Hitachi Koki DV 13SS F403 User manual

REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly ----------------------------------------------------------- 1
STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------13
CONTENTS
Page
PRODUCT NAMES
Hitachi 13 mm Impact Drill
Models DV 13SS, DV 13VSS
Hitachi 16 mm Impact Drill
Models DV 16SS, DV 16VSS
LIST Nos.
DV 13SS: F403
DV 13VSS: F404
DV 16SS: F405
DV 16VSS: F406
Mar. 2009
International Sales Division
D
DV16SS/DV16VSS

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1. Precautions on Disassembly and Reassembly
The [Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded
view assembly diagram for the Models DV 13SS and DV 16SS, and the <Bold> numbers to those in the
Parts List and exploded view assembly diagram for Models DV 13VSS and DV 16VSS.
Note on disassembly: Before starting disassembly, be sure to disconnect the power plug from the power
supply.
1. Removal of the handle cover
Loosen the Tapping Screw (W/Flange) D4 X 20 (Black) [32] <32> and remove the Handle Cover [31] <31>.
2. Removal of the carbon brush
Use a small flat-blade screwdriver to slightly lift the Brush Holders [36] <36>. Then, while pushing the
Carbon Brush [37] <37> to the bottom of the Brush Holders [36] <36>, gently pull out and disconnect the
internal wire terminals. (Figs. 1 and 2)
3. Removal of the gear cover from the housing
Loosen the Tapping Screw (W/Flange) D4 x 60 (Black) [11] <11> and Tapping Screw (W/Flange) D4 x 45
[15] <15>, and then separate the Gear Cover [12] <12> from the Housing [34] <34>. Then remove the
Inner Cover [21] <21> together with the Armature [26] <26> from the Housing [34] <34>.
REPAIR GUIDE
Disassembl
y
Fig. 1 Terminal Carbon brush stop piece
Bush Holder [36] <36>
Push
Carbon brush [37] <37>
Carbon brush stop piece
Terminal
Projection
Fig. 2

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4. Removal of the armature ass'y from the inner cover
As illustrated in Fig. 3, support the Inner Cover [21] <21> with a tubular jig, and then push down on the top
of the pinion of the Armature [26] <26>.
5. Removal of the stator from the housing
[For DV 13SS, DV 16SS]
First insert a flat-blade screwdriver into the longitudinal cut of a sponge at the rear end of the switch, loosen
both of the upper two setscrews, and then remove the internal wires. Remove the Tapping Screws D4 x 45
[28], and then slightly tap the end surface of the Housing [34] with a wooden hammer. The stator [29] can
then be removed from the Housing.
[For DV 13VSS, DV 16VSS]
First, disconnect the internal wires from the upper side of the Switch <41> by pulling the faston terminal. To
disconnect the internal wires from the switch, insert a small flat-blade screwdriver into the windows near the
terminals and pull out the internal wires. Remove the Tapping Screws D4 x 45 <28> and slightly tap the end
surface of the Housing <34> with a wooden hammer. The stator <29> can then be removed from the
Housing <34>.
Fig. 3
Pinion
60 mm dia. to 70 mm in dia.
Push
Inner Cover [21]<21>
A
rmature
[
26
]
<26>
Tubular jig

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6. Removal of the drill chuck
[For DV 13SS, DV 16SS]
The Drill Chuck 13VLRC-D [3] is secured to the Spindle [6] with 1/2"-20 UNF (right hand) and Flat Hd.
Screw (A) (Left Hand) M6 x 25 [1]. At first, open the chuck jaw as far as possible and loosen Flat Hd. Screw
(A) (Left Hand) M6 x 25 [1] by turning it clockwise.
(a) Hold the drill so that only the Drill Chuck 13VLRC-D [3] rests firmly and squarely on the edge of a solid
bench. Insert the hex. bar wrench into the drill chuck. Turn the drill chuck until the wrench is at about a
30° angle to the bench top, and then sharply strike the wrench with a hammer so the drill chuck turns in
the counterclockwise direction. (Fig. 4)
[For DV 13VSS, DV 16VSS]
The Drill Chuck 13VLRC-D (or The Drill Chuck 13VLRJ-N (W/O Chuck Wrench)) <3> is secured to the
Spindle <6> with 1/2"-20 UNF (right hand) and Flat Hd. Screw (A) (Left Hand) M6 x 25 <1>. First, open the
chuck jaw as far as possible and loosen Flat Hd. Screw (A) (Left Hand) M6 x 25 <1> by turning it clockwise.
(a) Hold the drill so that only the Drill Chuck 13VLRC-D (or The Drill Chuck 13VLRJ-N (W/O Chuck
Wrench)) <3> rests firmly and squarely on the edge of a solid bench. Insert the hex. bar wrench into the
drill chuck. Turn the drill chuck until the wrench is at about a 30° angle to the bench top, and then
sharply strike the wrench with a hammer so the drill chuck turns in the counterclockwise direction. (Fig.
4)
If the drill chuck cannot be removed by striking the wrench, do not forcibly strike the wrench forcibly and
try another way as follows.
(b) Hold the Spindle [6] <6> with an open end wrench secured to the vise as shown in Fig. 5.
Mount the pipe onto the hex. bar wrench. Turn the hex. bar wrench counterclockwise to loosen the drill
chuck. (Fig. 5)
Fig. 5
Open end wrench
Vise
Turn it counterclockwise.
Pipe
Hex. bar
wrench
Fig. 4
Hex. bar
wrench
Flat Hd. Screw (A)
(Left Hand) M6 x 25 [1] <1>
Loosen

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(c) (For keyed chuck only)
Secure the drill chuck with a disassembly tool: Ring (J-78) to the drill chuck, which in proper sequence
should be secured with a vise. Then fit a disassembly tool: Wrench Ass'y (J-140) to the spindle, and turn
it counterclockwise to loosen the drill chuck. (Fig. 6)
7. Removal of the spindle
Remove the Retaining Ring for D32 Hole [4] <4> and Dust Seal [5] <5>. Place the end surface of the Gear
Cover [12] <12> on the tubular jig and press down on the Spindle [6] <6> with a hand press. The spindle
can then be removed together with the Ball Bearing 6002VVCMPS2L [9] <9>, Distance Ring [8] <8>,
Spring [7] <7> and the Retaining Ring for D15 Shaft [10] <10>. The Gear [13] <13> can then be removed
from the spindle. (Fig. 7)
CAUTION:
• Be sure to replace both the spindle and gear with new ones.
Fig. 6
Wrench Ass'y (J-140)
Ring Ass'y and Ring (J-78) Turn it counterclockwise.
Vise Drill chuck
Fig. 7
Gear [13] <13> Spindle [6] <6>
Push
Distance Ring [8] <8>
Dia. of 32 mm
Tubular jig

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8. Removal of the ratchet
Insert the tip of a flat-blade screwdriver between the Ratchet [17] <17> and Change Lever [22] <22>, and
then pry out the Change Lever [22] <22> to remove it. (Fig. 8) Remove the Tapping Screw (w/SP Washer)
D4 X 20 [16] <16> that mounts the Ratchet [17] <17> on the Inner Cover [21] <21>.
Place the end of the Inner Cover [21] <21> on the cylinder and push the end of the Bushing [18] <18> on
the rear of the ratchet with a hand press. The Ratchet [17] <17> then comes out together with the Change
Plate [20] <20>. (Fig. 9)
Perform reassembly by reversing the order of the disassembly procedure. However, special attention
should be given to the following items.
1. Internal wire arrangement
(1) Arrange the internal wires according to "7. Internal Wire Arrangement and Wiring Work."
(2) Be careful not to catch the internal wires when mounting the handle cover.
Change Lever [22] <22>
Change Plate [20] <20>
Bushing [18] <18>
Fig. 9
Inner Cover [21] <21>
Change Plate [20] <20> Bushing [18] <18>
Ratchet [17] <17>
Ø67 to Ø80
Push
Reassembl
y
Fig. 8
Insert the tip of the flat-blade
screwdriver here.
Cylinder

- 6 -
2. Lubrication
(1) Apply ATTOLUB MS No. 2 Grease (Code No. 309922) to the following parts:
•Teeth of the Armature [25] <25> and the Gear [13] <13> (with a brush)
•On the Spindle [6] <6>
Ground portion for fitting the Ball Bearing 6002VVCMPS2L [9] <9>, splined portion and hole on the
rear side
•Surface of Steel Ball D6.35 [14] <14>
•Lip portion of the Dust Seal [5] <5>
•On the Ratchet [17] <17>
Inside the Needle Bearing, teeth of ratchet
•Inside the Gear Cover [12] <12>: 5 g
3. Tightening torque
(1) Tapping Screw D4 -------------------------------------------------1.5 to 2.5 N•m (13.3 to 22.1 in-lbs.)
(2) Drill Chuck-----------------------------------------------------------30 to 50 N•m (266 to 443 in-lbs.)
(3) Machine Screw M3 (Switch [41] <40>)-----------------------0.4 to 0.8 N•m (3.5 to 7.1 in-lbs.)
(4) Flat HD. Screw (A) (Left Hand) M6 X 25 [1] <1> ----------4.4 to 5.4 N•m (38.9 to 47.8 in-lbs.)
(5) Bolt M3 [19] <19> -------------------------------------------------1.2 to 1.8 N•m (10.6 to 15.9 in-lbs.)
4. Change Plate
Place the Change Plate [20] <20> between the Ratchet [17] <17> and Bushing [18] <18> before
assembling in the Inner Cover [21] <21>. (Fig. 10)
5. Change Lever
Push the Change Lever [22] <22> forward until the front end of the Change Plate [20] <20> protrudes
about 1.5 mm. (Fig. 11)
Fig. 10
Change Lever [22] <22>
Fig. 11
1.5
Change Plate [20] <20>
Bushing [18] <18>
Ratchet
[17] <17>
Change Plate
[20] <20>
Place the Change Plate [20] <20> between the Ratchet [17]
<17> and Bushing [18] <18> before assembling.

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6. Wiring Diagrams
[For DV 13SS, DV 16SS]
(1) For products with noise suppressor
(2) For products without noise suppressor
[For DV 13VSS, DV 16VSS]
(1) For products with noise suppressor
(2) For products without noise suppressor
Blue
Brown
Choke Coil Connector
White
Gray
Stator
1a 1
2a 2
Black
Red
Choke Coil Connector Stator
Switch
Noise
Suppressor
White or Blue
Black or Brown
Cord Ass’y
Blue
Brown
Connector
White
Gray
Stator
1a 1
2a 2
Black Red
Connector Stator White or Blue
Black or Brown
Cord Ass’y
Switch
Blue
Brown
Choke Coil
Whit
e
Gray
Stator
1a 1
2a 2
Black
Red
Choke Coil Stator
Speed Control Switch
Noise
Suppressor
White or Blue
Black or Brown
Cord Ass’y
1a
2b
45
36
Reversing Switch
Blue
Brown
Whit
e
Gray
Stator
1a 1
2a 2
Black
Red
Stator
Speed Control Switch
White or Blue
Black or Brown
Cord Ass’y
1a
2b
45
36
Reversing Switch

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7. Internal Wire Arrangement and Wiring Work
A. Internal wire arrangement
[For DV 13SS, DV 16SS]
Stator: Red
Choke Coil: Brown
Choke Coil: Blue
Stator: White
Connector
Stator: Gray
Cord:
White or Blue
AA
Cord [45]
Cord Clip [38]
5 +5
0
Noise Suppressor
Cord:
Black or Brown
Stator: Red
Stator: Red
Stator: Gray
Stator: White
Stator: Black
Connector
Choke Coil:
Brown
Stator: White
Connector
Stator: Gray
Cord:
White or Blue
Cord [45]
Cord Clip [38]
5 +5
0
Cord:
Black or Brown
Stator: Red
(a)
(b)
Mounting the cord clip
(1) For products with noise suppressor (2) For products without noise suppressor
Stator: Gray
Stator: White
Stator: Black
Connector
Earth Terminal 46]
Insert the Earth Terminal [46] between
the Stator [29] and Housing [34].
Thread the lead wire under the
Brush Holder [36].
Neutral wire of capacitor
Neutral wire
of capacitor
Put the carbon terminal
between (a) and (b).
Thread the lead wire under the
Brush Holder [36].
Lead wire:
Blue
Thread the lead wire
under the Brush
Holder [36].
Thread the lead wire
under the Brush
Holder [36].

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[For DV 13VSS, DV 16VSS]
Choke Coil: Brown
Choke Coil: Blue
Stator: Black
Stator: Gray
Cord:
White or Blue
Cord <45>
Cord Clip <39>
5 +5
0
Noise Suppressor
Cord:
Black or Brown
Stator: Red
Stator: Gray
Stator: White
Stator: Black
Earth Terminal <46>
Stator: Black
Stator: Gray
Cord:
White or Blue
Cord <45>
Cord Clip <39>
5 +5
0
Cord:
Black or Brown
Stator: Red
(a)
(b)
(1) For products with noise suppressor (2) For products without noise suppressor
Stator: Gray
Stator: Black
Stator: White
Stator: Red
Thread the lead wire under the
Brush Holder [36].
Neutral wire of capacitor
A
pply silicon
grease to
prevent these
from falling
Thread the lead wire under the
Brush Holder [36].
Lead wire:
Blue
Thread the lead wire
under the Brush
Holder [36].
Thread the lead wire
under the Brush
Holder [36].
Lead wire:
Brown
Insert the Earth Terminal <46> between
the Stator <29> and Housing <34>.
Mounting the cord clip
Put the carbon terminal
between (a) and (b).
A
pply silicon
grease to prevent
these from falling
Stator: Red