Hitachi DH 40MR Technical And Service Manual Download Page 2

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REMARK:

Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s)

is(are) used in the place of company name(s) and model name(s) of our

competitor(s). The symbol(s) utilized here is(are) as follows:

Symbols Utilized

Competitors

Company Name

Model Name

BOSCH

GBH5-40DE

HILTI

TE55

MAKITA

HR4000C

Summary of Contents for DH 40MR

Page 1: ...POWER TOOLS TECHNICAL DATA AND SERVICE MANUAL ROTARY HAMMER DH 40MR SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT LIST No E467 Sep 2002 D MODEL DH 40MR ...

Page 2: ...ICE MANUAL a symbol s is are used in the place of company name s and model name s of our competitor s The symbol s utilized here is are as follows Symbols Utilized Competitors Company Name Model Name BOSCH GBH5 40DE B HILTI TE55 D MAKITA HR4000C C ...

Page 3: ...lling Speed Change by Pushing Force 10 6 5 Drilling Speed and Quantity of Body Jumping 11 7 PRECAUTIONS IN SALES PROMOTION 11 7 1 Handling Instructions 11 7 2 Caution Plate 12 8 REFERENCE INFORMATION 12 8 1 Grease Replacement 12 8 2 O Ring Replacement 12 8 3 Structure of DH 40MR Rotary Hammer 13 9 REPAIR GUIDE 18 9 1 Disassembly 18 9 2 Reassembly 20 9 3 Screw Locking Agent TB1401 23 9 4 Tightening...

Page 4: ...t of chisels etc 7 A very original design 3 APPLICATIONS Drilling holes in concrete and drilling anchor holes Demolishing and chiseling of concrete Edging gravel road digging compacting and tamping grooving cutting stripping and roughing etc Application examples Air conditioning Piping and wiring Electric fixtures Sanitary facilities Interior finishing Other building construction and repair work 4...

Page 5: ...rmance because the constant speed control minimizes changes in number of rotation and hammering Impact efficiency Maximum compressed air force piston force Quantity of body jumping About 10 up About 50 down About 25 down Full load noise level dB A No load noise level dB A 6 9 92 4 79 5 HITACHI DH 40MA MB 64 118 0 7 9 94 6 89 4 B 85 119 8 9 8 93 7 85 0 D 64 116 1 6 4 93 2 83 0 C 74 118 5 8 4 93 5 8...

Page 6: ...e Model DH 40MR provides three functions rotation hammering function for drilling neutral function for positioning the tool tip and hammering only function for chiseling and chipping These function modes can be easily switched by using the change lever The tool angle can be easily changed in 12 steps by turning the grip with the change lever positioned at Neutral 4 1 7 Needle pin type slip clutch ...

Page 7: ...4 22 7 8 25 1 28 1 1 8 32 1 1 4 38 1 1 2 40 1 9 16 Over length mm 540 21 1 4 540 21 1 4 520 20 15 32 520 20 15 32 570 22 7 16 570 22 7 16 570 22 7 16 570 22 7 16 Code No 313456 313457 313458 313459 313460 313461 313462 313463 2 Drilling work for anchor holes Rotation Hammering 1 Drill bit Taper shank 1 Drill bit Taper shank Outer diameter mm 11 7 16 12 3 15 32 12 7 1 2 14 3 9 16 14 5 9 16 17 5 11 ...

Page 8: ...h outer diameter of 25 mm 1 and 29 mm 1 1 8 3 Core bit Outer diameter mm 25 1 29 1 1 8 32 1 1 4 35 1 3 8 38 1 1 2 45 1 3 4 Code No 955994 955995 955996 955998 956000 955154 Outer diameter mm 50 2 54 2 1 8 60 2 3 8 64 2 1 2 70 2 3 4 75 2 15 16 Code No 959706 955155 959707 956002 959708 959709 Outer diameter mm 79 3 1 8 94 3 11 16 100 3 15 16 105 4 1 8 Code No 955157 956004 959710 955159 4 Hole dril...

Page 9: ...ing 280 mm 11 400 mm 15 3 4 Overall length Code No 313471 313472 7 Grooving and edging Hammering 1 Cold chisel SDS max shank 280 mm 11 400 mm 15 3 4 Overall length Code No 313473 313474 1 Cutter SDS max shank 400 mm 15 3 4 Overall length Width 50 mm 2 8 Cutting and stripping Asphalt cutting etc Hammering Code No 313475 9 Digging Substitute pick ax Hammering 1 Scoop SDS max shank 400 mm 15 3 4 Over...

Page 10: ...Shank SDS max shank 220 mm 8 21 32 Overall length Code No 313479 313478 150 mm x 150 mm Code No 500 g 1 1 lbs Can 12 Syringe for chip removal Code No 944575 Code No 980927 70 g 2 5 oz Tube Code No 308471 30 g 1 oz Tube Code No 981840 13 Impact drill grease Note Code numbers listed above are subject to change without noitce Please refer to periodic Technical News Bulletins ...

Page 11: ...MR 360 180 360 Hitachi DH 40MA MB 40 1 9 16 950 8 105 4 1 8 118 0 94 6 87 9 444 17 1 2 252 9 15 16 103 4 1 16 6 5 6 6 14 3 14 6 lbs Double insulation 40 1 9 16 950 10 240 480 1 320 2 650 105 4 1 8 116 8 92 4 79 5 435 17 1 8 255 10 3 64 104 4 7 64 6 5 14 3 lbs Double insulation 40 1 9 16 1 100 8 5 0 340 0 3 300 105 4 1 8 119 8 93 7 85 0 450 17 23 32 255 10 3 64 102 4 1 64 6 2 13 7 lbs Double insula...

Page 12: ...parison purposes only Fig 1 Note that the data marked with asterisks are test results using drill bits which are beyond the tool s rated capacity Use the above data as a reference for comparisons only Test conditions Direction Downward drilling Pushing force 98 N 10 kgf Test material Concrete panel with a compression strength of 2 919 N cm2 240 kgf cm2 ...

Page 13: ... tool because B increases only the number of hammering without changing the weight of the striker that is hammering energy The Model DH 40MR realizes self chiseling in addition to self drilling 4 1 2 Self drilling Good feeling 6 4 Comparison of Drilling Speed Change by Pushing Force The graph shown in Fig 3 illustrates the relationship between handle pushing force and drilling speed DH 40MR Tool s...

Page 14: ... is less than the similar products and the working tool quickly penetrates into the workpiece Body jumping is low Quantity of body jumping is low and the tool smoothly penetrates into the workpiece with good feeling Working tool quickly penetrates into the workpiece Tool shake is low Fast Pushing force 100 N Fig 4 Ratio of quantity of body jumping Ratio of drilling speed Self drilling ...

Page 15: ...s inherent in the use of any electric power tool cannot be completely eliminated Accordingly general precautions and suggestions for the use of electric power tools and specific precautions and suggestions for the use of the Rotary Hammer are listed in the Handling Instructions to enhance the safe efficient use of the tool by the customer Salespersons must be thoroughly familiar with the contents ...

Page 16: ...on special grease in the speed reduction portion Special grease would leak into the motor portion and cause subsequent trouble Periodically replenish the inside of the slip clutch with Hitachi Motor Grease No 29 to the full 8 2 O Ring Replacement The O rings mounted on the striker and piston are extremely important to ensure adequate sealing of the air pressure Although the O rings are made of spe...

Page 17: ...the striker to continuously strike against the end of the second hammer At the same time the air cushion effect within the air chamber absorbs the impact of the striker Should the air escape from the air chamber the air cushion effect would cease and the impact energy would not be absorbed Accordingly the O rings mounted on the striker and piston play an extremely important role in sealing the air...

Page 18: ...en the drill bit contacts steel bar wire in the concrete protecting the operator from unexpected motion of the side handle Bevel pinion Needle pin Bevel pinion Gear holder Gear holder Second gear Key Spring C Gear holder groove Fig 7 Cross section A A The tool inlet is covered with the front cap made of rubber to prevent chips from entering inside Two needle rollers fall into the round groove of t...

Page 19: ...in They are molded in one piece The newly designed handle and side handle structure ensures more comfortable grip for improved operability Sealing and dust proof structure The cylinder crank case section is tightly sealed with three o rings three oil seals and rubber seal as shown in Fig 9 This prevents leakage of grease from the cases while also protecting them against dust from outside The tool ...

Page 20: ...mission of rotation In this position the tool holder grip can be manually turned and the working tool for chiseling or chipping is adjustable to the desired position in 12 steps easily Fig 12 Figure 13 is likewise a cross sectional view showing the Hammering only mode With the change lever turned another 90 the splines on the inner circumference of the lock sleeve come into mesh with the splines o...

Page 21: ...66 from the Cylinder Crank Case 49 Remove the Bevel Pinion 50 slip clutch from the Cylinder Crank Case 49 otherwise Bevel Gear 35 cannot be removed later Remove the Seal Lock Hex Socket Hd Bolt M4 x 12 37 from the Change Lever 72 then remove the Change Lever 72 Remove the Retaining Ring for D20 Hole 74 using a retaining ring puller and remove the Lever Shaft 75 otherwise Bevel Gear 35 cannot be re...

Page 22: ...3DDCMPS2L 46 using a retaining ring puller At this time shift the position of the crank pin of the Crank Shaft 43 as shown in Fig 17 so that the hole of the retaining ring can be seen before removal Face the Connecting Rod 34 side of the Cylinder Crank Case 49 downward and place it on a support Press the end surface of the Crank Shaft 43 with a hand press to remove the First Gear 64 and the Crank ...

Page 23: ...the Retaining Ring for D10 Shaft 42 using a retaining ring puller Fig 21 9 2 Reassembly Reassembly can be accomplished by following the disassembly procedure in reverse However special attention should be given to the following items 1 Reassembly of the first gear and the crank shaft Press fit Oil Seal B 48 into the Cylinder Crank Case 49 and mount O ring S 40 47 Press fit the Ball Bearing 6203DDC...

Page 24: ...Bearing Washer 15 Lock Spring 25 Lock Sleeve 26 Clutch Spring 28 Clutch 31 and Bevel Gear 35 to the Cylinder 24 Mesh the claw of the Lock Sleeve 26 with the claw of the Clutch 31 Insert the retainer sleeve assembly into the Cylinder Crank Case 49 aligning the spline of the Lock Sleeve 26 with the spline groove at the inner circumference of the Cylinder Crank Case 49 If the slip clutch assembly and...

Page 25: ...n brush inspection The motor employs Carbon Brushes 91 which are consumable parts When they become worn to or near wear limit 7 mm it could result in motor trouble Replace the Carbon Brushes 91 with new ones which are numbered 73 as shown in Fig 24 In addition always keep Carbon Brushes 91 clean and ensure that they slide freely within the brush holders Wear limit No of carbon brush 73 means the l...

Page 26: ...to the threads during reassembly as the bolts loosened with vibration may cause damage to the tool body 9 4 Tightening Torque Front cover mounting bolts 13 7 N m 140 kgf cm Hex socket head bolt M6 x 25 Tapping screw D5 2 94 0 49 N m 30 5 kgf cm Hex socket head bolt M6 x 45 9 8 N m 100 kgf cm Hex socket head bolt M6 x 22 Tail cover mounting bolt 4 41 0 49 N m 45 5 kgf cm Hex socket head bolt M5 x 1...

Page 27: ...agram for products with noise suppressor Stator Armature Switch Pillar terminal Controller circuit ass y include noise suppressor Plug Mounting diagram for products with noise suppressor Tab Tail cover Fig 25 Lead wire of noise suppressor Control circuit ass y include noise suppressor Housing Lead wire of stator Case B Lead wires of switch and cord ...

Page 28: ...lation resistance 7 MΩ or more with DC 500 V Megohm Tester Dielectric strength AC 4 000 V 1 minute with no abnormalities 220 V 240 V and 110 V for U K products AC 2 500 V 1 minute with no abnormalities 110 V 127 V except U K products 9 7 No load Current Value After no load operation for 30 minutes the no load current value should be as follows 2 9 240 3 1 230 3 2 220 ...

Page 29: ... Ring Holder Ball Bearing 6007DD Bearing Washer Needle Roller Retainer Sleeve O ring C Second Hammer Damper Washer Damper Damper Holder Needle Cylinder Lock Spring Lock Sleeve Spring Holder Clutch Spring Clutch Bevel Gear 60 min 50 Handle Controller Circuit Gear Cover Needle Bearing Armature Ball Bearing 6201DD Ball Bearing 608VV Washer A Dust Washer B Striker O ring x 2 Piston Piston Pin Connecti...

Page 30: ...1 22 23 24 25 26 27 28 29 30 31 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 44 51 52 53 55 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 37 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 501 502 503 504 505 ...

Page 31: ...21 321 289 DAMPER 1 22 321 290 DAMPER HOLDER 1 23 313 057 NEEDLE PIN D6X6 4 24 321 291 CYLINDER 1 25 321 298 LOCK SPRING 1 26 321 299 LOCK SLEEVE 1 27 321 293 SPRING HOLDER B 1 28 321 294 CLUTCH SPRING 1 29 321 292 STRIKER 1 30 986 104 O RING 2 31 321 295 CLUTCH 1 32 321 284 PISTON 1 33 980 708 PISTON PIN 1 34 321 285 CONNECTING ROD 1 35 321 296 BEVEL GEAR 1 36 986 940 SEAL LOCK HEX SOCKET HD BOLT...

Page 32: ...873 095 O RING P 16 1 77 321 310 LEVER SPRING 1 78 321 311 PUSHING BUTTON 1 79 321 312 PIN D2X10 1 80 620 1DD BALL BEARING 6201DDCMPS2L 1 81 302 429 DUST WASHER B 1 82 360 591U ARMATURE ASS Y 110V 120V 1 INCLUD 80 81 86 87 82 360 591E ARMATURE 220V 230V 1 82 360 591F ARMATURE 240V 1 83 321 320 FAN GUIDE 1 84 953 174 HEX HD TAPPING SCREW D5X55 2 85 340 542C STATOR ASS Y 110V 1 INCLUD 96 85 340 542G...

Page 33: ...K 2 107 SDS MAX LABEL 1 108 NAME PLATE 1 109 980 063 TERMINAL 1 109 930 804 TERMINAL M4 0 10 PCS 1 FOR USA CAN 110 981 373 TUBE D 2 FOR CORD 111 958 049 CORD ARMOR D8 2 1 111 940 778 CORD ARMOR D10 7 1 112 959 141 CONNECTOR 50092 10 PCS 1 FOR HKG 113 938 307 PILLAR TERMINAL 1 EXCEPT FOR HKG 114 960 266 CORD CLIP 1 114 981 987Z CORD CLIP 1 FOR SUI 115 984 750 TAPPING SCREW W FLANGE D4X16 2 116 500 ...

Page 34: ...60 DRILL BIT SDS MAX D28X570 1 611 313 453 DRILL BIT SDS MAX D32X370 1 612 313 461 DRILL BIT SDS MAX D32X570 1 613 313 454 DRILL BIT SDS MAX D38X370 1 614 313 462 DRILL BIT SDS MAX D38X570 1 615 313 455 DRILL BIT SDS MAX D40X370 1 616 313 463 DRILL BIT SDS MAX D40X570 1 617 944 460 TAPER SHANK DRILL BIT D11X100 1 618 944 461 TAPER SHANK DRILL BIT D12 3X110 1 619 993 038 TAPER SHANK DRILL BIT D12 7...

Page 35: ... D32 35 1 647 955 165 CENTER PIN A 133L FOR CORE BIT D38 150 1 648 313 466 CORE BIT SHANK B SDS MAX D25 35 1 649 313 467 CORE BIT SHANK A SDS MAX D38 150 1 650 950 272 DRILL CHUCK 13VLA 1 INCLUD 651 651 930 515 CHUCK WRENCH 10G 1 652 313 468 CHUCK ADAPTER SDS MAX 1 653 313 469 CHEMICAL ANCHOR ADAPTER SDS MAX 12 7MM 1 654 313 470 CHEMICAL ANCHOR ADAPTER SDS MAX 19MM 1 655 313 471 BULL POINT SDS MAX...

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