Hitachi DH 40FR, Technical Data And Service Manual

Page 1: ...TECHNICAL DATA AND SERVICE MANUAL ROTARY HAMMER DH 40FR SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT LIST No E472 Jul 2003 D MODEL DH 40FR Hitachi Power Tools 6 ...

Page 2: ...ECHNICAL 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 BOSCH 11248EVS B ...

Page 3: ...ling Performance Comparison 9 7 PRECAUTIONS IN SALES PROMOTION 9 7 1 Handling Instructions 9 7 2 Caution Plate 9 8 REFERENCE INFORMATION 10 8 1 Grease Replacement 10 8 2 O Ring Replacement 10 8 3 Structure of the Model DH 40FR Rotary Hammer 10 9 REPAIR GUIDE 14 9 1 Disassembly 14 9 2 Reassembly 17 9 3 Screw Locking Agent TB1401 20 9 4 Tightening Torque 20 9 5 Internal Wiring 20 9 6 Insulation Test...

Page 4: ... 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 SELLING POINTS Ne...

Page 5: ...del DH 40FR 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 Full load noise level dB A No load noise level dB A 10 1 91 79 HITACHI DH 40FA FB 72 120 10 1 95 92 80 117 7 3 94 91 Ratio of drilling speed A 25 mm dia drill bit is used Full load vibrat...

Page 6: ... kg 14 3 lbs excluding cord and side handle Packed 10 0 kg 22 1 lbs Corrugated cardboard box with plastic tool case Plastic case 1 Side handle 1 Hex bar wrench for M6 1 Hex bar wrench for M5 1 Hex bar wrench for M4 1 Stopper 1 Grease A 1 Dust Cover 1 Voltage 120 V 9 2 A 230 V 4 8 A Enclosure Motor type AC single phase series commutator motor Materials Aluminum alloy die casting Nylon resin Handle ...

Page 7: ...d A taper B taper 2 Taper shank adaptor 3 Boring work for large dia holes rotation hammering 1 Guide plate 2 Center pin 3 Core bit 4 Core bit shank 1 Guide plate Core bits with outer diameter of 32 35 38 45 54 64 79 94 105 mm 1 1 4 1 3 8 1 1 2 1 3 4 2 1 8 2 1 2 3 1 8 3 11 16 4 1 8 Guide plate is not used with core bits with outer diameter of 25 mm 1 and 29 mm 1 1 8 2 Center pin Code No 956009 for ...

Page 8: ...ore bits with outer diameter of 25 29 32 35 mm 1 1 1 8 1 1 4 1 3 8 Code No 985379 for core bits with outer diameter of 38 45 54 64 79 94 105 mm 1 1 2 1 3 4 2 1 8 2 1 2 3 1 8 3 11 16 4 1 8 1 Bull point 4 Demolition work hammering 300 mm 12 Overall length Code No 985383 5 Grooving and edging work hammering 1 Cold chisel 300 mm 12 460 mm 18 Overall length Code No 985381 985382 1 Cutter 38 mm 1 1 2 Ov...

Page 9: ... 500 g 1 1 lbs Can 8 Syringe for chip removal Code No 980927 70 g 2 5 oz Tube Code No 308471 30 g 1 oz Tube Code No 981840 9 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 Code No 320859 Code No 318085 ...

Page 10: ...B A dB A mm mm Weight HITACHI DH 40FR 38 1 1 2 870 7 5 300 2 800 105 4 1 8 117 94 91 459 18 1 16 253 9 31 32 106 4 3 16 7 8 16 6 lbs Double insulation B 2 800 1 400 to 2 800 360 180 to 360 DH 40FA FB HITACHI 40 1 9 16 950 8 0 105 4 1 8 120 95 92 423 16 21 32 252 9 15 16 103 4 1 16 6 7 14 8 lbs 6 8 15 0 lbs Double insulation DH 38YE HITACHI 40 1 9 16 950 10 0 240 to 480 1 320 to 2 650 105 4 1 8 120...

Page 11: ...ength of 2 352 N cm2 240 kgf cm2 Drill bit dia mm Maker Model Drilling speed mm min 0 100 200 300 16 19 22 25 28 32 38 40 HITACHI HITACHI HITACHI B DH 40FR DH 40FA FB DH 38YE B HITACHI HITACHI HITACHI B DH 40FR DH 40FA FB DH 38YE B HITACHI HITACHI HITACHI B DH 40FR DH 40FA FB DH 38YE B HITACHI HITACHI HITACHI B DH 40FR DH 40FA FB DH 38YE B 45 45 30 35 HITACHI HITACHI HITACHI B DH 40FR DH 40FA FB D...

Page 12: ...tion 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 the Rotary Hammer are listed in the Handling Instructions to enhance the safe efficient use of the tool by the customer Salespersons must be ...

Page 13: ...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 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...

Page 14: ...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 within the air chamber Mech...

Page 15: ...r holder Gear holder Second gear Key Spring C Gear holder groove Fig 5 Cross section A A A lever type retainer is employed to permit easy one touch mounting and removal of drill bits bull points etc As illustrated in Fig 6 pull the knob in the direction indicated by arrow a and turn it 90 counterclockwise arrow b direction to align it with the alignment mark on the front cover Insert the tool shan...

Page 16: ...eakage of grease from the cases while also protecting them against dust from outside For additional dust proof protections a standard accessory dust cover is provided which serves to prevent dust and chips from entering the spline hole of the second hammer and causing imperfect fitting of the drill bit Rubber seal Oil seal Dust cover O ring Fig 7 O ring Oil seal O ring ...

Page 17: ...he Crank Cover 30 then remove the Crank Cover 30 from the Cylinder Crank Case 40 Remove the Seal Lock Hex Socket Hd Bolt M6 x 45 27 and Seal Lock Hex Socket Hd Bolt M6 x 22 82 Remove the Gear Cover 57 from the Cylinder Crank Case 40 Remove the Bevel Pinion 41 slip clutch from the Cylinder Crank Case 40 otherwise Bevel Gear 26 cannot be removed later Remove the Seal Lock Hex Socket Hd Bolt M4 x 12 ...

Page 18: ...ing 6203DDCMPS2L 37 using a retaining ring puller At this time shift the position of the crank pin of the Crank Shaft 34 as shown in Fig 10 so that the hole of the retaining ring can be seen before removal Face the Connecting Rod 25 side of the Cylinder Crank Case 40 downward and place it on a support Press the end surface of the Crank Shaft 34 with a hand press to remove the First Gear 55 and the...

Page 19: ...er 10 Cylinder Cap 13 Drill bit Wrench Vise 5 Disassembly of the slip clutch Remove the Ball Bearing 629VVC2PS2L 52 with a bearing puller Place the assembly on a sleeve type support facing Washer A 46 downward as shown in Fig 13 Push the Spacer 51 side of the Bevel Pinion 41 with a hand press to remove the Gear Holder 47 and the Spacer 51 from the Bevel Pinion 41 Before removal of the Second Gear ...

Page 20: ... the crank shaft Press fit Oil Seal B 39 into the Cylinder Crank Case 40 and mount O ring S 40 38 Press fit the Ball Bearing 6203DDCMPS2L 37 Mount the Retaining Ring for D40 Hole 36 using a retaining ring puller Press fit the Crank Shaft 34 into the Ball Bearing 6203DDCMPS2L 37 Put the Feather Key 3 x 3 x 8 35 in the groove of the Crank Shaft 34 and press fit the First Gear 55 with a suitable tool...

Page 21: ...ng 6007DDUAV2S 15 Cylinder Cap 13 Bearing Washer 16 Cylinder Shaft 34 Crank pin Piston 23 Clutch Spring 19 Clutch 22 Bevel Gear 26 Fig 17 4 Reassembly of the slip clutch Press fit the Bevel Pinion 41 into the Collar 42 and the Ball Bearing 6002DDCMPS2L 44 then insert it into the Washer 45 and Washer A 46 Mount the Feather Key 3 x 3 x 8 35 to the Bevel Pinion 41 then press fit into the Gear Holder ...

Page 22: ...cial grease for hammer and rotary hammer to the inner circumference of the Connecting Rod 25 the O rings 21 of the Striker 20 and the Piston 23 the sliding portion of the Second Hammer 10 O ring C 9 of the Second Hammer 10 the Damper 12 the inner and outer circumferences of the Bevel Gear 26 Oil Seal A 43 and Oil Seal B 39 Fill 50 g of the special grease in the Cylinder Crank Case 40 on the Connec...

Page 23: ... N m 30 5 kgf cm M6 x 45 hex socket head bolt 9 8 N m 100 kgf cm M6 x 22 hex socket head bolt Tail cover mounting bolt 4 41 0 49 N m 45 5 kgf cm M5 x 10 hex socket head bolt Crank cover mounting bolt 4 41 0 49 N m 45 5 kgf cm Lever shaft mounting bolt M4 x 12 hex socket head bolt D4 tapping screw W Flange 1 96 0 49 N m 20 5 kgf cm Handle mounting bolt 4 41 0 49 N m 45 5 kgf cm M5 x 14 hex socket h...

Page 24: ...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 120 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...

Page 25: ...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 Gear Slip Clutch Ass y Bevel Pinion Oil Seal A Ball Bearing 6002DD Washer A Gear Holder Second Gear Ball Bearing 629VV Cylinder Crank Case Front Cover O ri...

Page 26: ...12 13 14 15 17 16 18 19 20 21 23 21 22 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 40 41 42 43 44 46 47 45 48 49 50 51 52 53 55 54 56 57 58 62 63 64 65 66 67 68 72 73 74 75 76 77 78 79 80 81 82 83 501 502 503 505 506 504 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 106 103 104 105 69 70 71 4 59 60 61 ...

Page 27: ...NG 2 22 321 295 CLUTCH 1 23 321 284 PISTON 1 24 980 708 PISTON PIN 1 25 321 285 CONNECTING ROD 1 26 321 296 BEVEL GEAR 1 27 986 940 SEAL LOCK HEX SOCKET HD BOLT M6X45 4 28 983 162 SEAL LOCK HEX SOCKET HD BOLT M4X12 4 29 HITACHI LABEL 1 30 321 315 CRANK COVER 1 31 HITACHI LABEL 1 32 321 314 RUBBER SEAL 1 33 939 540 RETAINING RING FOR D10 SHAFT 10 PCS 1 34 321 275 CRANK SHAFT 1 35 944 109 FEATHER KE...

Page 28: ... Y 110V 120V 1 INCLUD 72 74 79 80 75 360 591E ARMATURE ASS Y 220V 230V 1 INCLUD 74 76 321 320 FAN GUIDE 1 77 953 174 HEX HD TAPPING SCREW D5X55 2 78 340 542G STATOR ASS Y 120V 1 INCLUD 89 78 340 542E STATOR ASS Y 220V 230V 1 INCLUD 89 79 982 631 WASHER A 1 80 608 VVM BALL BEARING 608VVC2PS2L 1 81 318 721 MAGNET 1 82 321 313 SEAL LOCK HEX SOCKET HD BOLT M6X22 2 83 935 829 BRUSH CAP 2 84 999 073 CAR...

Page 29: ...5 DUST COVER 1 601 985 374 DRILL BIT D13X400L D1 2 X16 1 602 985 375 DRILL BIT D25X400L D1 X16 1 603 985 376 DRILL BIT D38X400L D1 1 2 X16 1 604 985 377 A TAPER SHANK ADAPTER 1 605 985 378 B TAPER SHANK ADAPTER 1 606 944 477 COTTER 1 607 984 029 CORE BIT SHANK D35 1 3 8 OR BELOW 1 608 985 379 CORE BIT SHANK D38 1 1 2 OR ABOVE 1 609 985 380 CORE BIT 50MM 1 INCLUD 610 610 985 388 GUIDE PLATE FOR COR...

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