Hitachi DH 40MEY Service Manual Download

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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

Summary of Contents for DH 40MEY

Page 1: ...EY 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 ...

Page 2: ... 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 Repla...

Page 3: ... 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 t...

Page 4: ...etainer 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 t...

Page 5: ... 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 ...

Page 6: ...5 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...

Page 7: ...stic 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 ...

Page 8: ...te 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 Pis...

Page 9: ...long 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 Nex...

Page 10: ...earing 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 t...

Page 11: ...the Crank Case 89 Wipe off all excessive grease after inserting the Weight Shaft 93 The Weight Shaft 93 can be inserted into the Crank Case 89 in any posture Mount the Washer 90 to the opposite side of the shaft insert the Feather Key 94 Weight 91 and Washer M5 108 in this order and then secure these parts with Nut M5 107 NOTE Do not alter the Washer 90 assembly order Note that you cannot mount th...

Page 12: ...ight spring comes off due to vibration during work 7 Change lever When inserting the Lever Shaft 104 into the Crank Cover 101 set the eccentric pin of the Lever Shaft 104 on the rotation and hammering mode mark side of the Crank Cover 101 Then mount the Change Lever 99 on the Lever Shaft 104 with the mark of the Change Lever 99 aligned with the mark of the Crank Cover 101 91 Two grooves on the Wei...

Page 13: ...Rotor 134 2 Wiring of the controller set See Fig 18 Connect the terminals of the three internal wires red white and black coming from the Stator Sensor PCB Set 42 to the Controller Set 49 terminals of the same colors Insert each terminal into the mating terminal securely until it contacts the innermost end Connect the 5 wire connector of the Stator Sensor PCB Set 42 to the Controller Set 49 connec...

Page 14: ...ires are interchangeable 5 Wiring of the cord See Fig 18 Connect the core exposed internal wires of the Cord 71 to Pillar Terminal A 67 These internal wires are interchangeable 63 112 42 Check the connector orientation Check the connector orientation 49 58 68 Interchangeable wires 67 Interchangeable wires Red Black Black Black White Red Black 71 Interchangeable wires Red Red ...

Page 15: ...inserting the Weight Shaft 93 as shown in Fig 25 Apply specified grease to the inner lips of Oil Seal A 117 and Oil Seal B 88 inner and outer diameter portions of the Bevel Gear 34 Thrust Washer 35 inner periphery of the Clutch 32 inner diameter portion of the metal in the Cylinder Case 13 inner lip of oil seal in the Cylinder Case 13 Damper 23 Retainer Damper B 16 and inner and outer peripheral p...

Page 16: ... ring 27 2 Insert the Striker 26 into the Cylinder 25 in the arrow direction until it contacts the innermost end 3 Apply a small amount of specified grease to the inner diameter portion of the Cylinder 25 once more to give a thin film of grease Crank Case 89 Fill the space between the metals with 0 5 to 1 0 g of grease Piston 38 Slider 33 Apply to inner and outer polished surfaces Apply to outer p...

Page 17: ... 16 Fig 25 Weight Shaft 93 Crank Case 89 Metal Apply grease to the inner diameter portion of the metal on both sides of the crank case ...

Page 18: ...9 N m 5 kgf cm D5 Screw D5 x 55 41 2 94 0 49 N m 30 5 kgf cm D4 Screw D4 x 16 70 1 96 0 49 N m 20 5 kgf cm Screw D4 x 20 75 1 96 0 49 N m 20 5 kgf cm After completing disassembly and repair measure the insulation resistance and dielectric strength Insulation resistance 7 Mȍ or higher as measured with a 500 VDC megohm tester Dielectric strength 4 000 VAC 1 minute with no abnormalities 220 V 240 V a...

Page 19: ...ig 26 Wiring diagram Connecting diagram Panel board set 5 wire Switch Pillar terminal Controller set Stator sensor board set M Filter board set Cord Red Red Black Black Black Black Red Red White White 8 wire ...

Page 20: ...lider Piston O ring Connecting Rod Ass y Gear Cover Rotor Ball Bearing 6201DD Ball Bearing 629VV Crank Shaft Ball Bearing 6203DD First Gear Slip Clutch Ass y Bevel Gear Housing Stator Sensor PCB Set Crank Case Work Flow Handle B Handle A Switch Filter PCB Set Cord Cord Armor Tail Cover Crank Cover Change Lever Guide Plate Lever Shaft Change Plate Front Cap Grip Cylinder Case Cover Retainer Washer ...

Page 21: ...32 33 34 35 36 37 38 40 41 42 43 44 48 49 45 46 47 10 53 54 53 54 53 54 53 54 55 57 60 61 62 63 66 67 68 69 70 71 72 73 74 75 66 76 77 78 79 80 81 82 83 84 85 86 87 88 89 95 96 97 98 99 100 101 102 103 104 105 91 90 92 94 93 94 91 90 92 108 107 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 64 58 503 52 51 50 65 501 502 ...

Page 22: ... 337538 DAMPER WASHER 1 23 321835 DAMPER 1 24 337539 DAMPER HOLDER 1 25 337540 CYLINDER 1 26 337541 STRIKER 1 27 986104 O RING 1 28 337550 SPRING HOLDER B 1 29 337551 LOCK SPRING 1 30 331535 LOCK SLEEVE 1 31 337542 CLUTCH SPRING 1 32 337543 CLUTCH 1 33 337544 SLIDER 1 34 337545 BEVEL GEAR 1 35 337546 THRUST WASHER 1 36 986104 O RING 1 37 980708 PISTON PIN 1 38 326369 PISTON 1 39 337535 CONNECTING ...

Page 23: ... 2 71 500390Z CORD 1 CORD ARMOR D10 7 71 500434Z CORD 1 CORD ARMOR D10 7 FOR USA CAN MEX 71 500446Z CORD 1 CORD ARMOR D10 7 FOR GBR 230V 71 500465Z CORD 1 CORD ARMOR D10 7 FOR GBR 110V 71 500439Z CORD 1 CORD ARMOR D8 2 FOR AUS 71 500408Z CORD 1 CORD ARMOR D8 2 FOR NZL 71 500235Z CORD 1 CORD ARMOR D8 2 FOR INA 71 500424Z CORD 1 CORD ARMOR D8 2 FOR MAL 72 NAME PLATE 1 73 337574 HOLDER 1 74 326377 HA...

Page 24: ... 338313 CAP SCREW 1 111 995396 VALVE 1 112 337581 PANEL 1 113 983162 SEAL LOCK HEX SOCKET HD BOLT M4 X 12 2 114 337533 SLIP CLUTCH ASS Y 1 INCLUD 94 115 116 118 126 115 337534 BEVEL PINION 1 116 321279 COLLAR 1 117 313050 OIL SEAL A 1 118 6002DD BALL BEARING 6002DDCMPS2L 1 119 313058 WASHER 1 120 313053 WASHER A 1 121 321281 GEAR HOLDER 1 122 320343 NEEDLE 10 123 321282 SPRING C 10 124 331215 SECO...

Page 25: ...0 1 613 313460 DRILL BIT SDS MAX D28 X 570 1 614 313453 DRILL BIT SDS MAX D32 X 370 1 615 313461 DRILL BIT SDS MAX D32 X 570 1 616 313454 DRILL BIT SDS MAX D38 X 370 1 617 313462 DRILL BIT SDS MAX D38 X 570 1 618 313455 DRILL BIT SDS MAX D40 X 370 1 619 313463 DRILL BIT SDS MAX D40 X 570 1 620 318085 SYRINGE BELLOWS TYPE 1 621 944460 TAPER SHANK DRILL BIT D11 X 100 1 622 944461 TAPER SHANK DRILL B...

Page 26: ...105MM 1 647 313466 CORE BIT SHANK B SDS MAX D25 35 1 648 313467 CORE BIT SHANK A SDS MAX D38 150 1 649 956009 CENTER PIN B 147L FOR CORE BIT D32 35 1 650 955165 CENTER PIN A 133L FOR CORE BIT D38 150 1 651 321813 DRILL CHUCK 13VLD D 1 652 313468 CHUCK ADAPTER SDS MAX 1 653 303334 CHUCK HANDLE 1 654 930515 CHUCK WRENCH 10G 1 655 313469 CHEMICAL ANCHOR ADAPTER SDS MAX 12 7MM 1 656 313470 CHEMICAL AN...

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