Hitachi DH 40SR Service Manual And Technical Data
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Hitachi DH 40SR Service Manual And Technical Data

Hitachi DH 40SR Service Manual And Technical Data

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

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  • Page 1 MODEL DH 40SR POWER TOOLS TECHNICAL DATA ROTARY HAMMER DH 40SR SERVICE MANUAL LIST No. E471 Apr. 2003 SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT...
  • Page 2 REMARK: Throughout this 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: Competitors Symbols Utilized Model Name Company Name HR3811 MAKITA...

  • Page 3: Table Of Contents

    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.

  • Page 4: Product Name

    Hitachi Rotary Hammer, Model DH 40SR 2. MARKETING OBJECTIVE The Model DH 40SR is an upgraded version of the current Model DH 40SA, which features the use of Hitachi 13 mm hexagonal tools. The performance, durability and operability are greatly improved. With this competitive Model DH 40SR, we aim to enhance the share of Hitachi 13 mm hexagonal shank type rotary hammers.

  • Page 5: Selling Point Descriptions

    4-1-4. Constant speed control The Model DH 40SR is equipped with a built-in electronic control circuit that can keep constant speed in either no- load operation or actually loaded operation. The Model DH 40SR provides better operability and stable, efficient drilling performance even if the load varies because the constant speed control minimizes changes in speed and number of hammering.

  • Page 6: Specifications

    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 and the second hammer to prevent to idle hammering.

  • Page 7: Optional Accessories

    5-2. Optional Accessories 1. Drilling work for through-holes (rotation + hammering) (1) Drill bit (hexagon shaft) Outer length (mm) 280 (11") 400 (15-3/4") 505 (19-7/8") 550 (21-5/8") Code No. Code No. Code No. Code No. Outer diameter (mm) (5/8") 985721 985720 985722 991330...
  • Page 8 Taper shank adapters for A-taper or 9.7 mm (3/8") x 1/20 Taper (A) A-taper 985754 B-taper shanks are provided as optional accessories. Taper shank drill bits are B-taper 12.9 mm (1/2") x 1/20 Taper (B) 985755 not provided. For Australia K-taper shank adapter 992813 (1) Drill bit (ratio shank)
  • Page 9 (5) Core bit for efficient drilling Center pin (C) Core bit (with guide plate) Core bit shank Code No. Outer diameter (in) Code No. Code No. 992814 65 mm (9-2/16") 992815 80 mm (3-5/32") 992819 903901 992816 90 mm (3-1/2") 992817 100 mm (3-15/16") 992818...
  • Page 10 6. Demolition work (hammering) (1) Bull point Overall length: 280 mm (11"), 450 mm (17-3/4") Overall length Code No. 280 mm 981922 450 mm 981923 7. Grooving and edging work (hammering) (1) Cold chisel Overall length: 280 mm (11"), 450 mm (17-3/4") Overall length Code No.
  • Page 11 11. Tamping work (hammering) (2) Shank (1) Rammer Code No. 955181 Overall length Code No. O. D. 140 mm (5-1/2") 250 mm (10") 955186 12. Syringe (for chip removal) Code No. 318085 13. Grease for hammer, hammer drill 70 g (2.5 oz) Tube 30 g (1 oz) Tube 500 g (1.1 lbs.) Can Code No.

  • Page 12: Comparisons With Similar Products

    6. COMPARISONS WITH SIMILAR PRODUCTS 6-1. Specification Comparisons Maker Model • HITACHI HITACHI DH 40SR DH 40SA Item Capacity Drill bit dia. (mm) (1-9/16") (1-9/16") (1-1/2") Core bit dia. (mm) (4-3/4") (4-1/8") (4-21/32") 1,130 Power input Impact energy per stroke...

  • Page 13: 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. Drilling speed (mm/min.) Drill bit Model Maker dia. (mm) HITACHI DH 40SR HITACHI DH 40SA HITACHI DH 40SR HITACHI DH 40SA HITACHI DH 40SR...

  • Page 14: Chiseling Performance Comparison

    7. PRECAUTIONS IN SALES PROMOTION In the interest of promoting the safest and most efficient use of the Model DH 40SR Rotary Hammer by all of our customers, it is very important that at the time of sale the salesperson carefully ensures that the buyer seriously recognizes the importance of the contents of the Handling Instructions, and fully understands the meaning of the precautions listed on the Caution Plate attached to each tool.

  • Page 15: Reference Information

    8-1. Grease Replacement The striking portion and the speed reduction portion of the Model DH 40SR respectively use different types of grease. It is not necessary to replenish the grease unless the tool is disassembled for repair or there is grease leakage due to a damaged seal.

  • Page 16: Structure Of The Model Dh 40Sr Rotary Hammer

    8-3. Structure of the Model DH 40SR Rotary Hammer Front Second Striker Bevel gear Crank shaft Handle chamber cover hammer Connecting First gear Piston Retainer Driver Cylinder Clutch Needle pin O-ring Hammer sleeve Second gear Bevel pinion Armature Control circuit ass'y Fig.
  • Page 17 Fig. 5 then the cushion (damper (B)) provided between driver holder and front cover absorbs the striking force of the second hammer. Thus the durability of the Model DH 40SR is increased greatly because the second hammer does not strike the tool retainer directly.
  • Page 18 Gear holder groove Cross section A - A Fig. 6 Tool holder The Model DH 40SR is equipped with an easy pushbutton- Pushing button type tool holder. To attach a tool, pull up the retainer in the Retainer arrow direction and insert a tool into the hexagonal hole of the front cover then pull down the retainer (Fig.
  • Page 19 Sealing and dust-proof structure The cylinder crank case section is tightly sealed with three o-rings, three 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.

  • Page 20: Repair Guide

    9. REPAIR GUIDE The numbers in [Bold] correspond to the item numbers in the Parts List and exploded assembly diagrams. 9-1. Disassembly (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.
  • Page 21 (2) Disassembly of the piston and the striker Remove the Seal Lock Hex. Socket Hd. Bolt M4 x 12 [44] from the Crank Cover [46] then remove the Crank Cover [46] from the Cylinder Crank Case [56]. Remove the Seal Lock Hex. Socket Hd. Bolt M6 x 45 [43] and Seal Lock Hex.
  • Page 22 (3) Disassembly of the cylinder and the hammer sleeve Remove the Second Hammer [23] from the Hammer Sleeve [21] side. As shown in Fig. 12, 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] then remove it from the slot of the Cylinder [31] and the Hammer Sleeve [21].

  • Page 23: Reassembly

    (5) Disassembly of the slip clutch Remove the Ball Bearing 629VVC2PS2L [69] with a Press the end surface of the bevel pinion with bearing puller. Place the assembly on a sleeve-type a hand press. support facing Washer (A) [63] downward as shown in Bevel Pinion [57] Fig.
  • Page 24 Retaining Ring for Cylinder Crank Case [56] Crank Pin D10 Shaft [49] Piston Pin [40] Mark Crank Shaft [50] Connecting Rod [41] O-ring [37] Piston [39] Fig. 17 (3) Reassembly of the cylinder and the hammer sleeve Press-fit the Hammer Sleeve [21] into the Ball Bearing 6007DDUAV2S [17] and secure it with the Retaining Ring for D35 Shaft [16].
  • Page 25 Retaining Ring for D35 Shaft [16] Slide Ring [29] Ball Bearing 6007DDUAV2S Damper (C) [28] [17] Cylinder [31] Damper Holder (B) [27] Damper Damper Holder [26] Washer [24] Damper [25] Hammer Sleeve [21] Fig. 18 Slide Sleeve (A) [33] Slide Sleeve (B) [32] Oil Seal (B) [14] Second Bevel Gear [42]...
  • Page 26 Gear [67]. Insert the ten Needles [66] being careful not to incline them, then push in ten Springs (C) [65] as shown in Fig. 20. Fill the slots and the through holes of the Gear Holder [64] with Hitachi Motor Grease No.
  • Page 27 [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.

  • Page 28: Screw Locking Agent Tb1401

    9-3. Screw Locking Agent TB1401 Apply screw locking agent TB1401 to all hex. socket head bolts M4, M5 and M6. (Note) Be sure to apply screw locking agent ThreeBond TB1401 to the threads during reassembly, as the bolts loosened with vibration may cause damage to the tool body. 9-4.

  • Page 29: Insulation Tests

    Mounting diagram Case (B) Control circuit ass'y (include noise suppressor) Housing Lead wires of switch and cord Lead wire of stator Lead wire of noise suppressor Tail cover Fig. 23 9-6. Insulation Tests On completion of disassembly and repair, measure the insulation resistance and dielectric strength. Insulation resistance: 7 MΩ...

  • Page 30: Standard Repair Time (Unit) Schedules

    10. STANDARD REPAIR TIME (UNIT) SCHEDULES Variable 60 min. MODEL Fixed DH 40SR Work Flow Housing Ass'y Stator Ass'y Gear Cover Needle Bearing Switch (C) Cord Armature Ass'y Cord Armor Ball Bearing (6201DD) Tail Cover Dust Washer (B) Ball Bearing...
  • Page 31 LIST NO. E471 ELECTRIC TOOL PARTS LIST ROTARY HAMMER 2003 • • Model DH 40SR (E1)
  • Page 32 PARTS DH 40SR ITEM CODE NO. DESCRIPTION REMARKS USED 990-131 RETAINER 322-078 DUST COVER 981-942 SEAL LOCK HEX. SOCKET HD. BOLT M6X25 991-697 ROLL PIN D4X20 990-135 RETAINER PIN 990-134 DAMPER (B) 990-133 PUSHING BUTTON 990-132 SET SPRING 321-844 FRONT COVER (A)
  • Page 33 PARTS DH 40SR ITEM CODE NO. DESCRIPTION REMARKS USED 948-391 RETAINING RING FOR D40 HOLE 620-3DD BALL BEARING 6203DDCMPS2L 996-363 O-RING (S-40) 321-274 OIL SEAL (B) 321-826 CYLINDER CRANK CASE 321-278 BEVEL PINION 944-109 FEATHER KEY 3X3X8 321-279 COLLAR 313-050...

  • Page 34: Standard Accessories

    PARTS DH 40SR ITEM CODE NO. DESCRIPTION REMARKS USED * 100 321-862 CONTROLLER CIRCUIT 230V 1 FOR EUROPE 317-113 INTERNAL WIRE 321-859 HANDLE 998-485 HEX. SOCKET HD. BOLT (W/FLANGE) M5X14 313-093 SWITCH (C) (2P SCREW TYPE W/O LOCK) 321-324 HANDLE COVER...
  • Page 35 DH 40SR OPTIONAL ACCESSORIES ITEM CODE NO. DESCRIPTION REMARKS USED 985-730 DRILL BIT D25.0 X 280 (HEX. SHANK TYPE) 985-729 DRILL BIT D25.0 X 400 (HEX. SHANK TYPE) 985-731 DRILL BIT D25.0 X 505 (HEX. SHANK TYPE) 991-336 DRILL BIT D25.0 X 550 (HEX. SHANK TYPE) 985-733 DRILL BIT D28.0 X 280 (HEX.
  • Page 36 OPTIONAL ACCESSORIES DH 40SR ITEM CODE NO. DESCRIPTION REMARKS USED 955-159 CORE BIT 105MM INCLUD. 668 955-169 GUIDE PLATE (FOR CORE BIT 105MM) 956-008 CORE BIT SHANK (B) 300L (FOR D25-35) 955-163 CORE BIT SHANK (A) 300L (FOR D38-120) 956-009...

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