Hitachi H 45MEY Manual de usuario

Overseas Sales Division

LIST No.

H 45MEY: F435

H 45ME: F434

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

-1-

[Bold] numbers in the description below correspond to the item numbers in the parts list and exploded

assembly diagram for the Model H 45MEY, {Bold} numbers to those for the Model H 45ME, and <Bold>

numbers to the item numbers for both models.

1. Troubleshooting and corrective action

Perform troubleshooting and take a necessary corrective action according to the table below if there is a

problem that cannot be solved by the corrective action described in the handling instructions.

Problem Cause Check Corrective action

All the four LEDs

of the display

lamp are flashing.

• Broken Controller

[53]{50}.

• No check needed. • Replace the Controller

[53]{50} with a new one.

Three LEDs of

the display lamp

are flashing.

• Mix-up of three

internal wires of

Stator Sensor PCB

Set [45]{42} and

Controller [53]{50}

• Check the heat-shrinkable

tube colors (red, black, and

white) of internal wires

connecting the Stator Sensor

PCB Set [45]{42} and

Controller [53]{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

flashing.

• Broken Controller

[53]{50}

• No check needed. • Replace the Controller

[53]{50} with a new one.

One LED of the

display lamp is

flashing.

• Improperly

connected

connector cable of

the Stator Sensor

PCB Set [45]{42}

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

11.)

• Firmly plug the connector

cable.

• Broken Stator

Sensor PCB Set

[45]{42}

• When the connector cable is

not defective

• Replace the Stator

Sensor PCB Set [45]{42}

with a new one.

• Broken Controller

[53]{50}

• Check the plug-in 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.

TROUBLESHOOTING GUIDE

-2-

Problem Cause Check Corrective action

No LED of the

display lamp is

ON.

• Improperly

connected

connector cable of

the Panel [98]{95}

PCB

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

11.)

• Firmly plug in the

connector cable.

• Internal wires

loosely plugged

into the Controller

[53]{50} and Filter

PCB Set [62]{59}

• Check the plug-in state of the

internal wires.

(See “Reassembly of the

power supply unit” on page

11.)

• Firmly plug the internal

wires into the Controller

[53]{50} and Filter PCB

Set [62]{59}.

• Broken Controller

[53]{50}

• When the Controller [53]{50}

connector is not defective

• When the 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}

• Check the plug-in state of

internal wires to the Switch

[69]{66}. (See “Reassembly

of the power supply unit” on

page 11.)

• Firmly connect all internal

wires to the Switch

[69]{66}.

• Broken Controller

[53]{50}

• When internal wires of the

Controller [53]{50} are not

defective

• Replace the Controller

[53]{50} with a new one.

• Broken Switch

[69]{66}

• When internal wires of the

Controller [53]{50} are not

defective

• Replace the Switch

[69]{66} with a new one.

-3-

1. Precautions on disassembly and reassembly

WARNING: Be sure to disconnect the power cord plug from the wall outlet before conducting

repair. Otherwise, the motor may run suddenly and you could get injured.

1. Disassembly of the tool retainer

Remove the Front Cap <1> while pulling the Grip <4> in the arrow direction. Note that the Front Cap <1>

is firmly fitted to the Retainer Sleeve <24>. Insert the edge of a flat-head screwdriver or similar tool into

the gap between the Front Cap <1> and Grip <4>, and then pry up the Front Cap <1> by placing the

fulcrum on the Grip <4> as shown below. Then remove the Front Cap <1> from the Retainer Sleeve <24>.

Remove the Stopper Ring <2> by using a retaining ring puller. Then remove the Retainer Washer <3>,

Grip <4>, Retainer Damper (A) <5>, Bit Lock Holder <6>, two Bit Locks <23>, Spring Holder (A) <8>,

Retainer Spring <9>, and Spring Holder (B) <10> from the Retainer Sleeve <24>.

Remove the Stopper Ring <11> by using 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 Crank Case [91]{88}.

Remove the Retaining Ring for D52 Hole [39] by using a retaining ring puller. Then remove the

two Weight Washers [29], two Weight Springs [37], and Weight [38] from the Cylinder Case [19].

NOTE: Be careful not to pop out the Weight Washers [29], Weight Springs [37], and Weight

[38] when removing the Retaining Ring for D52 Hole [39].

(d) Remove the Cylinder <33>, Cylinder Holder <32>, Damper Holder <31>, Damper <28>, Damper

Washer <27>, Damper (C) <30>, and Weight Washer <29> from the Cylinder Case <19>.

(e) Tap the end of the Cylinder <33> with a plastic hammer to pull out the Striker <35>.

Disassembly

REPAIR GUIDE

Flat-head screwdriver

<2>

<24>

<4>

<1>

<3>

<6> <9>

<5> <8>

<11>

<10>

<23>

<13>

<19>

<7>

<12>

-4-

(f) Remove the Ring <16> from the Retainer Sleeve <24> by using a retaining ring 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

-5-

(2) Removal of the piston

Move the Connecting Rod Ass'y [42]{39} as shown below and remove the Piston [41]{38} from the

Crank Shaft [86]{83}.

(3) Removal of the first gear and crank shaft

(a) Remove the Bolt M5 x 16 [65]{62}, and then remove the Crank Cover [84]{81} from the Crank

Case [91]{88}.

(b) Remove the Bolt M5 x 16 [65]{62}, Bolt M5 x 12 [56]{53}, and Screw D5 x 25 [70]{67}, and then

remove handle (A), handle (B), and Back Cover [64]{61}.

45 [49]{46}, and then remove the Crank Case [91]{88} from 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 its Crank Cover [84]{81} fixing surface

facing down, and then use a hand press to press down on the end surface of the Crank Shaft

[86]{83}. Then remove the First Gear [96]{93} and Crank Shaft [86]{83} from the Crank Case

[91]{88}.

Adequate cradle

Hand press

[42]{39}

[86]{83}

[41]{38}

[96]{93}

[91]{88} [86]{83}

[91]{88}

[86]{83} Crank cover

fixing surface

[87]{84}

Crank cover

fixing surface

-6-

3. Disassembly of the motor unit

(1) Firmly hold the Housing [52]{49} and use a

plastic hammer to tap the shaft of the Rotor

[102]{99} until the spigot joint of the Gear Cover

[99]{96} is removed from the Housing [52]{49}.

(2) The Rotor [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.

[102]{99}

[52]{49}

[99]{96}

-7-

Reassembly can be accomplished by reversing the disassembly procedure. However, special attention

should be given to the following items.

1. Reassembly of the hammering mechanism

(1) Mounting the first gear and crank shaft

(a) Press-fit Oil Seal (B) [90]{87} to the Crank

Case [91]{88}. Mount the O-ring (S-40)

[89]{86}. Press-fit the Ball Bearing 6203DD

[88]{85}. Use a retaining ring puller to

mount the Retaining Ring for D40 Hole

[87]{84}. Press-fit the Crank Shaft [86]{83}

to the Ball Bearing 6203DD [88]{85}.

(b) Insert the Feather Key 3 x 3 x 10 [83]{80}

into the Crank Shaft [86]{83} groove.

Support the plane of the Crank Shaft

[86]{83} with an adequate 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}

project from the outer diameter of the Piston [41]{38}. Mount the O-ring (S-40) [89]{86} on the

Piston [41]{38} to make the piston ass’y.

(b) Turn the Crank Shaft [86]{83} to the position shown below, and then mount the piston ass’y to

the Crank Shaft [86]{83} from the Cylinder Case <19> side of the Crank Case [91]{88}.

Reassembly

Adequate steel rod

“Φ2” mark

Adequate tool

[83]{80}

[91]{88} [90]{87}

[96]{93}

[88]{85}

[86]{83}

[89]{86}

[87]{84}

[86]{83}

[91]{88}

[41]{38}

[40]{37}

[89]{86}

-8-

(3) Mounting the cylinder and retainer sleeve

(a) Mount Retainer Damper (B) <22> and Retainer Damper Holder <21> to the Retainer Sleeve <24>

in this order.

NOTE: Match the rounded surface of the Retainer Damper Holder <21> with the rounded

surface of the Retainer Sleeve <24>.

(b) Insert the assembly of the Retainer Sleeve <26> into the Cylinder Case <19> and then mount the

Ring <16> to the Retainer Sleeve <24> using a retaining ring puller.

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 <19>.

NOTE: Match the rounded surface of the Damper Washer <27> with the rounded surface of

the Second Hammer <26>.

Note the direction of <21>.

Note the direction of <27>.

<19>

<24> <16>

<21> <22>

<26>

<30>

<29> <33>

<27>

<28> <31> <32>

<34>

<36>

<25>

<35>

<19>

-9-

• Mounting the valve and felt

• Reassembly of the vibration reduction mechanism (Model H 45MEY only)

(4) Reassembly of the vibration reduciton mechanism (Model H 45MEY only):

Insert the Weight Washer [29], Weight Spring [37], Weight [38], Weight Spring [37], and Weight

Washer [29] into the Cylinder Case [19] in this order. Mount the Retaining Ring for D52 Hole [39] to

the Cylinder Case [19] by using a retaining ring puller.

NOTE: Be careful not to pop out the Weight Springs [37] when mounting the Retaining Ring for

D52 Hole [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 figure.

[65]{62}.

NOTE: Check that the Washer M3 [93]{90} is fitted in the hole of the Crank Case [91]{88}

before mounting the Back Cover [64]{61}.

[29]

[37] [38] [37] [19]

[29] [39]

[94][91}

[91]{88}

[93]{90}

[92]{89}

Mounting position of [94]{91}

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