Hitachi H 60MEY Manual de usuario

Overseas Sales Division

TROUBLESHOOTING GUIDE --------------------------------------------------------------------------------------------- 1

1. Troubleshooting and corrective action --------------------------------------------------------------------- 1

REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 3

1. Precautions on disassembly and reassembly ----------------------------------------------------------- 3

STANDARD REPAIR TIME (UNIT) SCHEDULES ------------------------------------------------------------------ 18

CONTENTS Page

PRODUCT NAME

Hitachi Demolition Hammer

Model H 60MEY

H 60ME

LIST No.

H 60MEY: F437

H 60ME: F436

Jun. 2016

-1-

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

assembly diagram for the Model H 60MEY, {Bold} numbers to those for the Model H 60ME, and <Bold>

numbers to those for both models.

1. Troubleshooting and corrective action

Perform troubleshooting and take 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

Ass'y <67>

• No check needed. • Replace the Controller

Ass'y <67> with a new

one.

Three LEDs of

the display lamp

are flashing.

• Mix-up of three

internal wires of

Stator Sensor PCB

Set <58> and

Controller Ass'y

<67>

• Check the heat-shrink tube

colors (red, black, and white)

of internal wires connecting

the Stator Sensor PCB Set

<58> and Controller Ass'y

<67>.

• Correctly connect internal

wires of the Stator Sensor

PCB Set <58> and

Controller Ass'y <67> by

their tube colors (red,

black, and white).

• Broken Controller

Ass'y <67>

• Check the state of the

Controller Ass'y <67>

connector.

• Replace the Controller

Ass'y <67> with a new

one.

• Broken Rotor <66> • Check the built-in magnet of

the fan for breaks.

• Replace the Rotor <66>

with a new one.

Two LEDs of the

display lamp are

flashing.

• Broken Controller

Ass'y <67>

• No check needed. • Replace the Controller

Ass'y <67> with a new

one.

One LED of the

display lamp is

flashing.

• Improperly

connected

connector cable of

Stator Sensor PCB

Set <58>

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug the connector

cable.

• Broken Stator

Sensor PCB Set

<58>

• When the connector cable is

not defective

• Replace the Stator

Sensor PCB Set <58>

with a new one.

• Broken Controller

Ass'y <67>

• Check the plug-in state of the

Controller Ass'y <67>

connector.

• Replace the Controller

Ass'y <67> with a new

one.

• Broken Rotor <66> • Check the built-in magnet of

the fan for breaks.

• Replace the Rotor <66>

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 Ass'y

<72> PCB

• Check the plug-in state of the

connector cable.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug in the

connector cable.

• Internal wires

loosely plugged

into the Controller

Ass'y <67> and

Filter PCB Ass'y

<78>

• Check the plug-in state of the

internal wires.

(See “Reassembly of the

power supply unit” on page

12.)

• Firmly plug the internal

wires into the Controller

Ass'y <67> and Filter

PCB Ass'y <78>.

• Broken Controller

Ass'y <67>

• When the Controller Ass'y

<67> connector is not

defective

• When the internal wire is not

defective

• Replace the Controller

Ass'y <67> with a new

one.

• Broken LED • When the connector cable is

not defective

• Replace the Panel Ass'y

<72> with a new one.

• Broken Filter PCB

Ass'y <78>

• When the internal wire is not

defective

• Replace the Filter PCB

Ass'y <78> with a new

one.

The LEDs of the

display lamp light,

but the motor

does not run.

• Internal wires

loosely connected

to the Switch <84>

• Check the plug-in state of

internal wires to the Switch

<84>. (See “Reassembly of

the power supply unit” on

page 12.)

• Firmly connect all internal

wires to the Switch <84>.

• Broken Controller

Ass'y <67>

• When internal wires of the

Controller Ass'y <67> are not

defective

• Replace the Controller

Ass'y <67> with a new

one.

• Broken Switch

<84>

• When internal wires of the

Controller Ass'y <67> are not

defective

• Replace the Switch <84>

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 <5> in the arrow direction. Note that the Front Cap <1> is

firmly fitted to the Retainer Sleeve <32>. Insert the edge of a flat-blade screwdriver or similar tool into the

gap between the Front Cap <1> and Grip <5>, and then pry up the Front Cap <1> by placing the fulcrum on

the Grip <5> as shown below. Then remove the Grip <5> from the Retainer Sleeve <32>.

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

Retainer Damper (A) <4>, Bit Lock Holder <6>, two Bit Locks <31>, Thrust Plate <7>, Retainer Spring

<8>, Spring Holder (A) <9>, and O-ring (S-26) <16> from the Retainer Sleeve <32>.

2. Disassembly of the hammering mechanism

(1) Removal of the second hammer and striker

(a) Remove the Bolt M5 x 18 <96> and then detach the Crank Cover <95> and lever holder ass'y from

the Crank Case [121]{111}. Then take out the Change Plate <104> and Slider <49> from the Crank

Case [121]{111}.

(b) Remove the Bolt M5 x 12 <18> from the Cylinder Case Cover <17> and then detach the Cylinder

Case Cover <17> from the Cylinder Case <24>.

(d) Remove the Retaining Ring D40 <19> and pull out the Roll Pin D2 x 10 <10> from the Cylinder Case

<24>. Then pull out the Retainer Sleeve <32>, Second Hammer <35>, Cylinder <39>, Striker <40>,

and other parts from the Cylinder Case <24> as a single assembly unit.

(e) Remove Metal (A) <50>, Slider <49>, Sleeve <48>, Clutch <47>, Clutch Spring <46>, Lock Spring

<44>, Lock Spring Washer <43>, Lock Sleeve <45>, and Spring Holder (B) <42> from the assembly

unit.

(f) Turn the Retainer Sleeve <32> and pull out the eight Needle Pins D8 <33> from the Retainer Sleeve

<32> to separate the Retainer Sleeve <32> from the Cylinder <39>.

Disassembly

REPAIR GUIDE

Flat-blade screwdriver

<9>

<32>

<2>

<3> <31> <8>

<5>

<7> <16>

<4>

<6>

<1>

-4-

• Removal of the second hammer and striker

(g) Remove the Second Hammer <35> together with the Damper Holder <38>, Damper <37>, and

Damper Washer <36> from the detached Retainer Sleeve <32>.

(h) Strike the end of the Cylinder <39> with a plastic hammer to pull out the Striker <40>.

<95>

<104>

Lever holder ass'y

Cylinder case ass'y

Crank case ass'y

<19>

<10>

Weight ass'y

Pin hole

<45> <44> <43> <42> <35>

<37> <36> <32>

<50> <48>

<39> <40> <46>

<33> <38>

<49>

<47>

-5-

• Removal of the piston ass'y

(2) Removal of the piston ass’y

Remove the Retaining Ring for D12 Shaft <105>,and then move the Connecting Rod <54> as shown

below. Remove the piston ass’y from the Crank Shaft <106>.

(3) Removal of the first gear and crank shaft

(a) Remove the Bolt M5 x 12 <73> and Screw D4 x 25 <85>, and then detach handle (A) and handle (B).

Remove the Bolt M5 x 14 <61> and Bolt M5 x 16 <93>, and then detach the Back Cover <92>.

(b) Remove the Bolt M6 x 45 [122]{112} and Bolt M6 x 22 [126]{116}, and then detach the Crank Case

[121]{111} from the Gear Cover [128]{118}.

NOTE: For the Model H 60MEY, also remove the weight ass’y.

• Disassembly of the weight ass’y (Model H 60MEY only)

Remove the Crank Cover <95> and then remove the Bolt M5 x 30 [115] from the Crank Case [121].

Then take out the low-vibration mechanism.

[121]{111}, and then use a retaining ring puller to remove the Retaining Ring for D47 Hole <108>

that retains the Ball Bearing 6204DD <109>, while turning the Crank Shaft <106> so that you can

see the hole of the Retaining Ring for D47 Hole <108>.

(d) Place the Crank Case [121]{111} on an adequate cradle with the Piston <53> facing down, and then

use a hand press to press down on the end surface of the Crank Shaft <106>. Remove the First

Gear [124]{114} and Crank Shaft <106> from the Crank Case [121]{111}.

Adequate cradle

Hand press

<106>

<108>

<121>

[121]{111}

<106>

<107>

[124]{114}

<109>

<54> <105> <106>

Piston ass'y

Crank case ass'y

-6-

3. Removal of the motor

(1) Firmly hold the Housing <59> and use a

plastic hammer to tap the shaft of the Rotor

<66> until the spigot joint of the Gear Cover

[128]{118} is removed from the Housing

<59>.

(2) The Rotor <66> has strong magnetic force.

Firmly hold the Housing <59> and pull out the

Gear Cover [128]{118} from the Housing

<59>.

NOTE: When the Gear Cover [128]{118} is

separated from the Rotor <66> and

the Rotor <66> remains in the

Housing <59>, press the Housing

<59> and push the shaft section of

the Rotor <66> to remove the

motor. Tap the shaft of the Rotor <66>.

• Removal of the motor

[128]{118}

<59>

<66>

-7-

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

be given to the following items.

1. Reassembly of the hammering mechanism and low vibration mechanism

(1) Mounting the first gear and crank shaft

(a) Press-fit Oil Seal [123]{113} to the Crank

Case [121]{111}. Mount O-ring (F) <110>.

Press-fit the Ball Bearing 6204DD <109>.

Use a retaining ring puller to mount the

Retaining Ring for D47 Hole <108>.

Press-fit the Crank Shaft <106> to the Ball

Bearing 6204DD <109>.

(b) Insert the Feather Key <107> into the

Crank Shaft <106> groove. Support the

plane of the Crank Shaft <106> with an

adequate steel rod and use an adequate

tool to press-fit the First Gear [124]{114}.

NOTE: Prior to press-fitting, make sure

the Feather Key <107> matches

the key groove of the First Gear

[124]{114}.

(2) Mounting the piston

(a) Insert the Connecting Rod <54> into the Piston <53> and then press-fit the Piston Pin <52> into the

D10 hole (marked “Φ2”) of the Piston <53>. Then mount the O-ring <51> on the Piston <53> to

complete the piston ass’y.

NOTE: Be careful not to let the Piston Pin <48> project from the outer diameter of the Piston

<53>.

(b) Next, turn the Crank Shaft <106> to the position shown below, and then mount the piston ass’y to

the Crank Shaft <106> from the Cylinder Case <24> side of the Crank Case [121]{111}. Use a

retaining ring puller to fix the Retaining Ring for D12 Shaft <105>.

Reassembly

Adequate tool

[121]{111}

Adequate steel rod

<106>

<107>

[124]{114}

<110>

[123]{123}

<109>

<105>

<106>

<54>

<53>

<51>

<52> Marked with “Φ2”

-8-

(3) Mounting the cylinder and retainer sleeve

(a) Insert the Second Hammer <35> with O-ring <34>, Damper Washer <36>, Damper <37>, and

Damper Holder <38> to the Retainer Sleeve <32> in this order.

NOTE: Match the rounded surface of the Damper Washer <36> with the rounded surface of

the Second Hammer <35>.

(b) Insert the Cylinder <39> into the Retainer Sleeve <32> and insert eight Needle Pins D8 <33> into

the 8 mm dia. hole to connect them. To avoid dropping, apply Hitachi Motor Grease No. 29 to the

inside of Spring Holder (B) <42> lightly and then cover the needle pin insertion section of the

Retainer Sleeve <32> with Spring Holder (B) <42>.

(d) Mount the Retainer Damper Washer <30>, Damper Sleeve <29>, Retainer Damper (B) <28>, and

the Retainer Damper Holder <27> around the tip of the Retainer Sleeve <32> in this order.

NOTE: Match the rounded surface of the Retainer Damper Washer <30> with the rounded

surface of the Retainer Sleeve <32>. The Damper Sleeve <29> must be at the Retainer

Damper Washer <30> side.

(e) Insert the Retainer Sleeve <32> into the Ball Bearing 6008DDU <21> in the Cylinder Case <24>

ass’y, and then fix it with the Retaining Ring D40 <19>.

NOTE: Insert the Retainer Sleeve <32> straight in to avoid turning up the lip section of the Oil

Seal <23>.

(f) Insert the Lock Spring Washer <43> deep into the Cylinder Case <24>. Insert the Lock Spring <44>

until it contacts the Lock Spring Washer <43>. Then insert the Lock Sleeve <45> until it contacts the

Lock Spring <44>.

(g) Insert the Clutch Spring <46> until it contacts Spring Holder (B) <42> and then insert the Clutch

<47>.

(h) Insert the Sleeve <48>, Slider <49>, and Metal (A) <50> into the Cylinder Case <24> in the direction

indicated in the figure. Fix Metal (A) <50> and the Cylinder Case <24> with the Roll Pin D2 x 10

<10>.

NOTE: Insert these parts in the correct direction as shown in the figure on the next page.

If Metal (A) <50> cannot be inserted fully, use the J-390 clutch jig (Code No. 370652).

Fix the tip of the Retainer Sleeve <32> and turn the J-390 clutch jig engaging with the

Clutch <47> until the Clutch <47> engages with the spline of the Cylinder <39>. If Metal

(A) <50> is still not inserted fully, fix the Cylinder Case <24> and turn the Clutch <47>

until the Lock Sleeve <45> engages with the spline of the Cylinder Case <24>. Perform

the above step (h) again if the engagement fails.

-9-

• Mounting the cylinder and retainer sleeve

<43>

<10>

Position the

concave portions

sideways.

Avoid the Oil Seal <23>

from being turned up.

Pay attention to the direction of the Retainer Damper

Washer <30> and Damper Washer <36>.

<45>

Position the notch downward.

Engage the Clutch <47>

with the J-390 clutch jig.

Engage the Lock Sleeve <45>

with the Clutch <47>.

Engage the Clutch <47>

with the Cylinder <39>.

Engage the Lock

Sleeve <45> with the

Cylinder Case <24>.

<50>

<41> <39>

<40>

J-390 clutch jig (Code No. 370652)

<24>

<47>

<46> <48>

<44>

Position the slider groove upward.

Insert position of the Lock Spring Washer <43>

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