Hitachi DH 52ME, Service Manual

Page 1: ...EY F427 May 2015 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 Models DH 52ME DH 52MEY ...

Page 2: ...rrectly connect internal wires of the Stator Sensor PCB Set 54 and Controller Ass y 63 by their tube colors red black and white Broken Controller Ass y 63 Check the state of the Controller Ass y 63 connector Replace the Controller Ass y 63 with a new one Broken Rotor 62 Check the built in magnet of the fan for breaks Replace the Rotor 62 with a new one Two LEDs of the display lamp are flashing Bro...

Page 3: ...ll internal wires to the Switch 77 Broken Controller Ass y 63 When internal wires of the Controller Ass y 63 are not defective Replace the Controller Ass y 63 with a new one Broken Switch 77 When internal wires of the Controller Ass y 63 are not defective Replace the Switch 77 with a new one Improperly inserted connector cable of On Lock PCB A Ass y 92 Check insertion of the connector cable See 2 ...

Page 4: ...from the Retainer Sleeve 26 2 Disassembly of the hammering mechanism 1 Removal of the second hammer and striker a Remove the Bolt M5 x 18 112 121 and then detach the Crank Cover 111 120 and lever shaft holder ass y from the Crank Case 125 135 Then take out the Change Plate 120 129 and Slider 43 from the Crank Case 125 135 b Remove the Bolt M5 x 12 12 from the Cylinder Case Cover 11 and then detach...

Page 5: ... Damper Washer 30 from the detached Retainer Sleeve 26 h Strike the end of the Cylinder 33 with a plastic hammer to pull out the Striker 34 2 Removal of the piston ass y Remove the Retaining Ring for D12 Shaft 102 101 and then move the Connecting Rod 50 as shown below Remove the piston ass y from the Crank Shaft 103 102 111 120 120 129 Lever shaft holder ass y 46 Cylinder case ass y 29 37 38 27 Cr...

Page 6: ...e from the Crank Case 125 135 or Gear Cover 145 155 strike it with a plastic hammer to remove it d Wipe off grease from the Piston 49 side and the First Gear 139 149 side in the Crank Case 125 135 and then use a retaining ring puller to remove the Retaining Ring for D47 Hole 105 104 that retains the Ball Bearing 6204DD 106 105 while turning the Crank Shaft 103 102 so that you can see the hole of t...

Page 7: ...dle Pin D6 x 6 134 144 3 Disassembly of the motor 1 Firmly hold the Housing 55 and use a plastic hammer to tap the shaft of the Rotor 62 until the spigot joint of the Gear Cover 145 155 is removed from the Housing 55 2 The Rotor 62 has strong magnetic force Firmly hold the Housing 55 and pull out the Gear Cover 145 155 from the Housing 55 NOTE When the Gear Cover 145 155 is separated from the Roto...

Page 8: ...39 149 Simillarly press fit the Second Pinion 140 150 NOTE Prior to press fitting make sure the Feather Key 104 103 matches the key groove of the First Gear 139 149 and the Second Pinion 140 150 2 Mounting the piston a Insert the Connecting Rod 50 into the Piston 49 and then press fit the Piston Pin 48 into the D10 hole marked ĭ2 of the Piston 49 Then mount the O ring 47 on the Piston 49 to comple...

Page 9: ...se 18 ass y and then fix it with Retaining Ring D40 13 NOTE Insert the Retainer Sleeve 26 straight in to avoid turning up the lip section of the Oil Seal 17 f Insert the Lock Spring Washer 37 deep into the Cylinder Case 18 Insert the Lock Spring 38 until it contacts the Lock Spring Washer 37 Then insert the Lock Sleeve 39 until it contacts the Lock Spring 38 g Insert the Clutch Spring 40 until it ...

Page 10: ...Washer 24 and Damper Washer 31 39 Insert position of the Lock Spring Washer 37 Position the notch downward Position the slider groove upward Insert from the convex side 45 Engage the clutch with the bevel gear Engage the Lock Sleeve 39 with the Clutch 41 Engage the Clutch 41 with the Cylinder 33 Engage the Lock Sleeve 39 with the Cylinder Case 18 38 101 107 18 40 41 42 44 46 34 35 33 ...

Page 11: ...f the vibration reduction mechanism a Apply Hitachi Motor Grease No 29 to the Washer 109 and adhere it to the end face of the hole portion of the Weight 110 b Insert the Weight 110 into the Base 116 and then insert the Weight Pin 112 NOTE At this time apply Hitachi Motor Grease No 29 to the Weight Pin 112 c Sandwich the Base 116 between Leaf Spring A 114 and the Spring Holder 115 engaging the conv...

Page 12: ...properly Insert the Change Lever 113 122 into the hole of the Lever Shaft Holder 117 126 and fix it with the Retaining Ring for D20 Shaft 118 127 NOTE Rotate the Change Lever 113 122 to check that the lever clicks at each mode position Insert the Change Lever 113 122 into the Lever Shaft Holder 117 126 straight to avoid damaging the O ring 7 Mounting the valve and felt a Insert the Valve 123 133 i...

Page 13: ...Gear Cover 145 155 NOTE Without the gear cover the Rotor 62 will be strongly attracted and fixed to the Stator Sensor PCB Set 54 by its own magnetic force Be careful not to let your hand be suddenly pulled by the magnetic force of the Rotor 62 Insert the Gear Cover 145 155 into the Housing 56 in proper direction Press fit the Gear Cover 145 155 into the Housing 55 as far as it will go by using an ...

Page 14: ...wire of the Controller Ass y 63 through the window of the Back Cover 87 and then connect it with the terminal No 2 or 3 of the Switch 77 Connect one core exposed internal wire of On Lock PCB A Ass y 92 with the terminal No 2 or 3 of the Switch 77 whichever is not connected NOTE The internal wires are connectable with either terminal 5 Wiring of the cord See the figure on page 15 Connect the core e...

Page 15: ...ring 91 On Lock Button 90 Pillar Terminal A 81 the connectors to connect On Lock PCB A Ass y 92 and Controller Ass y 63 Switch 77 and Trigger 76 into the positions shown in the figure NOTE Do not insert the Filter PCB Ass y 71 On Lock PCB A Ass y 92 and On Lock Button 90 in the wrong direction e Put the internal wires in Handle A 70 and mount Handle B 79 without getting the internal wires caught T...

Page 16: ...k the connector orientation Check the connector orientation 63 71 82 Interchangeable wires 81 Interchangeable wires 85 Check the connector orientation Check the connector orientation 92 109 111 Interchangeable wires Red Red Black Black Red Black White ...

Page 17: ...Grease No 29 to the following points Fill a total of 30 g of grease in the Crank Case 125 135 on the First Gear 139 149 side and the Gear Cover 145 155 side Apply a total of 5 g of grease to the 8 mm dia holes of the Gear Holder 133 143 and Spring C 135 145 Apply grease to the Weight Pin 112 weight pin inserting portion of the Base 116 Washer 110 sliding surfaces of Leaf Spring B 114 and Weight As...

Page 18: ...mounting the back cover 3 92 0 49 N m 40 5 kgf cm Bolt M5 x 14 59 for mounting the tail cover 5 9 1 5 N m 60 15 kgf cm Bolt M5 x 12 12 for mounting the cylinder case cover 3 92 0 49 N m 40 5 kgf cm Bolt M5 x 30 113 for mounting the vibration absorber 7 84 N m 80 kgf cm Bolt M5 x 16 118 for mounting the spring holder 7 84 N m 80 kgf cm D4 Screw D4 x 16 84 for mounting the cord clip 1 96 0 49 N m 20...

Page 19: ...th no abnormalities 110 to 127 V Except UK products After no load operation for 30 minutes the no load current values should be as follows Voltage 110 V 120 V 127 V 220 V 230 V 240 V Current max 5 7 A 5 4 A 5 0 A 3 2 A 3 0 A 2 9 A Connecting diagram No load current value Insulation test 5 wire 8 wire Panel Ass y 67 On Lock PCB A Ass y 92 Controller Ass y 63 Stator Sensor PCB Set 54 Filter PCB Ass ...

Page 20: ...ng Rod Gear Cover Rotor Ass y Ball Bearing 6202DD Ball Bearing 6201VV Crank Shaft Ball Bearing 6204DD First Gear Second Pinion Slip Clutch Ass y Bevel Gear Housing Stator Sensor PCB Set Crank Case Work Flow Handle A Handle B Switch Filter PCB Ass y Cord Cord Armor Tail Cover Crank Cover Change Lever Lever Shaft Holder On Lock PCB B Change Plate On Lock Button On Lock PCB A Ass y Front Cap Grip Cyl...

Page 21: ...er B Slider Piston O ring Connecting Rod Gear Cover Rotor Ass y Ball Bearing 6202DD Ball Bearing 6201VV Crank Shaft Ball Bearing 6204DD First Gear Second Pinion Slip Clutch Ass y Bevel Gear Housing Stator Sensor PCB Set Crank Case Work Flow Handle A Handle B Switch Filter PCB Ass y Cord Cord Armor Tail Cover Crank Cover Change Lever Lever Shaft Holder On Lock PCB B Change Plate On Lock Button On L...

Page 22: ...3 44 45 46 47 48 49 50 53 54 51 52 56 58 59 60 61 62 63 67 59 79 78 68 69 69 68 73 72 80 74 81 82 83 84 85 86 87 88 89 75 76 77 90 91 92 94 95 97 98 96 99 100 102 103 104 105 107 106 124 125 108 109 112 111 113 114 115 116 117 118 120 119 126 127 128 129 130 131 132 133 135 134 136 137 138 124 140 141 142 145 144 70 55 57 71 93 110 121 122 123 14 15 16 17 24 10 101 65 64 65 66 ...

Page 23: ...222 O RING C 1 21 338204 RETAINER DAMPER HOLDER 1 22 338203 RETAINER DAMPER B 1 23 339064 DAMPER SLEEVE 1 24 338202 RETAINER DAMPER WASHER 1 25 337554 BIT LOCK 2 26 338205 RETAINER SLEEVE 1 27 338210 NEEDLE PIN D8 8 28 986104 O RING 1 29 338206 SECOND HAMMER 1 30 338207 DAMPER WASHER 1 31 328887 DAMPER 1 32 338208 DAMPER HOLDER 1 33 338209 CYLINDER 1 34 338214 STRIKER 1 35 328880 O RING 1 36 33821...

Page 24: ...D 1 67 338184 PANEL ASS Y 1 INCLUD 65 68 991690 SEAL LOCK HEX SOCKET HD BOLT M5 X 12 2 69 991711 DISTANCE PIECE B 2 70 338173 HANDLE A 1 71 338180 FILTER PCB ASS Y 100V 127V 1 INCLUD 80 71 338181 FILTER PCB ASS Y 220V 240V 1 INCLUD 80 72 310123 TRANSATORY UNIT 1 73 310124 HANDLE DAMPER 4 74 338162 HANDLE DAMPER HOLDER 1 75 338176 BELLOWS 1 76 337588 TRIGGER 1 77 337587 SWITCH 1 78 338174 HANDLE B ...

Page 25: ...328869 FEATHER KEY 3 X 3 X 25 1 105 948227 RETAINING RING FOR D47 HOLE 1 106 6204DD BALL BEARING 6204DDCMPS2L 1 107 338227 O RING F 1 108 986940 SEAL LOCK HEX SOCKET HD BOLT M6 X 45 4 109 338179 ON LOCK PCB B 1 110 339050 FELT PACKING D 1 111 338237 CRANK COVER 1 112 338177 HEX SOCKET HD BOLT W FLANGE M5 X 18 4 113 338159 CHANGE LEVER 1 114 337567 LEVER SPRING 1 115 959149 STEEL BALL D4 76 10 PCS ...

Page 26: ...RST GEAR 1 140 338226 SECOND PINION 1 141 629VVM BALL BEARING 629VVC2PS2L 1 142 944525 BEARING WASHER C 1 143 338240 SEAL PACKING 1 144 321313 SEAL LOCK HEX SOCKET HD BOLT M6 X 22 2 145 338241 GEAR COVER 1 DESCRIPTION REMARKS 501 981840 GREASE A FOR HAMMER HAMMER DRILL 30G 1 502 339066 CASE PLASTIC 1 503 971786 STOPPER ROD 1 5 15 5 STANDARD ACCESSORIES ALTERNATIVE PARTS PARTS NO USED CODE NO ITEM ...

Page 27: ...ANK DRILL BIT D12 7 X 110 1 624 944500 TAPER SHANK DRILL BIT D14 5 X 110 1 625 944477 COTTER 1 626 313465 ADAPTER SDS MAX FOR SDS PLUS SHANK BIT 1 627 955994 CORE BIT 25MM 1 628 955995 CORE BIT 29MM 1 629 955996 CORE BIT 32MM 1 INCLUD 630 630 955997 GUIDE PLATE FOR CORE BIT 32MM 1 631 955998 CORE BIT 35MM 1 INCLUD 632 632 955999 GUIDE PLATE FOR CORE BIT 35MM 1 633 956000 CORE BIT 38MM 1 INCLUD 634...

Page 28: ... 659 313469 CHEMICAL ANCHOR ADAPTER SDS MAX 12 7MM 1 660 313470 CHEMICAL ANCHOR ADAPTER SDS MAX 19MM 1 661 313471 BULL POINT SDS MAX 280L 1 662 313472 BULL POINT SDS MAX 400L 1 663 313473 COLD CHISEL SDS MAX 280MM 1 664 313474 COLD CHISEL SDS MAX 400MM 1 665 313475 CUTTER SDS MAX W50 X 400L 1 666 313476 SCOOP SDS MAX 400L 1 667 313478 RAMMER SDS MAX 150MM X 150MM 1 668 313477 BUSHING TOOL SDS MAX ...

Page 29: ... 47 48 49 50 53 54 51 52 56 58 59 60 61 62 63 67 59 79 78 68 69 69 68 73 72 80 74 81 82 83 84 85 86 87 88 89 75 76 77 90 91 92 94 95 96 97 98 99 100 101 102 103 104 106 105 134 135 130 111 121 120 122 123 124 125 126 127 129 128 136 137 138 139 140 141 142 143 145 144 146 147 152 150 151 153 155 154 70 110 110 109 113 112 116 117 114 115 118 55 57 71 93 119 131 134 133 14 15 16 17 24 10 107 108 14...

Page 30: ...222 O RING C 1 21 338204 RETAINER DAMPER HOLDER 1 22 338203 RETAINER DAMPER B 1 23 339064 DAMPER SLEEVE 1 24 338202 RETAINER DAMPER WASHER 1 25 337554 BIT LOCK 2 26 338205 RETAINER SLEEVE 1 27 338210 NEEDLE PIN D8 8 28 986104 O RING 1 29 338206 SECOND HAMMER 1 30 338207 DAMPER WASHER 1 31 328887 DAMPER 1 32 338208 DAMPER HOLDER 1 33 338209 CYLINDER 1 34 338214 STRIKER 1 35 328880 O RING 1 36 33821...

Page 31: ...338184 PANEL ASS Y 1 INCLUD 65 68 991690 SEAL LOCK HEX SOCKET HD BOLT M5 X 12 2 69 991711 DISTANCE PIECE B 2 70 338173 HANDLE A 1 71 338180 FILTER PCB ASS Y 100V 127V 1 INCLUD 80 71 338181 FILTER PCB ASS Y 220V 240V 1 INCLUD 80 72 310123 TRANSATORY UNIT 1 73 310124 HANDLE DAMPER 4 74 338162 HANDLE DAMPER HOLDER 1 75 338176 BELLOWS 1 76 337588 TRIGGER 1 77 337587 SWITCH 1 78 338174 HANDLE B 1 79 30...

Page 32: ...LL PIN D2X8 10 PCS 1 108 339112 WEIGHT DAMPER 2 109 339067 WEIGHT ASS Y 1 INCLUD 108 110 338191 WASHER 2 111 338179 ON LOCK PCB B 1 112 338192 WEIGHT PIN 1 113 306061 SEAL LOCK HEX SOCKET HD BOLT M5 X 30 4 114 338187 LEAF SPRING B 2 115 328906 SPRING HOLDER 2 116 338190 BASE 1 117 338194 WEIGHT BUMPER 2 118 990079 SEAL LOCK HEX SOCKET HD BOLT M5 X 16 2 119 339050 FELT PACKING D 1 120 338237 CRANK ...

Page 33: ...RING C 8 146 338232 SECOND GEAR 1 147 338233 SPACER 1 148 629VVM BALL BEARING 629VVC2PS2L 1 149 338225 FIRST GEAR 1 150 338226 SECOND PINION 1 151 629VVM BALL BEARING 629VVC2PS2L 1 152 944525 BEARING WASHER C 1 153 338240 SEAL PACKING 1 154 321313 SEAL LOCK HEX SOCKET HD BOLT M6 X 22 2 155 338241 GEAR COVER 1 DESCRIPTION REMARKS 501 981840 GREASE A FOR HAMMER HAMMER DRILL 30G 1 502 339066 CASE PLA...

Page 34: ...HANK DRILL BIT D12 7 X 110 1 624 944500 TAPER SHANK DRILL BIT D14 5 X 110 1 625 944477 COTTER 1 626 313465 ADAPTER SDS MAX FOR SDS PLUS SHANK BIT 1 627 955994 CORE BIT 25MM 1 628 955995 CORE BIT 29MM 1 629 955996 CORE BIT 32MM 1 INCLUD 630 630 955997 GUIDE PLATE FOR CORE BIT 32MM 1 631 955998 CORE BIT 35MM 1 INCLUD 632 632 955999 GUIDE PLATE FOR CORE BIT 35MM 1 633 956000 CORE BIT 38MM 1 INCLUD 63...

Page 35: ... 659 313469 CHEMICAL ANCHOR ADAPTER SDS MAX 12 7MM 1 660 313470 CHEMICAL ANCHOR ADAPTER SDS MAX 19MM 1 661 313471 BULL POINT SDS MAX 280L 1 662 313472 BULL POINT SDS MAX 400L 1 663 313473 COLD CHISEL SDS MAX 280MM 1 664 313474 COLD CHISEL SDS MAX 400MM 1 665 313475 CUTTER SDS MAX W50 X 400L 1 666 313476 SCOOP SDS MAX 400L 1 667 313478 RAMMER SDS MAX 150MM X 150MM 1 668 313477 BUSHING TOOL SDS MAX ...