Set [49] and Filter PCB

Set [58].

• Broken Controller

Set [49] • When the Controller Set [49]

connector is not defective

• When the internal wire is not

defective

• Replace the Controller

Set [49] with a new

one.

• Broken LED • When the connector cable is

not defective • Replace the Panel [112]

with a new one.

• Broken Filter PCB

Set [58] • When the internal wire is not

defective • Replace the Filter PCB

Set [58] with a new

one.

The LEDs of the

display lamp light,

but the motor does

not run.

• Internal wires

loosely connected

to the Switch [63]

• Check the plug-in state of

internal wires to the Switch

[63]. (See “Reassembly of

the power supply unit” on

page 12.)

• Firmly connect all

internal wires to the

Switch [63].

• Broken Controller

Set [49] • When internal wires of the

Controller Set [49] are not

defective

• Replace the Controller

Set [49] with a new

one.

• Broken Switch

[63] • When internal wires of the

Controller Set [49] are not

defective

• Replace the Switch [63]

with a new one.

-3-

Fig. 1

1. Precautions on disassembly and reassembly

WARNING: Be sure to disconnect the power cord plug from the wall outlet before conducting

repair. Otherwise, the motor may run suddenly and you could get injured.

1. Disassembly of the tool retainer

Remove the Front Cap [1] while pulling the Grip [2] in the arrow direction. Note that the Front Cap [1] is

firmly fitted to the Retainer Sleeve [19]. Insert the edge of a flat-head screwdriver or similar tool into the

gap between the Front Cap [1] and Grip [2], and then pry up the Front Cap [1] by placing the fulcrum on

the Grip [2] as shown below. You can now separate the Grip [2] from the Retainer Sleeve [19].

Remove the Stopper Ring [3] by using a retaining ring puller. You can now separate the Retainer

Washer [4], Retainer Damper (A) [5], Bit Lock Holder [6], two Bit Locks [18], Thrust Plate [7], Retainer

Spring [8], and Spring Holder (A) [9] from the Retainer Sleeve [19].

2 Disassembly of the hammering mechanism

(1) Second hammer and striker

First, remove the Bolt M5 x 12 [10] from the Cylinder Case Cover [11] and detach the Cylinder Case

Cover [11] from the Cylinder Case [13]. Remove the Bolt M6 x 25 [12] and detach the Cylinder Case

[13] from the Crank Case [89]. You can now separate Spring Holder (B) [28], Retainer Sleeve [19],

and other parts from the main body.

You can take out the Second Hammer [21] together with the Damper Holder [24], Damper [23], and

Damper Washer [22] from the detached Retainer Sleeve [19].

You can take out the Cylinder [25] together with the Lock Spring [29], Lock Sleeve [30], Clutch Spring

[31], and Clutch [32] from the main body.

Strike the end of the Cylinder [25] with a plastic hammer to pull out the Striker [26].

Disassembly

REPAIR GUIDE

[3]

Flat-head screwdriver

[19]

[2]

[1]

[4] [6] [7]

[5] [18]

[9]

[8]

Fig. 2

-4-

Fig. 3

Fig. 4

(2) Piston ass’y

You can remove the piston ass’y from the main body without disassembling the Bevel Gear [34] and

Slip Clutch Ass’y [114]. Move the Connecting Rod Ass’y [39] as shown below to remove the piston

ass’y from the Crank Shaft [83].

[19]

Cylinder case ass'y

[21]

[26] [25]

[23] [24]

[22]

[29]

[28]

Crank case ass'y

[31] [30] [32] [33]

[17]

[15] [16]

[34] [39] [83]

Piston ass’y

-5-

Fig. 5

(3) First gear and crank shaft

Remove the Bolt M5 x 16 [66] and detach the Crank Cover [101] from the Crank Case [89]. Then take

out the Change Plate [105] and Slider [33] from the Crank Case [89].

Remove the Bolt M5 x 16 [66] and Bolt M5 x 12 [53], and then detach Handle (A) [64], Handle (B) [55],

and the Back Cover [60].

Remove the Bolt M6 x 45 [45] and Bolt M6 x 20 [131], and then detach the Crank Case [89] from the

Housing [48]. Disconnect the Panel [112] connector from the Controller Set [49] beforehand.

If the Slip Clutch Ass’y [114] is difficult to remove from the Crank Case [89] or Gear Cover [130], strike

it with a plastic hammer to remove it.

Wipe off grease from the Piston [38] side and the First Gear [128] side in the Crank Case [89], and

then remove the Retaining Ring [85] that retains the Ball Bearing 6203DD [87] by a retaining ring

puller, while turning the Crank Shaft [83] so that you can see the Retaining Ring [85] hole.

Place the Crank Case [89] on an adequate cradle with its Piston [38] facing down, and then use a

hand press to press down on the end surface of the Crank Shaft [83]. The First Gear [128] and Crank

Shaft [83] can be removed from the Crank Case [89].

(4) Slip clutch ass’y

Remove the Ball Bearing 629VV [126] by using

a bearing puller. Support Washer (A) [120] by

an adequate sleeve-like cradle as shown below.

Use a hand press to press the Bevel Pinion

[115] on the Spacer [125] side. Detach the

Gear Holder [121] and Spacer [125] from the

Bevel Pinion [115]. When removing the Second

Gear [124] from the Gear Holder [121], put

these parts in a plastic bag and disassemble in

the bag to avoid losing Spring (C) [123] and the

Needle [122].

[89] [83]

[85]

[89]

[83]

[128]

Adequate cradle

Hand press

Fig. 6

[126]

Cradle

[120]

[124]

[115]

[125]

[121]

[123]

Hand press

[122]

-6-

Fig. 7

3. Disassembly of the motor

Firmly hold the Housing [48] and use a plastic

hammer to tap the shaft of the Rotor [134] until the

spigot joint of the Gear Cover [130] is removed from

the Housing [48].

The Rotor [134] has strong magnetic force. Firmly

hold the Housing [48] and pull out the Gear Cover

[130] from the Housing [48].

[130]

[48]

[134]

Tap the shaft of the rotor.

-7-

Fig. 8

Fig. 9

Reassembly can be accomplished by reversing the disassembly procedure. However, special attention

should be given to the following items.

1. Reassembly of the hammering mechanism and low vibration mechanism

(1) First gear and crank shaft

Press-fit Oil Seal (B) [88] to the Crank

Case [89]. Mount the O-ring [86].

Press-fit the Ball Bearing 6203DD [87].

Use a retaining ring puller to mount the

Retaining Ring [85].

Press-fit the Crank Shaft [83] to the Ball

Bearing 6203DD [87].

Insert the Feather Key [84] into the

Crank Shaft [83] groove. Support the

plane of the Crank Shaft [83] with an

adequate steel rod and use an adequate

tool to press-fit the First Gear [128].

Prior to press-fitting, make sure the

Feather Key [84] matches the key

groove of the First Gear [128].

(2) Piston

Insert the Connecting Rod Ass’y [39] into the Piston [38], and then press-fit the Piston Pin [37] from

the D8 hole (marked “ĭ2”) of the Piston [38]. Be careful not to let the Piston Pin [37] project from the

outer diameter of the Piston [38]. Mount the O-ring [36] on the Piston [38] to make the piston ass’y.

Next, turn the Crank Shaft [83] to the position shown below, and then mount the piston ass’y to the

Crank Shaft [83] from the Cylinder Case [13] side of the Crank Case [89].

The piston ass’y can be assembled even when the Bevel Gear [34] and Slip Clutch Ass’y [114] are

mounted to the Crank Case [89].

Reassembly

[84][89]

Adequate

steel rod

[128]

[88]

[86] [87] [83] [85]

[83]

[89]

[39]

[38][36]

[37] “ĭ2” mark

Adequate tool

-8-

Fig. 10

(3) Cylinder and retainer sleeve

Mount the Retainer Damper Washer [17], Retainer Damper (B) [16], and the Retainer Damper Holder

[15] in this order to the Retainer Sleeve [19] with the rounded surface of the Retainer Damper Washer

[17] facing that of the Retainer Sleeve [19] and the rounded surface of the Retainer Damper Holder

[15] facing that of the Retainer Sleeve [19].

Insert the Second Hammer [21] (equipped with O-ring (C) [20]), Damper Washer [22], Damper [23],

and Damper Holder [24] in this order with the rounded surface of the Damper Washer [22] facing that

of the Second Hammer [21].

Insert the assembled Retainer Sleeve [19] into the Cylinder Case [13]. Be careful not to curl the lip of

the oil seal.

Insert the Slider [33] into the outer periphery of the Bevel Gear [34] along the Crank Case [89] groove.

As shown below, push in the Slider [33] until its stopper contacts the butting position of the Crank Case

[89]. Insert so that the Clutch [32] engages with the internal claw of the Bevel Gear [34].

Insert the Striker [26] equipped with the O-ring [27] into the Cylinder [25]. Fit the Clutch Spring [31] to

the Cylinder [25], and then insert the assembled Cylinder [25] into the Crank Case [89].

Next, insert the Lock Sleeve [30] into the Crank Case [89] with the inner spline groove of the Crank

Case [89] matched with the Lock Sleeve [30] spline. Then place the Lock Spring [29] and Spring

Holder (B) [28] on the Lock Sleeve [30].

Finally, fit the protrusion of the Retainer Sleeve [19] to the Cylinder [25] groove, and then assemble the

Cylinder Case [13] equipped with the Retainer Sleeve [19] with the Crank Case [89] equipped with the

Cylinder [25].

[19]

[13] [15] [16] [17]

[24][23]

[22]

[25] [31] [28] [30] [32] [33] [34]

[26] [29]

[35]

Note directions of [15],

[17], and [22].

[21]

[27]

[20]

Do not curl the

oil seal lip.

-9-

Fig. 11

Fig. 12

(4) Slip clutch ass’y

Press-fit the Collar [116] and Ball Bearing 6002DD [118] in this order to the Bevel Pinion [115], and

then insert the Washer [119] and Washer (A) [120] in this order. Mount the Feather Key [94] to the

Bevel Pinion [115] and press-fit the Gear Holder [121]. Insert the Second Gear [124] into the outer

periphery of the Gear Holder [121]. Apply Hitachi Motor Grease No. 29 to the inner periphery of the

Second Gear [124] in advance. Insert the ten Needles [122] upright as shown below, and then push in

ten Springs (C) [123]. Fill up the slotted groove and through-hole portions of the Gear Holder [121]

with Hitachi Motor Grease No. 29, and then press-fit the Spacer [125] and Ball Bearing 629VV [126] in

this order to the Bevel Pinion [115].

(5) Handle shaft and handle (A)

Push the Holder [73] into the Back Cover [60]

by hand. Make sure the gap of the Holder [73]

is at the bottom and the Holder [73] does not

protrude from the surface of the Back Cover

[60]. Make sure the convex mark on the Back

Cover [60] is aligned with the convex mark on

the Handle Shaft [74]. Assemble the Handle

Shaft [74] and push the four Handle Dampers

[56] into the gap between the Holder [73] and

Handle Shaft [74]. Make sure the Handle

Dampers [56] do not protrude from the end

surface of the Back Cover [60].

To mount Handle (A) [64] and Handle (B) [55],

rotate the Handle Shaft [74] about 10°, and

then fit the Transatory Unit [57] and Handle

Shaft [74] to Handle (A) [64] and Handle (B)

[55] simultaneously.

[115]

[120]

[124] [126] [125]

[118]

[116]

[115]

[121] [122]

[123]

[94]

Slotted groove in

the gear holder Section A—A

[119]

Convex mark

Gap portion

[73]

[56]

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