Hitachi H 45ME, Service Manual

Page 1: ... Jun 2016 TROUBLESHOOTING GUIDE 1 1 Troubleshooting and corrective action 1 REPAIR GUIDE 3 1 Precautions on disassembly and reassembly 3 STANDARD REPAIR TIME UNIT SCHEDULES 16 CONTENTS Page PRODUCT NAME Hitachi Demolition Hammer Model H 45MEY Model H 45ME H ...

Page 2: ... 50 Correctly connect internal wires of the Stator Sensor PCB Set 45 42 and Controller 53 50 by their tube colors red black and white Broken Controller 53 50 Check the state of the Controller 53 50 connector Replace the Controller 53 50 with a new one Broken Rotor 102 99 Check the built in magnet of the fan for breaks Replace the Rotor 102 99 with a new one Two LEDs of the display lamp are flashin...

Page 3: ...internal wire is not defective Replace the Controller 53 50 with a new one Broken LED When the connector cable is not defective Replace the Panel 98 95 with a new one Broken Filter PCB Set 62 59 When the internal wire is not defective Replace the Filter PCB Set 62 59 with a new one The LEDs of the display lamp light but the motor does not run Internal wires loosely connected to the Switch 69 66 Ch...

Page 4: ... a retaining ring puller Then remove the Ball Holder 12 Grip B 13 and four Steel Balls D5 7 from the Cylinder Case 19 2 Disassembly of the hammering mechanism 1 Removal of the second hammer and striker a Remove the Bolt M5 x 12 14 from the Cylinder Case Cover 15 and detach the Cylinder Case Cover 15 from the Cylinder Case 19 b Remove the Bolt M6 x 25 18 and detach the Cylinder Case 19 from the Cra...

Page 5: ...puller Then remove the Retainer Sleeve 24 Retainer Damper B 22 Retainer Damper Holder 21 from the Cylinder Case 19 g Separate the Second Hammer 26 from the removed Retainer Sleeve 24 27 19 38 26 22 29 30 24 21 16 91 88 29 2 pcs 37 2 pcs 39 33 32 28 31 19 35 33 Model H 45MEY only ...

Page 6: ...the Housing 52 49 d Wipe off grease from the Piston 41 38 side and the First Gear 96 93 side in the Crank Case 91 88 and then use a retaining ring puller to remove the Retaining Ring for D40 Hole 87 84 that retains the Ball Bearing 6203DD 88 85 while turning the Crank Shaft 86 83 so that you can see the Retaining Ring for D40 Hole 87 84 hole e Place the Crank Case 91 88 on an adequate cradle with ...

Page 7: ...otor 102 99 has strong magnetic force Firmly hold the Housing 52 49 and pull out the Gear Cover 99 96 from the Housing 52 49 NOTE Without the Gear Cover 99 96 the Rotor 102 99 will be strongly attracted and fixed to the Stator Sensor PCB Set 45 42 by its own magnetic force Be careful not to get your hand caught between the Rotor 102 99 and the Stator Sensor PCB Set 45 42 Tap the shaft of the rotor...

Page 8: ...steel rod and use an adequate tool to press fit the First Gear 96 93 NOTE Prior to press fitting make sure the Feather Key 3 x 3 x 10 83 80 matches the key groove of the First Gear 96 93 2 Mounting the piston a Insert the Connecting Rod Ass y 42 39 into the Piston 41 38 Press fit the Piston Pin 40 37 into the D8 hole marked Φ2 of the Piston 41 38 being careful not to let the Piston Pin 40 37 proje...

Page 9: ...ing puller c Insert the Striker 35 mounted with O ring I D 27 2 36 into the Cylinder 33 Mount the Stopper Ring 34 to the Cylinder 33 using a retaining ring puller d Mount the Cylinder Holder 32 Damper Holder 31 Damper C 30 Weight Washer 29 Damper 28 Damper Washer 27 and Second Hammer 25 mounted with O ring C 25 to the Cylinder 33 Then insert the assembly of the Cylinder 33 into the Cylinder Case 1...

Page 10: ...le 39 to the Cylinder Case 19 Check that the Retaining Ring for D52 Hole 39 is properly fitted in the groove on the Cylinder Case 19 5 Mounting the valve and felt a Insert the Valve 92 89 into the Crank Case 91 88 Then mount the Washer M3 93 90 to the Valve 92 89 NOTE Without the Valve 92 89 grease leaks out b Insert the Felt 94 91 into the specified portion in the Crank Case 91 88 as shown in the...

Page 11: ...Spacer 48 45 deep into the Housing 52 49 so that the Spacer 48 45 does not protrude from the end surface of the Housing 52 49 NOTE After mounting the Spacer 48 45 turn the Housing 52 49 upside down to check whether the Spacer 48 45 drops from the Housing 52 49 or not 52 49 Grooves for mounting 48 45 Protrusions of 48 45 Push the spacers deep into the housing so that the spacers do not protrude fro...

Page 12: ...3 50 connector Do not reverse the connector orientation Connect the 8 wire connector of the Panel 98 95 to the Controller 53 50 connector Do not reverse the connector orientation 3 Wiring of the filter PCB set See the figure on the next page Connect the two terminal equipped internal wires of the Controller 53 50 to those of the Filter PCB Set 62 59 The internal wires are connectable with either t...

Page 13: ...he connector orientation Check the connector orientation 53 50 62 59 72 69 Connectable with either terminal 71 68 Connectable with either terminal Red Black Black Black White Red Black 75 72 Connectable with either terminal Red Red ...

Page 14: ...f Oil Seal B 90 87 inside of the metal in the Crank Case 91 88 inside of the Weight 38 Weight Spring 37 Damper 28 Retainer Damper B 22 Damper C 30 and inside and outside polished surfaces of the Retainer Sleeve 24 Fill or apply Hitachi Motor Grease No 29 to the following points Fill a total of 20 g of Hitachi Motor Grease No 29 in the Crank Case 91 88 on the First Gear 96 93 side and the Gear Cove...

Page 15: ...t Hd Bolt M4 x 12 95 92 0 49 N m 5 kgf cm D5 Hex Hd Tapping Screw D5 x 55 44 41 2 94 0 49 N m 30 5 kgf cm Tapping Screw W Flange D5 x 25 Black 70 67 2 94 0 49 N m 30 5 kgf cm D4 Tapping Screw W Flange D4 x 16 74 71 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 MΩ or higher as measured with a 500 V...

Page 16: ...5 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 17: ...s y Controller Set Panel Retainer Sleeve Retainer Damper B Retainer Damper Holder Gear Cover Rotor Ball Bearing 6201DD Ball Bearing 629VV Crank Shaft Ball Bearing 6203DD First Gear Housing Stator Sensor PCB Set Crank Case Work Flow Handle A B Set Switch Filter PCB Set Cord Cord Armor Tail Cover Crank Cover Front Cap Grip Retainer Damper A Bit Lock Holder Bit Lock Spring Holder A Spring Holder B Gr...

Page 18: ... 79 82 16 65 48 83 36 1 2 3 4 5 6 8 9 10 14 11 7 15 13 12 20 17 22 23 25 26 27 28 29 31 32 33 34 29 35 36 37 38 29 39 40 41 43 44 45 46 47 52 53 49 50 51 14 56 57 70 57 56 57 70 57 58 61 64 67 68 69 65 71 72 73 74 75 76 66 77 86 87 88 89 90 91 84 85 98 95 96 97 99 100 101 102 62 55 54 59 501 502 63 48 ...

Page 19: ...1 23 337554 BIT LOCK 2 24 370227 RETAINER SLEEVE 1 25 324921 O RING C 1 26 370228 SECOND HAMMER 1 27 370229 DAMPER WASHER 1 28 370259 DAMPER 1 29 370230 WEIGHT WASHER 3 30 326662 DAMPER C 1 31 370231 DAMPER HOLDER 1 32 370232 CYLINDER HOLDER 1 33 370233 CYLINDER 1 34 370235 STOPPER RING 1 35 370234 STRIKER 1 36 325297 O RING I D 27 2 2 37 370236 WEIGHT SPRING 2 38 370237 WEIGHT 1 39 967270 RETAINI...

Page 20: ...L A 1 72 940778 CORD ARMOR D10 7 1 72 958049 CORD ARMOR D8 2 1 73 960266 CORD CLIP 1 74 984750 TAPPING SCREW W FLANGE D4 X 16 2 75 321537 CORD 1 CORD ARMOR D10 7 75 500434Z CORD 1 CORD ARMOR D10 7 FOR USA CAN PAN 120V 75 500408Z CORD 1 CORD ARMOR D8 2 FOR AUS NZL 75 500390Z CORD 1 CORD ARMOR D10 7 FOR PAN 220V 75 500465Z CORD 1 CORD ARMOR D10 7 FOR GBR 110V 75 500446Z CORD 1 CORD ARMOR D10 7 FOR G...

Page 21: ... GREASE A FOR HAMMER HAMMER DRILL 30G 1 602 308471 GREASE FOR HAMMER HAMMER DRILL 70G 1 603 980927 GREASE FOR HAMMER HAMMER DRILL 500G 1 EXCEPT FOR USA CAN 604 313471 BULL POINT SDS MAX 280L 1 605 313472 BULL POINT SDS MAX 400L 1 606 313473 COLD CHISEL SDS MAX 280MM 1 607 313474 COLD CHISEL SDS MAX 400MM 1 608 313475 CUTTER SDS MAX W50 X 400L 1 609 313476 SCOOP SDS MAX 400L 1 610 313477 BUSHING TO...

Page 22: ... 76 77 78 76 79 16 62 45 80 1 2 3 4 5 6 8 9 10 14 11 7 15 13 12 20 17 22 23 25 26 27 28 29 31 32 33 34 35 36 37 38 40 41 42 43 44 49 50 46 47 48 14 53 54 67 54 53 54 67 54 55 58 61 64 65 66 62 68 69 70 71 72 73 63 74 83 84 85 86 87 88 81 82 95 92 93 94 96 97 98 99 59 52 51 56 501 502 60 45 ...

Page 23: ...DAMPER B 1 23 337554 BIT LOCK 2 24 370227 RETAINER SLEEVE 1 25 324921 O RING C 1 26 370228 SECOND HAMMER 1 27 370229 DAMPER WASHER 1 28 370259 DAMPER 1 29 370230 WEIGHT WASHER 1 30 326662 DAMPER C 1 31 370231 DAMPER HOLDER 1 32 370232 CYLINDER HOLDER 1 33 370233 CYLINDER 1 34 370235 STOPPER RING 1 35 370234 STRIKER 1 36 325297 O RING I D 27 2 2 37 324917 PISTON PIN 1 38 324915 PISTON 1 39 339049 C...

Page 24: ... ARMOR D8 2 1 70 960266 CORD CLIP 1 71 984750 TAPPING SCREW W FLANGE D4 X 16 2 72 321537 CORD 1 CORD ARMOR D10 7 72 500424Z CORD 1 CORD ARMOR D8 2 FOR UAE MAL 72 500465Z CORD 1 CORD ARMOR D10 7 FOR GBR 110V 72 500446Z CORD 1 CORD ARMOR D10 7 FOR GBR 230V 72 500235Z CORD 1 CORD ARMOR D8 2 FOR IND 72 500487Z CORD 1 CORD ARMOR D8 2 FOR BRA 72 500434Z CORD 1 CORD ARMOR D10 7 FOR MEX 73 NAME PLATE 1 74...

Page 25: ...1 602 308471 GREASE FOR HAMMER HAMMER DRILL 70G 1 603 980927 GREASE FOR HAMMER HAMMER DRILL 500G 1 604 313471 BULL POINT SDS MAX 280L 1 605 313472 BULL POINT SDS MAX 400L 1 606 313473 COLD CHISEL SDS MAX 280MM 1 607 313474 COLD CHISEL SDS MAX 400MM 1 608 313475 CUTTER SDS MAX W50X400L 1 609 313476 SCOOP SDS MAX 400L 1 610 313477 BUSHING TOOL SDS MAX 1 611 313478 RAMMER SDS MAX 150MM X 150MM 1 612 ...