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9. REPAIR GUIDE

The numbers in [Bold] correspond to the item numbers in the Parts List and exploded assembly diagrams.

9-1. Disassembly

Roll Pin D4 x 20 [4]

M5 screw portion

Fig. 9

(1) Disassembly of the retainer

Remove Front Cover (A) [9] from the Cylinder Crank Case [56] and pull out the Roll Pin D4 x 20 [4]. Turning

the holder (J212 No. 970992) so that the special bolt M5 (J213 No. 970993) can be vertically inserted into the

screw hole of the Retainer Pin [5], make the bottom of the holder contact with the flat portion of the Retainer

[1]. Holding the special bolt M5 with a wrench to prevent turning, turn the special nut M5 (J211 No. 970991)

with a wrench and pull out the Retainer Pin [5]. Pull out the other Retainer Pin [5] by pushing an 8 mm-dia.

steel bar into the hole of Front Cover (A) [9] (Figs. 9 and 10).

Fig. 10

Retainer Pin [5]

Retainer [1]

Retainer Pin [5]

Special nut M5
(Turn it with a wrench.)

Front Cover (A) [9]

Holder

Special bolt M5
(Hold it with a wrench to
prevent turning.)

M5 screw portion

Содержание DH 40SR

Страница 1: ...POWER TOOLS TECHNICAL DATA AND SERVICE MANUAL ROTARY HAMMER DH 40SR SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT LIST No E471 Apr 2003 D MODEL DH 40SR ...

Страница 2: ...TECHNICAL DATA AND SERVICE MANUAL symbols are used in the place of company names and model names of our competitors The symbols utilized here are as follows Symbols Utilized Competitors Company Name Model Name MAKITA HR3811 C ...

Страница 3: ...ing Performance Comparison 11 7 PRECAUTIONS IN SALES PROMOTION 11 7 1 Handling Instructions 11 7 2 Caution Plate 11 8 REFERENCE INFORMATION 12 8 1 Grease Replacement 12 8 2 O Ring Replacement 12 8 3 Structure of the Model DH 40SR Rotary Hammer 13 9 REPAIR GUIDE 17 9 1 Disassembly 17 9 2 Reassembly 20 9 3 Screw Locking Agent TB1401 25 9 4 Tightening Torque 25 9 5 Internal Wiring 25 9 6 Insulation T...

Страница 4: ...anism results in prolonged service life and comfortable operation 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 finish...

Страница 5: ... S holder is adopted to realize double insulation construction Thus the housing has greater rigidity and the double insulated motor has greater durability The Model DH 40SR is heavy duty and the service life of the carbon brush is greatly prolonged 1 5 times longer than the conventional one minimizing disconnection of the armature deviation of the core and grease leakage 4 1 4 Constant speed contr...

Страница 6: ...life and comfortable operation Conventional mechanism for prevention of idle hammering is to open and close the air holes according to the movement of the striker The Model DH 40SR has air holes located at the position unaffected by the rebound of the striker at no load The air holes are opened and closed by the movement of slide sleeve A provided around the cylinder that interlocks with the tool ...

Страница 7: ... 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 16 Code No 944460 944461 993038 944462 944500 944463 2 Taper shank adapter Taper dimension Code No Morse taper No 1 985750 3 Cotter Code No 944477 400 15 3 4 Code No 985720 985723 985726 985729 985732 985735 985738 505 19 7 8 Code No 985722 ...

Страница 8: ...used with core bits with outer diameter of 25 mm 1 and 29 mm 1 1 8 2 Center pin Code No 956009 for core bits with outer diameter of 32 35 mm 1 1 4 1 3 8 Code No 955165 for core bits with outer diameter of 38 45 54 64 79 94 105 120 mm 1 1 2 1 3 4 2 1 8 2 1 2 3 1 8 3 11 16 4 1 8 4 3 4 Center pin is not used with core bits with outer diameter of 25 mm 1 and 29 mm 1 1 8 3 Core bit Outer diameter in 25...

Страница 9: ... 3 5 32 90 mm 3 1 2 100 mm 3 15 16 105 mm 4 1 8 Code No 903901 Core bit with guide plate Code No 992819 Core bit shank Code No 992814 992815 992816 992817 992818 4 Anchor work for self drilling anchors rotation hammering 2 Drift key Code No 944574 5 Anchor work for self drilling anchors hammering 1 Anchor adapter for hammering Anchor size W3 8 No 30 W1 2 No 40 W5 8 No 50 2 Turning handle Code No 9...

Страница 10: ...1 Cutter 280 mm 11 Width 45 mm 2 8 Cutting and stripping asphalt cutting etc hammering Code No 981924 9 Digging work substitute pick ax hammering 1 Scoop 405 mm 16 Overall length Code No 956126 Overall length 280 mm 11 450 mm 17 3 4 Overall length 280 mm 11 450 mm 17 3 4 Overall length 10 Roughing surface work hammering 1 Bushing tool 2 Shank 250 mm 10 Overall length Code No 955186 Code No 955183 ...

Страница 11: ...1 lbs Can 12 Syringe for chip removal Code No 318085 Code No 980927 70 g 2 5 oz Tube Code No 308471 30 g 1 oz Tube Code No 981840 13 Grease for hammer hammer drill Note Code numbers listed above are subject to change without notice Please refer to periodic Technical News Bulletins for updates O D 140 mm 5 1 2 ...

Страница 12: ...ensions Insulation structure Length Height Width mm kg Weight does not include cord and side handle min 1 dB A dB A mm mm Weight HITACHI DH 40SR 40 1 9 16 950 10 510 2 800 120 4 3 4 118 95 79 435 17 1 8 255 10 3 64 104 4 7 64 6 5 14 3 lbs Double insulation 38 1 1 2 1 130 8 270 3 300 118 4 21 32 120 96 87 435 17 1 8 245 9 21 32 108 4 1 4 7 7 17 0 lbs Single insulation C 2 800 360 DH 40SA HITACHI 40...

Страница 13: ... DH 40SA C 90 80 55 HITACHI HITACHI C 38 DH 40SR DH 40SA C 80 65 55 HITACHI HITACHI C 40 6 2 Drilling Speed Comparisons Drilling speed varies considerably depending on the work conditions Use the factory test results shown in Fig 1 for comparison purpose 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 da...

Страница 14: ...ached to each tool 7 1 Handling Instructions Although every effort is made in each step of design manufacture and inspection to provide protection against safety hazards the dangers 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...

Страница 15: ...ses Hitachi Motor Grease No 29 The proper supply volume is 30 g 1 oz Never use the striking portion 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 The tool retainer portion inside the front cover uses Doubrex 251 grease The pr...

Страница 16: ...r at the claws they rotate together The drill bit is connected into the hexagonal hole of the driver to transmit the revolution Striking operation The rotation of the armature is transferred to the crank shaft and connecting rod which in turn cause the piston to reciprocate inside the cylinder As the piston reciprocates the changing air pressure inside the air chamber between the piston and the st...

Страница 17: ...e thereby preventing striking operation Second hammer Moving distance of the second hammer and the striker Air chamber Slide sleeve A Air hole Fig 4 Sleeve A Slide ring Spring A Striker Shock absorbing mechanism At the instance of releasing the working tool from the workpiece by moving the main body up the second hammer contacts driver as shown in Fig 5 then the cushion damper B provided between d...

Страница 18: ...e 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 6 Cross section A A The Model DH 40SR is equipped with an easy pushbutton type tool holder To attach a tool pull up the retainer in the arrow direction and insert a tool into the hexagonal hole of the front cover then pull ...

Страница 19: ...hree oil seals and rubber seal as shown in Fig 8 This prevents leakage of grease from the cases while also protecting them against dust from outside The tool holder is also protected from foreign dust by means of a rubber dust cover Rubber seal Oil seal Dust cover O ring Oil seal Fig 8 O ring Oil seal O ring ...

Страница 20: ...ically inserted into the screw hole of the Retainer Pin 5 make the bottom of the holder contact with the flat portion of the Retainer 1 Holding the special bolt M5 with a wrench to prevent turning turn the special nut M5 J211 No 970991 with a wrench and pull out the Retainer Pin 5 Pull out the other Retainer Pin 5 by pushing an 8 mm dia steel bar into the hole of Front Cover A 9 Figs 9 and 10 Fig ...

Страница 21: ...6 x 25 3 from Front Cover A 9 Then the tool holder Driver 13 Driver Holder 12 Damper B 11 can be removed from the Cylinder Crank Case 56 Remove Oil Seal B 14 from the Cylinder Crank Case 56 At this time secure the Cylinder Crank Case 56 and pull out Oil Seal B 14 by holding the protrusion with pliers Remove the Retaining Ring for D62 Shaft 15 using a retaining ring puller Then the Hammer Sleeve 21...

Страница 22: ...port Press the end surface of the Crank Shaft 50 with a hand press to remove the First Gear 72 and the Crank Shaft 50 Fig 14 Cylinder Crank Case 56 Hole of Retaining Ring for D40 Hole 52 Crank Shaft 50 Fig 13 Crank Shaft 50 Cylinder Crank Case 56 First Gear 72 Press the end surface of the Crank Shaft 50 with a hand press Support 3 Disassembly of the cylinder and the hammer sleeve Remove the Second...

Страница 23: ...the Retaining Ring for D10 Shaft 49 using a retaining ring puller Fig 17 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 55 into the Cylinder Crank Case 56 and mount O ring S 40 54 Press fit the Ball Bearing 6203DDC...

Страница 24: ...per C 28 into the slot of the Hammer Sleeve 21 and the Cylinder 31 Tilt the assembly of the Slide Ring 29 and Damper C 28 slightly with respect to the shaft of the Cylinder 31 and turn it 90 on the protrusion of the Slide Ring 29 At this time apply special grease for hammer and hammer drill to the Slide Ring 29 and Damper C 28 before assembling Fig 18 Insert the Striker 36 into the Cylinder 31 Mou...

Страница 25: ...mer Sleeve 21 Damper Holder 26 Damper C 28 Cylinder 31 Damper Holder B 27 Fig 19 Slide Sleeve B 32 Oil Seal B 14 Second Hammer 23 Bevel Gear 42 Cylinder Crank Case 56 Striker 36 Clutch 38 Ring Holder 20 Bearing Washer 18 Sleeve A 35 Urethane Ring 19 Spring A 34 Cylinder Shaft 50 Crank pin Piston 39 Slide Sleeve A 33 ...

Страница 26: ...he through holes of the Gear Holder 64 with Hitachi Motor Grease No 29 Press fit the Bevel Pinion 57 into the Spacer 68 and the Ball Bearing 629VVC2PS2L 69 Collar 59 Needle 66 Bevel Pinion 57 Washer A 63 Bevel Pinion 57 Spring C 65 Slot of gear holder Ball Bearing 6002DDCMPS2L 61 Gear Holder 64 Washer 62 Gear Holder 64 Ball Bearing 629VVC2PS2L 69 Spacer 68 Second Gear 67 Feather Key 3 x 3 x 8 58 C...

Страница 27: ... A 33 inner circumference of Slide Sleeve B 32 inner circumference of Sleeve A 35 the Slide Ring 29 Damper C 28 Damper Holder B 27 Oil Seal A 60 Oil Seal B 14 and Oil Seal B 55 Fill 50 g of the special grease in the Cylinder Crank Case 56 on the Connecting Rod 41 side and 20 g in the Cylinder Crank Case 56 on the Clutch 38 side Apply Hitachi Motor Grease No 29 to the Needle Bearing M661 73 and the...

Страница 28: ... 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 10 Crank cover mounting bolt 4 41 0 49 N m 45 5 kgf cm Lever shaft mounting bolt Hex socket head bolt M4 x 12 Tapping screw W Flange D4 1 96 0 49 N m 20 5 kgf cm Handle mounting bolt 4 41 0 49 N m 45 5 ...

Страница 29: ...ion of disassembly and repair measure the insulation resistance and dielectric strength Insulation resistance 7 MΩ or more with DC 500 V Megohm Tester Dielectric strength AC 4 000 V 1 minute with no abnormalities 230 V AC 2 500 V 1 minute with no abnormalities 110 V 9 7 No load Current Value After no load operation for 30 minutes the no load current value should be as follows Voltage V Current A M...

Страница 30: ...amper Holder Damper Holder B Damper C Slide Ring Cylinder Slide Sleeve B Slide Sleeve A Spring A Sleeve A Clutch Bevel Gear 60 min 50 Controller Circuit Handle Gear Cover Needle Bearing Armature Ass y Ball Bearing 6201DD Dust Washer B Ball Bearing 608VV Magnet Striker O ring Piston Connecting Rod General Assembly Housing Ass y Stator Ass y Crank Shaft Ball Bearing 6203DD O ring Oil Seal B First Ge...

Страница 31: ...25 26 27 28 29 30 35 36 37 38 37 39 41 42 78 79 80 81 82 83 84 96 97 99 100 103 104 105 106 107 108 101 109 110 111 112 113 102 85 86 87 88 89 98 92 91 93 94 95 90 77 76 75 40 34 31 32 33 15 16 17 18 19 20 21 22 23 8 9 10 11 44 45 46 47 48 57 58 59 60 61 62 63 64 65 66 67 68 69 70 72 73 74 71 49 50 51 52 53 54 55 56 43 12 ...

Страница 32: ...ING HOLDER 1 21 321 837 HAMMER SLEEVE 1 22 313 396 O RING C 1 23 321 833 SECOND HAMMER 1 24 321 836 DAMPER WASHER 1 25 321 835 DAMPER 1 26 321 834 DAMPER HOLDER 1 27 321 856 DAMPER HOLDER B 1 28 321 832 DAMPER C 1 29 321 831 SLIDE RING 1 30 313 057 NEEDLE PIN D6X6 4 31 321 827 CYLINDER 1 32 321 830 SLIDE SLEEVE B 1 33 321 829 SLIDE SLEEVE A 1 34 321 828 SPRING A 1 35 321 977 SLEEVE A 1 36 321 976 ...

Страница 33: ...OVER 1 75 313 078 SIDE HANDLE 1 76 313 079 HANDLE HOLDER 1 77 313 080 HANDLE BOLT 1 78 971 786 STOPPER ROD 1 79 620 1DD BALL BEARING 6201DDCMPS2L 1 80 302 429 DUST WASHER B 1 81 321 640 FAN 1 82 360 591U ARMATURE ASS Y 110V 120V 1 INCLUD 79 81 86 87 82 360 591E ARMATURE ASS Y 220V 230V 1 INCLUD 81 83 321 320 FAN GUIDE 1 84 953 174 HEX HD TAPPING SCREW D5X55 2 85 340 542C STATOR ASS Y 110V 1 INCLUD...

Страница 34: ...UROPE 501 321 325 CASE 1 502 981 840 GREASE A FOR HAMMER HAMMER DRILL 30G 1 503 943 277 HEX BAR WRENCH 3MM 1 504 944 458 HEX BAR WRENCH 4MM 1 505 944 459 HEX BAR WRENCH 5MM 1 601 985 721 DRILL BIT D16 0 X 280 HEX SHANK TYPE 1 602 985 720 DRILL BIT D16 0 X 400 HEX SHANK TYPE 1 603 985 722 DRILL BIT D16 0 X 505 HEX SHANK TYPE 1 604 991 330 DRILL BIT D16 0 X 550 HEX SHANK TYPE 1 605 991 331 DRILL BIT...

Страница 35: ...2 3 X 110 1 636 993 038 TAPER SHANK DRILL BIT D12 7 X 110 1 637 944 462 TAPER SHANK DRILL BIT D14 3 X 110 1 638 944 500 TAPER SHANK DRILL BIT D14 5 X 110 1 639 944 463 TAPER SHANK DRILL BIT D17 5 X 120 1 640 944 464 TAPER SHANK DRILL BIT D21 5 X 140 1 641 985 752 TAPER SHANK ADAPTER NO 1 1 INCLUD 643 642 985 753 TAPER SHANK ADAPTER NO 2 1 INCLUD 643 643 944 477 COTTER 1 644 985 754 A TAPER SHANK A...

Страница 36: ...R NO 30 W3 8 FOR ROTATION 1 683 985 759 ANCHOR ADAPTER NO 40 W1 2 FOR ROTATION 1 684 985 760 ANCHOR ADAPTER NO 50 W5 8 FOR ROTATION 1 685 981 929 ANCHOR ADAPTER NO 30 1 686 981 930 ANCHOR ADAPTER NO 40 1 687 981 931 ANCHOR ADAPTER NO 50 1 688 985 761 RATIO SHANK ADAPTER 1 689 944 574 DRIFT KEY 1 690 944 573 TURNING HANDLE 1 691 981 922 BULL POINT 280MM ROUND SHANK TYPE 1 692 981 923 BULL POINT 450...

Страница 37: ......

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