Hitachi H 45MRY Technical Data And Service Manual

MODEL
H 45MRY
Hitachi
Power Tools
DEMOLITION HAMMER
H 45MRY
LIST No.: E495
TECHNICAL DATA
AND
SERVICE MANUAL
Oct. 2006
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
H
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
Company Name
Model Name
C
MAKITA
HM0860C
B
BOSCH
GSH5E
CONTENTS
Page
1. PRODUCT NAME ........................................................................................................................... 1
2. MARKETING OBJECTIVE ............................................................................................................. 1
3. APPLICATIONS .............................................................................................................................. 1
4. SELLING POINTS .......................................................................................................................... 2
4-1. Selling Point Descriptions .............................................................................................................. 3
5. SPECIFICATIONS .......................................................................................................................... 5
5-1. Optional Accessories ..................................................................................................................... 6
6. COMPARISONS WITH SIMILAR PRODUCTS ..............................................................................9
6-1. Specification Comparison .............................................................................................................. 9
6-2. Demolition Performance Comparison ............................................................................................ 9
7. PRECAUTIONS IN SALES PROMOTION ...................................................................................10
7-1. Handling Instructions ................................................................................................................... 10
7-2. Grease Replacement ................................................................................................................... 10
7-3. O-ring Replacement ..................................................................................................................... 10
8. REFERENCE INFORMATION ...................................................................................................... 11
8-1. Striking Operation ......................................................................................................................... 11
8-2. Dynamic Damper with Leaf Spring .............................................................................................. 12
8-3. Vibration-proof Handle thanks to the Transatory Unit and the Neidhardt Spring ......................... 12
8-4. Idling-proof Mechanism ............................................................................................................... 13
8-5. Shock-absorbing Mechanism ...................................................................................................... 14
8-6. Sealed and Dustproof Construction ............................................................................................. 14
8-7. Tool Retainer ................................................................................................................................ 15
8-8. Adjusting Mechanism for the Tool Swivel Angle ........................................................................... 15
8-9. Side Handle ................................................................................................................................. 16
9. REPAIR GUIDE ............................................................................................................................17
9-1. Precautions and Suggestions for Disassembly and Reassembly of the Main Body .................... 17
10. STANDARD REPAIR TIME (UNIT) SCHEDULES .....................................................................28
Assembly Diagram for H 45MRY
1. PRODUCT NAME
Hitachi Demolition Hammer, Model H 45MRY
2. MARKETING OBJECTIVE
The Model H 45MRY is an upgraded version of the current Model H 45MR that features the use of maker B's
SDS-max shank tools. The performance, durability and operability are greatly improved. In addition, the vibration
level of the Model H 45MRY is low enough to meet the requirements of the EU Physical Agents (Vibration)
Directive that requires employers to take action to reduce exposure of workers to vibration below the exposure
limit values (enforced in July 2005).
The main features of the Model H 45MRY are as follows:
(1) Lowest vibration level in the class thanks to the dynamic damper with a leaf spring and the new vibrationabsorbing handle
(2) High chipping and demolishing performance with low vibration and noise level
(3) Self-chiseling (Good feeling)
(4) A highly reliable mechanism for prevention of idle hammering and shock-absorbing mechanism results in
prolonged service life and comfortable operation
(5) D-type side handle with adjustable mechanism for 360û rotation plus positioning from front to rear
(6) Soft-touch grip for easier handling
(7) Simply turning method, variable lock mechanism for easy working-angle adjustment of chisels etc.
3. APPLICATIONS
Demolishing and chiseling of concrete
Edging, gravel road digging, compacting and tamping, grooving, cutting, stripping and roughing, etc.
--- 1 ---
4. SELLING POINTS
Lowest vibration level in the class
High chipping and demolishing performance with low vibration and noise level
Self-chiseling (Good feeling)
A highly reliable mechanism for prevention of idle
hammering and shock-absorbing mechanism results
in prolonged service life and comfortable operation.
Newly designed vibrationabsorbing handle
Simply turning method, variable lock mechanism
for easy working-angle adjustment of chisels etc.
Large trigger switch for
comfortable operation
Soft-touch grip for
easier handling
D-type side handle with adjustable mechanism for
360û rotation plus positioning from front to rear
Vibration reduction mechanism
--- 2 ---
4-1. Selling Point Descriptions
4-1-1. Lowest vibration level in the class
The vibration level of the Model H 45MRY is about 50% to 60% lower than the similar products. It is the lowest
vibration level in the class. Therefore, the vibration exposure limit time defined by the EU Physical Agents
(Vibration) Directive is longest in the class.
Maker . Model
Full-load vibration level (Tri-axial)
HITACHI
H 45MRY
HITACHI
H 45MR
C
B
m/sec2
7.7
14.2
14.0
19.2
min
202.4
59.5
61.2
32.6
Vibration exposure limit
4-1-2. High chipping and demolishing performance with low vibration and noise level
The hammering energy is transmitted more efficiently while the vibration level and the full-load noise level are
lowest in the class. The demolishing performance is about 1.2 times higher than the similar products.
Maker . Model
HITACHI
H 45MRY
HITACHI
H 45MR
C
B
%
100
84
87
86
m/sec2
7.7
14.2
14.0
19.2
dB
99
101
103
101
Ratio of demolished weight
Full-load vibration level (Tri-axial)
Full-load noise level
4-1-3. Self-chiseling (Good feeling)
Thanks to the computer-simulated optimum hammering characteristics, the quantity of body jumping is less than
that of the current Model H 45MR, and the working tool smoothly penetrates into the workpiece with a light
pressing force. The Model H 45MRY realizes quicker self-chiseling with better feeling.
Demolished amount
About 20% up
Maximum compressed air force (piston force)
About 32% down
Quantity of body jumping
About 24% down
4-1-4. Vibration reduction mechanism
The Model H 45MRY is equipped with Hitachi's own dynamic damper that absorbs vibration from the main body
by means of resonance of a leaf spring and a spindle. As a result, the vibration level of the Model H 45MRY is
remarkably lower than the current Model H 45MR.
4-1-5. Newly designed vibration-absorbing handle
The Model H 45MRY is equipped with the new vibration-absorbing mechanism based on the same Hitachi's own
vibration-absorbing mechanism as the current Model H 45MR that absorbs vibration by rolling and compressing
the four cylindrical rubber cushions on the inclined surface. In the new vibration-absorbing mechanism, the shaft
fixed to the handle is turned in conjunction with the handle movement and the four cylindrical rubber cushions are
rolled and compressed to absorb vibration more efficiently. The cushion effect not only greatly reduces vibration
but also maintains good operability.
--- 3 ---
4-1-6. A highly reliable mechanism for prevention of idle hammering and shock-absorbing mechanism results in
prolonged service life and comfortable operation
The Model H 45MRY 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 the slide sleeve provided around the cylinder that interlocks
with the tool and the second hammer to prevent idle hammering. This mechanism securely prevents idle
hammering even in wall hammering works or even if a tool that can cause great rebound on the striker such as a
cutter is used. Thanks to the highly reliable mechanism for prevention of idle hammering, the service life of the
Model H 45MRY is prolonged and hammering works requiring much attention not to break the surroundings can
be efficiently performed with the Model H 45MRY.
At the moment of releasing the bull point from the concrete by moving the main body up, the second hammer
contacts hammer holder (A) and the cushion (damper (A)) provided between hammer holder (A) and the front
cover absorbs the hammering force of the second hammer. Thus the Model H 45MRY has greater durability than
the similar products.
4-1-7. D-type side handle with adjustable mechanism for 360û rotation plus positioning from front to rear
The D-type side handle can be adjusted by 360û rotation and also allows convenient operation from front to rear.
This side handle has a two-layer plastic construction (integral molding) made of nylon resin as the base and soft
resin around it for a comfortable cushion grip.
4-1-8. Soft-touch grip for easier handling
The double-layer molded handle consists of a nylon resin base covered with a soft plastic layer to ensure a soft
touch and firm, non-slip grip of the handles.
4-1-9. Simply turning method, variable lock mechanism for easy working-angle adjustment of chisels, etc.
The tool swivel angle can be easily changed in 12 steps by pushing out grip (B) ahead and then turning grip (A).
--- 4 ---
5. SPECIFICATIONS
Power source
Single-phase AC 50/60 Hz
Voltage
110 V, 230 V
Motor type
AC single-phase series commutator motor
Insulation structure
Double insulation
Enclosure
Materials: Aluminum alloy die casting (Cylinder crank case)
Nylon resin (Handle, tail cover, back cover, hood, crank cover)
Polycarbonate resin (Housing)
Paint: Green, gunmetallic silver, black, silver
Switch
Trigger switch (with stopper)
Type of handles
D-shaped handle and side handle
Full-load current
9.1A (110 V), 4.4 A (230 V)
Power input
950 W
Striking speed
No-load: 4,000 min-1
Full-load: 3,000 min-1
Weight
Product: 5.9 kg (13.0 lbs.); Excluding cord and side handle
Packed: 12.4 kg (27.3 lbs.)
Packaging
Standard accessories
Corrugated cardboard box with plastic tool case
Bull point 280 mm (11-1/32")
Side handle
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Plastic tool case
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
--- 5 ---
1 pc.
1 pc.
1 pc.
5-1. Optional Accessories
(1) Demolishing work
+
(1) Bull point (SDS-max shank type)
Overall length
Code No.
280 mm (11-1/32")
313471
400 mm (15-3/4")
313472
(2) Grooving and chiseling work
+
(1) Cold chisel (SDS-max shank type)
Overall length
Code No.
280 mm (11-1/32")
313473
400 mm (15-3/4")
313474
(3) Cutting and stripping work (Asphalt cutting etc.)
+
(1) Cutter (SDS-max shank type)
Width
50 mm (2")
Overall length
400 mm (15-3/4")
--- 6 ---
Code No.
313475
(4) Digging (Substitute pick-ax)
+
(1) Scoop (SDS-max shank type)
Overall length
Code No.
400 mm (15-3/4")
313476
(5) Roughing surface work
+
+
(1) Bushing tool
(2) Shank (SDS-max shank type)
Code No.
Overall length
Code No.
313477
220 mm (8-21/32")
313479
(6) Tamping work
+
(1) Rammer
+
(2) Shank (SDS-max shank type)
Code No.
Overall length
Code No.
313478
220 mm (8-21/32")
313479
150 mm x 150 mm
--- 7 ---
(7) Grease for hammer and hammer drill
500 g (1.1 lbs.) Can
70 g (2.5 oz) Tube
30 g (1 oz) Tube
Code No. 980927
Code No. 308471
Code No. 981840
NOTE: Code numbers listed above are subject to change without notice. Please refer to periodic
Technical News Bulletins.
--- 8 ---
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparison
HITACHI
Maker
Model name
H 45MRY
H 45MR
C
B
Power input
W
950
950
1,100
1,100
Striking energy per stroke
J
12.7
12.5
1.8 to 12.0
2.0 to 12.0
3,000
3,000
m/sec
7.7
14.2
14.0
19.2
min
202.4
59.5
61.2
32.6
dB
99
475
(18-45/64")
230
(9-1/6")
104
(4-3/32")
5.9
(13.0 lbs.)
Double
insulation
101
454
(17-7/8")
230
(9-1/16")
106
(4-11/64")
5.9
(13.0 lbs.)
Double
insulation
103
454
(17-7/8")
223
(8-25/32")
99
(3-57/64")
4.7
(10.4 lbs.)
Double
insulation
101
min-1
Full-load impact rate
Full-load vibration level (Tri-axial)
2
Vibration exposure limit
Full-load noise level
Dimensions
Length
mm
Height
mm
Width
mm
Weight (without cord and side handle)
kg
Insulation structure
1,100 to 2,650 1,300 to 3,000
450
(17-23/32")
230
(9-1/16")
102
(4-1/64")
5.5
(12.1 lbs.)
Double
insulation
Vibration reduction mechanism
Vibration-absorbing handle
6-2. Demolition Performance Comparison
The data shown in Fig. 1 are obtained in actual factory tests, and are for reference only. Demolished amount may
vary in accordance with operating conditions, operator skill, etc.
Demolished amount (kg/30 min.)
0
40
20
Demolished weight
for 30 min. (kg)
H 45MRY
H 45MR
78.0
65.6
At rated
voltage
C
67.8
B
67.4
Fig. 1
--- 9 ---
100
80
60
7. PRECAUTIONS IN SALES PROMOTION
In the interest of promoting the safest and most efficient use of the Model H 45MRY Demolition 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.
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 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 Demolition Hammer are listed in the Handling Instructions to enhance the safe, efficient use of
the tool by the customer. Salespersons must be thoroughly familiar with the contents of the Handling Instructions
to be able to offer appropriate guidance to the customer during sales promotion.
7-2. Grease Replacement
The striking portion and the speed reduction portion of the Model H 45MRY respectively use different types of
grease. Grease replacement is required if the unit is disassembled for maintenance or O-rings become damaged
and worn as described in 7-3. The striking portion uses special grease. If the striking portion (inside the cylinder
crank case) is disassembled, thoroughly remove all of the old grease from each part. On reassembly, fill 27.0 g
(0.9 oz) of new grease in the crank case (connecting rod side). Do not exceed the designated amount of grease.
Excessive grease may cause reduced striking performance.
The speed reduction portion (inside the gear cover) uses Hitachi Motor Grease No. 29 (Code No. 930035).
The proper supply volume is 20 g (0.7 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.
7-3. O-ring Replacement
The O-rings (mounted on the striker and the piston) are extremely important to ensure adequate sealing of the air
pressure. Although the O-rings are made of special rubber to give them a long service life, they do nonetheless
become worn, and should be replaced by new ones periodically depending on frequency of use of the tool.
With average use, it is recommended that the O-rings be replaced at least every six months to ensure maximum
effectiveness.
--- 10 ---
8. REFERENCE INFORMATION
Structure:
Second hammer
Striker
Connecting rod
O-rings
Crank cover
Crank shaft
Cylinder
Air chamber
Piston
Armature
Fig. 2
8-1. Striking Operation
The rotation of the armature is transferred to the crank shaft and the 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 striker causes the striker to continuously 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 the piston play an extremely important role in
sealing air within the air chamber.
--- 11 ---
Vibration of
the main body
8-2. Dynamic Damper with Leaf Spring
Vibration of
the weight
The vibration caused by hammering operation of the
Model H 45MRY is transmitted to the cylinder crank
case, back cover, housing and finally to the weight
through the leaf spring supporting portion. Then the
weight moves in the reverse direction of the
transmitted vibration to negate the vibration of the
Vibration of
the main body
main body (Fig. 3).
Vibration of
the weight
Fig. 3
8-3. Vibration-proof Handle thanks to the Transatory Unit and the Neidhardt Spring
The Model H 45MRY has the vibration-proof handle equipped with the transatory unit and the Neidhardt spring.
Structure of the transatory unit
The main body (cylinder crank case) is connected to
Cylindrical rubbers
(handle damper: 4 pcs.)
the upper handle through four cylindrical rubbers
Handle damper
retaining material
(handle side)
(handle dampers). These rubbers are rolled and
compressed on the inclined surface to absorb the
Slotted groove
vibration. Since the transatory unit has nonlinear
spring characteristics, the spring constant is lower
Cylindrical
convex
than the conventional shearing type vibrationproofing structure. Thus the Model H 45MRY can
provide high vibration-proofing effect with good
cushioning properties. The joint of the slotted groove
and the cylindrical convex is provided at the center to
Handle damper retaining material
(Cylinder crank case)
prevent the handle from being pulled out by twisting
or pulling in hammering operation (Fig. 4).
Vibration
proof rubbers
Handle side
Rolled and compressed
Pressing force
of the main
body
Main body side
(a) At no-load
Fig. 4
--- 12 ---
Reaction
(b) At full-load
Structure of the Neidhardt spring
Compressed by turning
The main body (back cover) is connected to the
lower handle through four cylindrical rubbers (handle
dampers). The shaft fixed to the handle is turned in
Turning direction
of the handle
conjunction with the handle movement and the
rubbers are rolled and compressed to absorb the
vibration. The Neidhardt spring prevents the handle
from moving horizontally. Thus the Model H 45MRY
can provide high vibration-proofing effect without
Rebound
hindering the operability by twisting. In addition, the
handle is prevented from being pulled out (Fig. 5).
Fig. 5
8-4. Idling-proof Mechanism
When the bull point is released from the concrete surface, the slide sleeve and the second hammer are forcibly
moved to the position illustrated in Fig. 6 by spring (B), and the striker moves out of striking position. When this
occurs, the air holes located at the position unaffected by the rebound of the striker at no load are opened and the
pressure within the air chamber remains unchanged even though the piston continues to reciprocate, thereby
preventing striking operation.
Slide sleeve
Second hammer
Striker
Spring (B)
Forward movement of
second hammer & striker
Air chamber
Air hole
Fig. 6
--- 13 ---
8-5. Shock-absorbing Mechanism
At the instance of releasing the bull point from the concrete by moving the main body up, the second hammer
contacts hammer holder (A) as shown in Fig. 7 then the cushion (damper (A)) provided between hammer holder
(A) and the front cover absorbs the striking force of the second hammer. Thus the durability of the Model
H 45MRY is greatly increased because the second hammer does not strike the tool retainer directly.
Second hammer
Hammer holder (A)
Damper (A)
Fig. 7
8-6. Sealed and Dustproof Construction
The cylinder crank case is sealed by five O-rings and an oil seal which serve to prevent leakage of the grease, as
well as to prevent dust and dirt from entering the mechanism (Fig. 8).
Front cover
Retainer sleeve
O-ring
O-ring
O-ring
Cylinder crank case
Vibration absorbing unit
O-ring
Oil seal
O-ring
Housing
Vibration absorbing unit
Fig. 8
--- 14 ---
Switch handle
8-7. Tool Retainer
The Model H 45MRY is equipped with a slide-type tool retainer. Tools can be attached and detached just by
pulling grip (A). While pulling grip (A) in A direction, insert the tool in the hole of the front cap (Fig. 9). Adjust the
groove position by turning the tool and push it in to the end. Lock the tool by returning grip (A) back to the original
position.
Grip (A)
A
Tool shank
Front cap
Fig. 9
8-8. Adjusting Mechanism for the Tool Swivel Angle
The tool swivel angle can be easily changed in 12 steps. The tool swivel angle can be set freely to the desired
position by pushing out grip (B) ahead in A direction and then turning grip (A) in B (Fig. 11).
B
A
Grip (A)
Grip (B)
Fig. 10
--- 15 ---
8-9. Side Handle
The side handle can be adjusted by 360û rotation and also allows operation from front to rear. Loosen the handle
by turning the grip in A direction and adjust the handle to a convenient position. Turn the grip in B direction to
fix the side handle (Fig. 11).
Grip
Fig. 11
--- 16 ---
9. REPAIR GUIDE
9-1. Precautions and Suggestions for Disassembly and Reassembly of the Main Body
The numbers in [Bold] correspond to the item numbers in the Parts List and the exploded assembly diagrams of
the Model H 45MRY.
9-1-1. Disassembly
Retainer disassembly (See Figs. 12 and 13.)
Pull Grip (A) [2] fully in the arrow direction as
shown in Fig. 12 and remove the Front Cap [1]
(since the Front Cap [1] is made of rubber and
engaged firmly with the Retainer Sleeve [16], pull
it strongly to remove). This allows Grip (A) [2] to
be separated from the Retainer Sleeve [16].
Grip (A) [2]
Front Cap [1]
Fig. 12
Ball holder
Needle roller D8 x 20
(2 pcs.)
Grip (B)
Spring (A)
Grip (C)
Ring
Front cover
Needle holder
Steel ball (4 pcs.)
Retainer sleeve
Retaining ring
Fig. 13
Remove the Ring [3] by means of a snap ring remover, then the Needle Holder [4], two Needle Rollers
D8 x 20 [15] and Spring (A) [5] can be removed from the Retainer Sleeve [16]. Remove the Retaining Ring
D42 [6] by means of a snap ring remover, then the Ball Holder [7], Grip (B) [8] and four Steel Balls D6.35 [10]
can be removed from the Front Cover [12]. Furthermore, remove the Retaining Ring D42 [6] by means of a
snap ring remover, then Grip (C) [9] can be removed from the Front Cover [12] (Fig. 13).
--- 17 ---
Removal of hammer holder (A), damper (A) and retainer sleeve
Remove the Seal Lock Hex. Socket Hd. Bolt M6 x 25 [11] from the Front Cover [12]. Then the Front Cover
[12] and the Retainer Sleeve [16] can be removed from the Cylinder Crank Case [47]. Insert a small flat-blade
screwdriver into the groove of the Front Cover [12] and remove Ring (B) [20]. Then Hammer Holder (A) [18]
and Damper (A) [17] can be removed from the Front Cover [12]. Remove the Ring [3] to remove the Retainer
Sleeve [16] from the Front Cover [12] (Fig. 14).
Front cover
Ring (B)
Front cover
Ring
Groove
Retainer sleeve
Hammer holder (A)
Damper (A)
Fig. 14
Fig. 15
Removal of the piston and the striker
Remove the Seal Lock Hex. Socket Hd. Bolt M6 x 25 [11] from the Front Cover [12]. Then the Front Cover
[12], Retainer Sleeve [16], Second Hammer [21], Hammer Holder (B) [24], Damper (B) [25], Hammer Holder
(C) [27], Damper (C) [22] and Sleeve (A) [23] can be removed from the Cylinder Crank Case [47].
The Cylinder [30], Striker [28], Slide Sleeve [31] and Spring (B) [32] are remained in the Cylinder Crank Case
[47]. Lightly tap the Front Cover [12] side of the Cylinder Crank Case [47] with a plastic hammer to remove
the Cylinder [30]. Then the Slide Sleeve [31] and Spring (B) [32] can be removed from the Cylinder Crank
Case [47]. The Striker [28] can be removed by tapping the Cylinder [30] lightly with a plastic hammer.
The Piston [35] is remained in the Cylinder Crank Case [47]. Remove the Seal Lock Hex. Socket Hd. Bolt
M5 x 16 [39] from the Crank Cover [40] to remove the Crank Cover [40] from the Cylinder Crank Case [47].
Remove the Retaining Ring for D10 Shaft [37] using a retaining ring puller and remove the Connecting Rod
[36] from the Crank Shaft [42].
--- 18 ---
Removal of the first gear and the crank shaft
Degrease the Connecting Rod [36] side and the First Gear [60] side of the Cylinder Crank Case [47]. Place
the Cylinder Crank Case [47] on a workbench facing the Connecting Rod [36] side downward. Apply light
pressure on the end surface of the Crank Shaft [42] with a hand press and pull out the Retaining Ring for D40
Hole [43] that fixes the Ball Bearing 6203DDCMPS2L [45] from the groove of the Cylinder Crank Case [47].
Before removal, move the crank pin of the Crank Shaft [42] as shown in Fig. 16 so that the hole of the
Retaining Ring for D40 Hole [43] can be seen.
Crank Shaft
Cylinder crank case
Hole of the Retaining
Ring for D40 Hole [43]
Fig. 16
Place the Cylinder Crank Case [47] on a workbench facing the Connecting Rod [36] side downward. Apply
light pressure on the end surface of the Crank Shaft [42] with a hand press to remove the First Gear [60] and
the Crank Shaft [42] (Fig. 17). Before removal, be sure to check that the Retaining Ring for D40 Hole [43] is
removed from the groove of the Cylinder Crank Case [47].
Apply pressure on the
end surface of the crank
shaft with a hand press.
Cylinder crank case
Crank shaft
First gear
Retaining ring for D40 hole
Workbench
Fig. 17
--- 19 ---
9-1-2. Reassembly
Reassembly can be accomplished by following the disassembly procedure in reverse. However, special attention
should be given to the following items.
Mounting hammer holder (A)
Set the Retainer Sleeve [16], O-ring (S-34) [14],
Proper jig
Damper (A) [17] and Hammer Holder (A) [18] in the
Front Cover [12]. Supporting the flange portion of the
Ring (B)
Front Cover [12] with a proper jig, lightly push in Ring Damper (A)
O-ring
(B) [20] using a proper jig of 44 mm outside dia. and
a hand press. At this time, check that Ring (B) [20] is
fitted in the groove of the Front Cover [12] securely
Hammer holder (A)
Front cover
(Fig. 18).
Retainer sleeve
Fig. 18
Mounting the first gear and the crank shaft
Mount the O-ring (S-40) [44] to the Cylinder Crank Case [47]. Press-fit the Ball Bearing 6203DDCMPS2L [45]
and mount the Retaining Ring for D40 Hole [43] using a retaining ring puller. Press-fit the Crank Shaft [42] in
the Ball Bearing 6203DDCMPS2L [45] and mount the Oil Seal [46]. Put one Feather Key 4 x 4 x 10 [38] in the
groove of the Crank Shaft [42]. Supporting the flat portion of the Crank Shaft [42] with a proper steel bar,
press-fit the First Gear [60] with a proper jig. Before press-fitting, check that the key groove of the Feather Key
4 x 4 x 10 [38] is aligned with the key groove of the First Gear [60] (Fig. 19).
Feather key
Suitable tool
First gear
Oil seal
Ball bearing
O-ring
Retaining ring for D40 hole
Crank shaft
Steel bar
Cylinder crank case
Fig. 19
--- 20 ---
Mounting the piston
Insert the Piston Pin [34] into the 8-mm dia. hole (marked) of the Piston [35] and the Connecting Rod [36]
then press-fit it. Mount the O-ring (I.D 27.2) [33] to the Piston [35]. At this time, do not protrude the Piston Pin
[34] from the outside of the Piston [35]. Move the crank pin of the Crank Shaft [42] to the bottom dead center
and insert the piston ass'y into the Crank Shaft [42] from the cylinder case of the Cylinder Crank Case [47].
Mount the Retaining Ring for D10 Shaft [37] using a retaining ring puller (Fig. 20).
Piston pin
Retaining ring
Connecting rod
D8 hole
Crank pin portion
Mark
Crank shaft
O-ring
Piston
Cylinder crank case
Fig. 20
Mounting the cylinder
Insert the concave side of the Slide Sleeve [31] into the Cylinder [30]. Insert the assembly of the Striker [28]
and the O-ring (I.D 27.2) [29] into the Cylinder [30] (Fig. 21).
Concave
Slide sleeve
Striker
O-ring
Fig. 21
--- 21 ---
Cylinder
Move the crank pin of the Crank Shaft [42] then move the Piston [35] to the top dead center. Insert Spring (B)
[32] into the cylinder case of the Cylinder Crank Case [47] then insert the assembly of the Cylinder [30], Slide
Sleeve [31] and Striker [28] into the Cylinder Crank Case [47] (Fig. 22).
Spring (B)
Striker
Piston
Cylinder
Crank pin portion
Crank shaft
Slide sleeve
Cylinder crank case
Fig. 22
Mounting the fan guide
Mount the Fan Guide [106] to the Housing Ass'y [114] paying attention to the direction of the 0.05 convex line
(Fig. 23).
0.05 convex line
Fan guide
Housing ass'y
Fig. 23
--- 22 ---
Mounting the handle shaft and handle (A)
Push the Holder [88] in the Back Cover [76] by hand. At this time, check that the clearance of the Holder [88]
does not protrude from the main body and the Holder [88] does not protrude from the end surface of the Back
Cover [76]. Check that the convex mark of the Back Cover [76] aligns with the convex mark of the Handle
Shaft [87]. Then mount the Handle Shaft [87] and push the four Handle Dampers [86] in the clearances
between the Holder [88] and the Handle Shaft [87] by hand being careful not to protrude the Handle Dampers
[86] from the end surface of the Back Cover [76] (Fig. 24).
Convex mark
Holder
Holder damper
Handle shaft
Clearance
Fig. 24
To mount Handle (A).(B) Set [81], turn the Handle Shaft [87] by about 10û and fit the Transatory Unit [90] and
the Handle Shaft [87] in Handle (A).(B) Set [81] together.
--- 23 ---
Mounting the leaf spring
Sandwich the Leaf Spring [51] between Weight
(A) [59] and Weight (B) [58] and fix it with the
Leaf spring
Seal Lock Hex. Socket Hd. Bolt M5 x 22 [56].
Weight (B)
Sufficiently degrease the adhering surface of
Weight (A)
Weight (B) [58] and adhere Rubber Sheet (C)
[57] securely. Be careful that the Leaf Spring [51]
is curved to Weight (B) [58]. At this time, do not
misalign Weight (A) [59] and Weight (B) [58],
and do not turn the Leaf Spring [51] (Fig. 25).
Seal lock hex. socket
hd. bolt M5 x 22
Rubber sheet (C)
Curved portion
Fig. 25
Mount the Spring Base [115] to the Housing Ass'y [114] being careful of the mounting direction. Mount one
Needle Roller [55] to the Cylinder Crank Case [47] and three Needle Rollers [55] to the Spring Base [115].
Before mounting, apply grease to the Needle Rollers [55] to avoid being removed (Fig. 26).
Cylinder crank case
Needle roller
Leaf spring
Spring base
Needle roller
Needle roller
Fig. 26
--- 24 ---
Mount the assembly of the Leaf Spring [51], Weight (A) [59] and Weight (B) [58] to the Cylinder Crank Case
[47]. Then mount Spring Bumper (A) [52] and Washer M4.5 [53] to the Cylinder Crank Case [47] in this order
and fix it with the Seal Lock Hex. Socket Hd. Bolt M4 x 10 [54]. At this time, check that the Leaf Spring [51] is
fitted in the center of the Needle Rollers [55] mounted to the Spring Base [115] and the Leaf Spring [51] is
curved to the housing.
Apply grease to Spring Bumper (B) [75] and mount it to the Back Cover [76] being careful of the mounting
direction. To replace Rubber Sheet (A) [74], sufficiently degrease the adhering surface of the Back Cover [76]
and adhere Rubber Sheet (A) [74] securely.
Mount the Back Cover [76] to the Cylinder Crank Case [47] and the Housing Ass'y [114]. At this time, check
that Spring Bumper (B) [75] and Rubber Sheet (A) [74] are adhered and the Needle Rollers [55] are mounted
to the Cylinder Crank Case [47] and the Spring Base [115] (Fig. 27).
Spring bumper (A)
Needle roller
Washer
Seal lock hex. socket
hd. bolt M4 x 10
Rubber sheet (A)
Spring bumper (B)
Leaf spring
Spring base
Fig. 27
--- 25 ---
Lubrication
Apply special grease (grease for hammer and hammer drill) to the inner circumference of the Connecting Rod
[36], O-rings (I.D 27.2) [29] in the Striker [28] and in the Piston [35], outer circumference of the Retainer
Sleeve [16], sliding portion of the Second Hammer [21], Oil Seal [46], Damper (A) [17], Damper (B) [25],
Damper (C) [22], inner circumference of the Slide Sleeve [31], Hammer Holder (B) [24], Hammer Holder (C)
[27], and the end surface of Spring (A) [5]. Seal 27 g of the special grease into the Cylinder Crank Case [47]
(the Connecting Rod [36] side).
Apply Hitachi Motor Grease No. 29 to the Needle Bearing (M661) [61], pinion portion of the Armature Ass'y
[67], Needle Roller D8 x 20 [15] and Steel Ball D6.35 [10]. Seal 20 g of the Hitachi Motor Grease No. 29 into
the Cylinder Crank Case [47] (the First Gear [60] side).
Oil seals
Be very careful not to damage the O-ring (1AS-50) [13] on the Front Cover [12], O-ring (S-34) [14] in the Front
Cover [12], O-ring (S-25) [19] in Hammer Holder (A) [18], O-ring [41] in the Crank Cover [40], O-rings (I.D
27.2) [29] in the Striker [28] and in the Piston [35], O-ring (S-40) [44] and Oil Seal [46] in the Cylinder Crank
Case [47], and O-ring (S-32) [63] in the Gear Cover Ass'y [62].
9-1-3. Screw locking agent TB1401
Apply screw locking agent TB1401 to all hex. socket hd. bolts M4, M5 and M6.
CAUTION: If bolts are loosened by vibration, they could cause damage to the hammer body. Ensure
without fail that screw locking agent is applied to the threaded portions of the bolts prior to
reassembly.
9-1-4. Tightening torque
13.7
1.96 N.m (140
(2) Tapping screw D4
1.96
0.49 N.m (20
5 kgf.cm, 17.4
4.3 in-lbs.)
(3) Tapping screw D5
2.94
0.49 N.m (30
5 kgf.cm, 26.0
4.3 in-lbs.)
(4) Hex. socket hd. bolts M6 x 45
9.8
0.98 N.m (100
10 kgf.cm, 86.8
(1) Attached bolts of the front cover
20 kgf.cm, 121.5
17.4 in-lbs.)
(Hex. socket hd. bolts M6 x 25)
(5) Attached bolts of the crank cover
7.84
+1.96
0
N.m (80
+20
0
8.7 in-lbs.)
+17.4
kgf.cm, 69.4 0 in-lbs.)
(Hex. socket hd. bolts M5 x 16)
(6) Attached bolts of the handle
4.9
+1.96
0
N.m (50
+20
0
kgf.cm, 43.4 +17.4
0 in-lbs.)
(Hex. socket hd. bolts M5 x 12)
(7) Attached bolts of the back cover
3.92
0.49 N.m (40
5 kgf.cm, 34.7
4.3 in-lbs.)
(Hex. socket hd. bolts M5 x 30
(8) Attached bolts of the leaf spring
7.84 +1.96
N.m (80 +200 kgf.cm, 69.4 +17.4
0 in-lbs.)
0
(Hex. socket hd. bolts M5 x 22)
(9) Attached bolts of the hood
3.92
0.49 N.m (40
5 kgf.cm, 34.7
4.3 in-lbs.)
4.41
0.49 N.m (45
5 kgf.cm, 39.1
4.3 in-lbs.)
(Hex. socket hd. bolts M5 x 12)
(10) Attached bolts of the leaf spring
(Hex. socket hd. bolts M4 x 10)
--- 26 ---
9-1-5. Internal wiring
Wiring diagram for products with noise suppressor
9-1-6. Insulation tests
On completion of disassembly and repair, measure the insulation resistance and the dielectric strength.
Insulation resistance: 7 M Ω or more with DC 500 V megohm tester
Dielectric strength: AC 4,000 V/1 minute, with no abnormalities
• • • • • • •
220 V --- 240 V
(and 110 V for U.K. products)
9-1-7. No-load current value
After no-load operation for 30 minutes, the no-load current value should be as follows:
Voltage (V)
110
230
Current (A) (Max.)
3.8
2.1
--- 27 ---
10. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL
Variable
Fixed
10
20
30
40
50
60 min.
Work Flow
H 45MRY
Housing Ass'y
Stator Ass'y
Handle (A).(B)
Set
Transatory Unit
Switch (B)
Cord
Handle Damper
Handle Damper
Handle Shaft
Holder
Gear Cover
Ass'y
Needle
Bearing (A)
Armature Ass'y
Ball Bearing
(6201DD)
Ball Bearing
(608VV)
Dust Washer (B)
Washer (A)
Bearing Holder
O-ring
Tail Cover
Crank Cover
O-ring
General Assembly
Front Cap
Grip (A)
Needle Holder
Ball Holder
Grip (B)
Grip (C)
Back Cover
Leaf Spring
Spring Bumper
(A)
Rubber
Front Cover
Sheet (C)
O-ring
Weight (B)
O-ring
Weight (A)
Retainer Sleeve Spring Bumper
Spring (A)
(B)
Damper (A)
Hammer
Holder (A)
O-ring
Second Hammer
Damper (B)
Damper (A)
Hammer
Holder (B)
Hammer
Holder (C)
Striker
O-ring
Piston
Piston Pin
Connecting Rod
O-ring
--- 28 ---
Crank Shaft
Cylinder Crank
Case
Feather Key
Ball Bearing
(6203DD)
Oil Seal
First Gear
O-ring
Cylinder Sleeve
Spring (B)
Cylinder
Hitachi Power Tools
LIST NO. E495
ELECTRIC TOOL PARTS LIST
HAMMER
Model H 45MRY
2006
8•3
•
(E1)
1
2
39
8
3
6
501
40
4
9
5
3
41
37
6
10
502
7
11
12
17
13
42
14
18
38
15
19
16
20
43
21
22
44
23
29
24
30
45
25
46
27
31
28
47
32
33
51
48
34
52
35
53
36
55
49
68
50
60
54
56
57
73
58
61
69
59
74
70
62
106
77
71
A
78
79
70
63
107
64
108
65
69
109
83
80
75
82
66
110
76
72
67
111
112
81
89
113
90
91
114
83
82
93
92
83
115
88
82
118
87
86
99
83
119
A
97
85
116
104
98
82
117
100
105
96
95
55
120
122
94
121
103
102
101
PARTS
ITEM
NO.
1
H 45MRY
CODE NO.
NO.
USED
DESCRIPTION
315-529
FRONT CAP
1
2
320-802
GRIP (A)
1
3
320-803
RING
2
4
320-804
NEEDLE HOLDER
1
5
320-806
SPRING (A)
1
6
317-088
RETAINING RING D42
2
7
320-810
BALL HOLDER
1
8
320-807
GRIP (B)
1
9
320-808
GRIP (C)
1
10
959-150
STEEL BALL D6.35 (10 PCS.)
4
11
981-942
SEAL LOCK HEX. SOCKET HD. BOLT M6X25
4
12
326-494
FRONT COVER
1
13
990-067
O-RING (1AS-50)
1
14
980-879
O-RING (S-34)
1
15
313-421
NEEDLE ROLLER D8X20
2
16
320-805
RETAINER SLEEVE
1
17
322-528
DAMPER (A)
1
18
326-379
HAMMER HOLDER (A)
1
19
319-572
O-RING (S-25)
1
20
326-380
RING (B)
1
21
326-381
SECOND HAMMER
1
22
326-662
DAMPER (C)
1
23
326-495
SLEEVE (A)
1
24
320-814
HAMMER HOLDER (B)
1
25
320-815
DAMPER (B)
1
27
326-382
HAMMER HOLDER (C)
1
28
326-383
STRIKER
1
29
325-297
O-RING (I.D 27.2)
1
30
326-496
CYLINDER
1
31
326-497
SLIDE SLEEVE
1
32
326-498
SPRING (B)
1
33
325-297
O-RING (I.D 27.2)
1
34
324-917
PISTON PIN
1
35
326-384
PISTON
1
36
326-385
CONNECTING ROD
1
37
939-540
RETAINING RING FOR D10 SHAFT (10 PCS.)
1
38
930-511
FEATHER KEY 4X4X10
1
39
990-079
SEAL LOCK HEX. SOCKET HD. BOLT M5X16
4
40
326-500
CRANK COVER
1
41
326-501
O-RING
1
42
326-499
CRANK SHAFT
1
43
948-391
RETAINING RING FOR D40 HOLE
1
44
996-363
O-RING (S-40)
1
45
620-3DD
BALL BEARING 6203DDCMPS2L
1
46
310-119
OIL SEAL
1
47
326-502
CYLINDER CRANK CASE
1
48
986-940
SEAL LOCK HEX. SOCKET HD. BOLT M6X45
4
49
998-471
HEX. SOCKET HD. BOLT (W/FLANGE) M5X12
1
50
326-503
HOOD
1
51
326-386
LEAF SPRING
1
52
326-375
SPRING BUMPER (A)
1
--- 2 ---
* ALTERNATIVE PARTS
REMARKS
8 -- 06
PARTS
ITEM
NO.
53
H 45MRY
CODE NO.
NO.
USED
DESCRIPTION
326-477
WASHER M4.5
1
54
878-356
SEAL LOCK HEX. SOCKET HD. BOLT M4X10
1
55
878-418
NEEDLE ROLLER
4
56
317-245
SEAL LOCK HEX. SOCKET HD. BOLT M5X22
1
57
326-515
RUBBER SHEET (C)
1
58
326-508
WEIGHT (B)
1
59
326-507
WEIGHT (A)
1
60
320-830
FIRST GEAR
1
61
939-299
NEEDLE BEARING (M661)
1
62
326-510
GEAR COVER ASS’Y
1 INCLUD. 61
63
872-767
O-RING (S-32)
1
64
620-1DD
BALL BEARING 6201DDCMPS2L
1
65
302-429
DUST WASHER (B)
1
66
321-640
FAN
1
*
67
360-571C ARMATURE ASS’Y 110V
1 INCLUD. 66
*
67
360-571E
1 INCLUD. 66
ARMATURE ASS’Y 220V-230V
68
317-107
BOLT M8
1
69
317-106
HANDLE HOLDER (B)
2
70
317-105
HANDLE HOLDER (A)
2
71
320-635
BAND
1
72
317-108
GRIP
1
73
317-103
SIDE HANDLE ASS’Y
1 INCLUD. 68-72
74
326-487
RUBBER SHEET (A)
1
75
326-376
SPRING BUMPER (B)
1
76
326-505
BACK COVER
1
77
326-378
BELLOWS
1
78
306-061
SEAL LOCK HEX. SOCKET HD. BOLT M5X30
2
NAME PLATE
1
80
302-089
TAPPING SCREW (W/FLANGE) D5X20 (BLACK)
4
81
326-485
HANDLE (A).(B) SET
1
82
991-711
DISTANCE PIECE (B)
4
83
991-690
SEAL LOCK HEX. SOCKET HD. BOLT M5X12
4
85
307-028
TAPPING SCREW (W/FLANGE) D4X25 (BLACK)
3
86
310-124
HANDLE DAMPER
4
87
326-377
HANDLE SHAFT
1
88
326-479
HOLDER
1
89
310-124
HANDLE DAMPER
4
90
310-123
TRANSATORY UNIT
1
91
306-143
SWITCH (B) (1P SCREW TYPE) W/LOCK
1
92
949-423
WASHER M4 (10 PCS.)
1
93
980-063
TERMINAL
1 FOR CORD
94
326-541
VINYL TUBE (I.D.9.5XT0.56X85)
1
95
326-509
INTERNAL WIRE L75
1
96
325-566
NOISE SUPPRESSOR
1
97
317-492
SUPPORT (B)
1
98
994-190
INTERNAL WIRE
1
99
984-750
TAPPING SCREW (W/FLANGE) D4X16
2
* 100
960-266
CORD CLIP
1
* 100
981-987Z
CORD CLIP
1 FOR SUI
101
959-140
CONNECTOR 50091 (10 PCS.)
1
102
938-307
PILLAR TERMINAL
1
79
*
8 -- 06
* ALTERNATIVE PARTS
REMARKS
--- 3 ---
PARTS
ITEM
NO.
103
H 45MRY
CODE NO.
959-141
NO.
USED
DESCRIPTION
CONNECTOR 50092 (10 PCS.)
1
REMARKS
104
953-327
CORD ARMOR D8.8
1
*
105
500-390Z
CORD
1 (CORD ARMOR D8.8)
*
105
500-454Z
CORD
1 (CORD ARMOR D8.8) FOR GBR (110V)
*
105
500-446Z
CORD
1 (CORD ARMOR D8.8) FOR GBR (230V)
*
105
500-391Z
CORD
1 (CORD ARMOR D8.8) FOR SUI
106
321-320
FAN GUIDE
1
HEX. HD. TAPPING SCREW D5X55
107
953-174
*
108
340-681C STATOR ASS’Y 110V
1 INCLUD. 109
2
*
108
340-681E
STATOR ASS’Y 220V-230V
1 INCLUD. 109
109
930-703
BRUSH TERMINAL
2
110
930-804
TERMINAL M4.0 (10 PCS.)
1
111
982-631
WASHER (A)
1
112
608-VVM
BALL BEARING 608VVC2PS2L
1
113
326-484
BEARING HOLDER
1
114
326-481
HOUSING ASS’Y
1
115
326-506
SPRING BASE
1
116
935-829
BRUSH CAP
2
117
999-073
CARBON BRUSH (AUTO STOP TYPE) (1 PAIR)
2
118
971-001
BRUSH HOLDER
2
119
938-477
HEX. SOCKET SET SCREW M5X8
2
120
326-504
TAIL COVER
1
121
302-089
TAPPING SCREW (W/FLANGE) D5X20 (BLACK)
2
122
326-488
COVER (A)
1
STANDARD ACCESSORIES
ITEM
NO.
501
502
CODE NO.
NO.
USED
DESCRIPTION
313-471
BULL POINT (SDS MAX) 280L
1
326-511
CASE (PLASTIC)
1
REMARKS
OPTIONAL ACCESSORIES
ITEM
NO.
601
CODE NO.
DESCRIPTION
NO.
USED
981-840
GREASE (A) FOR HAMMER. HAMMER DRILL (30G)
1
602
308-471
GREASE FOR HAMMER. HAMMER DRILL (70G)
1
603
980-927
GREASE FOR HAMMER. HAMMER DRILL (500G)
1
604
313-472
BULL POINT (SDS MAX) 400L
1
605
313-473
COLD CHISEL (SDS MAX) 280MM
1
606
313-474
COLD CHISEL (SDS MAX) 400MM
1
607
313-475
CUTTER (SDS MAX) W50X400L
1
608
313-476
SCOOP (SDS MAX) 400L
1
609
313-478
RAMMER (SDS MAX) 150MM X 150MM
1
610
313-477
BUSHING TOOL (SDS MAX)
1
611
313-479
SHANK (SDS MAX) FOR RAMMER, BUSHING TOOL
1
--- 4 ---
* ALTERNATIVE PARTS
REMARKS
Printed in Japan
(060803N)
8 -- 06