Hitachi H 41SD User manual

-6-
PRODUCT NAME
Hitachi Demolition Hammer
Model H 41SD
LIST No.
H 41SD: F413
Nov. 2012
REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly ----------------------------------------------------------- 1
STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------- 8
CONTENTS Page
International Sales Division
H

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Be sure to disconnect the power cord plug from the wall outlet before conducting repair. Otherwise, the
motor may suddenly run, posing a very dangerous situation.
1. Precautions on disassembly and reassembly
[Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded
assembly diagram for the Model H 41SD.
1. Disassembly of the hammering mechanism
(a) Second Hammer [12], Piston [23] and Striker [20]
Note that the front cover and the cylinder case cannot be loosened. Remove the cylinder case and
the crank case before removing the parts inside the cylinder case.
Remove the Hex. Socket Hd. Bolt (W/Flange) M5 x 16 [28] fixing the Crank Cover [29] and the Hex.
Socket Hd. Bolt (W/Flange) M5 x 12 [41] fixing the Hood [42], then the Crank Cover [29] and the
Hood [42] can be removed from the Crank Case [44]. Remove the Retaining Ring D45 [3] and the
Front Washer [4] fixing the Cylinder Case Cover [6], then the Cylinder Case Cover [6] can be
removed from the Cylinder Case Ass’y [5]. Remove the Hex. Socket Hd. Bolt (W/Flange) M6 x 25
[8] fixing the Cylinder Case Ass’y [5], then the Cylinder Case Ass’y [5],Striker[20], Second
Hammer [12], Damper [14], Damper Washer [13], Hammer Holder [2] and Retainer Damper [1]
can be removed from the Crank Case [44].
As the Piston [23] remains on the Crank Case [44] side, use the retaining ring puller to remove the
Retaining Ring for D10 Shaft [26], and then remove the Connecting Rod [24] from the Crank Shaft
[31]. The Striker [20] can be removed by lightly tapping on the Cylinder [19] with a plastic hammer.
If it does not come out easily, push the disassembled Piston [23] with the Connecting Rod [24]
back into the Cylinder [19], and then quickly pull them apart again. The Striker [20] can come out at
the same time as shown in Fig. 1 on the next page.
REPAIR GUIDE
Disassembl
y

-2-
(b) First Gear [45] and Crank Shaft [31]
Remove the Seal Lock Hex. Socket Hd. Bolt M6 x 35 [43], Hex. Socket Hd. Bolt (W/Flange) M5 x
16 [28] and Tapping Screw (W/Flange) D5 x 20 (Black) [69]. Remove the Crank Case [44] from the
Housing Ass'y [58] and Handle [76]. Remove grease from the Piston [23] side and the First Gear
[45] side of the Crank Case [44]. Use a retaining ring puller to remove the Retaining Ring for D40
Hole [32] fixing the Ball Bearing 6203DDCMPS2L [33]. At this time, turn the Crank Shaft [31] to
expose the hole of the Retaining Ring for D40 Hole [32] prior to removal. Use a hand press to press
the end face of the Crank Shaft [31], and then remove the First Gear [45] and the Crank Shaft [31]
from the Crank Case [44] as shown in Fig. 2 on the next page.
Striker [20]
Cylinder [19]
Damper [14] Second Hammer [12]
Cylinder case
Piston [23] Retaining Ring for D10 Shaft [26]
Crank Shaft [31]
Connecting Rod [24]
Damper Washer [13]
Retainer Damper [1] Hammer Holder [2]
Front cover ass’y
Cylinder Case Ass’y [5]
Fig. 1

-3-
Steel ball Front cover ass’y Cylinder case
Cylinder Case Ass’y [5]
2. Disassembly of the tool retainer
Use a snap ring remover to remove the retaining ring. The ring, slide grip, spring and six steel balls can
then be removed from the Cylinder Case Ass’y [5] as shown in Fig. 3 below.
Crank Shaft [31]
Crank Case [44]
Retaining Ring for D40 Hole [32]
Crank Case [44]
Crank Shaft [31]
First Gear [45]
Support
Ring
Spring
Retaining ring O-ring
Fig. 2
Fig. 3

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Conduct reassembly by reversing the order of the disassembly procedure. However, special attention
should be given to the following items.
1. Reassembly of the hammering mechanism
(a) First Gear [45] and Crank Shaft [31]
Press-fit the Oil Seal [35] into the Crank Case [44] and mount the O-ring (S-40) [34]. Then press-fit
the Ball Bearing 6203DDCMPS2L [33]. Use a retaining ring puller to mount the Retaining Ring for
D40 Hole [32]. Press-fit the Crank Shaft [31] into the Ball Bearing 6203DDCMPS2L [33]. Press-fit
the Crank Shaft [31] into the Distance Ring [36]. Fit the Feather Key 4 x 4 x 8 [27] into the groove
of the Crank Shaft [31] and then press-fit the First Gear [45] with a suitable jig, while holding the flat
portion of the Crank Shaft [31] with a steel bar. Before doing the press-fitting work above, make
sure that the Feather Key 4 x 4 x 8 [27] fits properly into the key groove of the First Gear [45] as
shown in Fig. 4 below.
(b) Second Hammer [12], Damper Washer [13], Damper [14], and Cylinder [19]
Fit the Damper Washer [13] and the Damper [14] onto the Second Hammer [12] and insert it into
the Cylinder [19] being careful of the direction of the Damper Washer [13]. Perform reassembly
aligning the inclined surface inside the Damper Washer [13] with the inclined surface of the Second
Hammer [12] as shown in Fig. 5 on the next page.
Reassembl
y
Oil Seal [35]
Ball Bearing 6203DDCMPS2L [33]
Feather Key 4 x 4 x 8 [27]
Retaining Ring for D40 Hole [32]
O-ring (S-40) [34]
Crank Shaft [31]
First Gear [45] Support
Steel bar
Distance Ring [36]
Fig. 4

-5-
Valve Cover [38]
Seal Lock Hex. Socket
Hd. Bolt M4 x 8 [40]
Sectional view of Valve [37]
Cylinder [19]
Damper Washer [13]
(c) Valve [37], Valve Cover [38], and Felt [39]
Stick the Felt [39] on the Valve Cover [38] mating their top edges after degreasing the location on
the Valve Cover [38] where the felt is to be adhered. Fix the Felt [39] to the Valve Cover [38] with
the O-ring (S-10) [87]. Insert the Valve [37] into the Crank Case [44]. Fix the Valve Cover [38] in
place using the Seal Lock Hex. Socket Hd. Bolt M4 x 8 [40] by matching it to the seating surface of
the Crank Case [44]. Confirm that ĭ2.4 hole of the Valve [37] can be seen from the ĭ2 hole of the
Valve Cover [38] as shown in Fig. 6 below. Note that grease will leak if the Valve [37] is not
properly inserted. (Fig. 6)
The Felt [39] must not stick out
from the Valve Cover [38].
Felt [39]
ĭ2.4
ĭ2 hole of the Valve Cover [38]
Valve [37]
O-ring (S-10) [87]
Second Hammer [12]
Damper [14]
Fig. 5
Fig. 6

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• Filling special grease (for the hammer and hammer drill)
Connecting Rod [24] side in the Crank Case [44]: 35 g
• Applying special grease (for the hammer and hammer drill)
Inner circumferences on the Piston [23] side of the Connecting Rod [24], sliding portion of the Second
Hammer [12], sliding portion of the Striker [20], O-ring [21] mounted on the Striker [20] and Piston [23],
O-ring (A) [15] of the Piston [23], and lip portions along the inner circumference of the Oil Seal [35] and
Damper [14]
• Filling Hitachi Motor Grease No. 29
First Gear [45] side and Gear Cover Ass’y [48] side in the Crank Case [44]: 10 g in total
• Applying Hitachi Motor Grease No. 29
Needle Bearing M661 [46] and pinion portion of the Armature [52]
• Applying Doubrex 251
Damper Washer [13], inner circumference of the Second Hammer [12], around the Hammer Holder [2],
inner circumference of the Hammer Holder [2], and Retainer Damper [1]
• Applying Molub-Alloy No. 777-1
Inner circumference of the Needle Bearing [25]
Apply screw locking agent TB1401 to all hex. socket head bolts M5 and M6.
NOTE: Be sure to apply screw locking agent (Three Bond TB1401) to the threads during
reassembly. Otherwise, any bolt loosened due to vibration may damage the tool body.
M6 • Seal Lock Hex. Socket Hd. Bolt M6 x 35 [43] and Seal Lock Hex. Socket Hd. Bolt M6 x 20 [49]
(For mounting the housing and crank case) ------------ 9.8 ± 0.98 N•m (100 ± 10 kgf•cm)
• Hex. Socket Hd. Bolt (W/Flange) M6 x 25 [8]
(For mounting the cylinder case) -------------------------- 12.7 N•m (130 kgf•cm)
M5 • Hex. Socket Hd. Bolt (W/Flange) M5 x 12 [41]
(For mounting the hood) ------------------------------------- 3.92 ± 0.49 N•m (40 ± 5 kgf•cm)
• Hex. Socket Hd. Bolt (W/Flange) M5 x 16 [28]
(For mounting the handle) ----------------------------------- 5.88 ± 0.98 N•m (60 ± 10 kgf•cm)
• Hex. Socket Hd. Bolt (W/Flange) M5 x 16 [28]
(For mounting the crank cover) ---------------------------- 7.84 N•m (80 kgf•cm)
M4 • Seal Lock Hex. Socket Hd. Bolt M4 x 8 [40]
(For mounting the valve cover) ----------------------------- 4.41 ± 0.49 N•m (45 ± 5 kgf•cm)
• Tapping screw (w/flange) D5 ------------------------------- 2.94 ± 0.49N•m (30 ± 5 kgf•cm)
• Tapping screw (w/flange) D4 ------------------------------- 1.96 ± 0.49 N•m (20 ± 5 kgf•cm)
+30
0
+2.94
0
+1.96
0
+20
0
A
pp
lication of lub
r
icant
Ti
g
htenin
g
tor
q
ue

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(1) Wiring diagram for products without a noise suppressor
(2) Wiring diagram for products with a noise suppressor
Upon the completion of disassembly and repair, measure the insulation resistance and dielectric strength.
Insulation resistance: 7 Mȍor more using a 500 VDC megohm tester
Dielectric strength: 4,000 VAC/minute, with no abnormalities (220 to 240 V)
(110VforU.K.products)
2,500 VAC/minute, with no abnormalities (110 to 127 V)
(ExceptforU.K.products)
After no-load operation for 30 minutes, the no-load current values should be as follows:
Voltage (V) 110 220 230 240
Current (A) max. 4.2 2.1 2.0 1.9
Switch
Stator ass’y
Plug
Armature ass’y
Connector or
p
illa
r
terminal
A
Noise suppressor
Switch
Stator ass’y
Plug
Armature ass’y
Pilla
r
terminal
A
Connecto
r
Connecto
r
Internal wirin
g
Insulation tests
No-load current value

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MODEL Variable
Fixed 10 20 30 40 50 60 min
H 41SD
General Assembly
O-ring
Second
Hammer
Damper
Washer
Damper
O-ring (A)
Handle
Cylinder
Striker
O-ring x 2
Piston
Connecting
Rod
Needle
Bearing
Gear Cover
Ass’y
Needle Bearing
Armature
Ball Bearing
(6201DD)
Ball Bearing
(608VV)
Crank Shaft
Ball Bearing
(6203DD)
Oil Seal
First Gear
Housing Ass’y
Stator Ass’y
Crank Case
Work Flow
Handle Cover
Switch (B)
Cord
Cord Armor
Tail Cover
Crank Cover
O-ring
Retainer
Damper
Hammer
Holder
Cylinder Case
Ass’y
STANDARD REPAIR TIME (UNIT) SCHEDULES

Model H 41SD
HAMMER
LIST NO. F413
2012·11·16
(E2)
25
47
48
79
38
1
3
4
6
7
2
8
10
11
12
13
14
15
26
27
19
20
21
22
24
41
42
43
44
28
29
30
31
32
33
34
35
36
37
87
39
40
28
16
17
18
45
46
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
69
70
71
72
73
74
75
76
77
78
80
81
82
83
84
85
86
501 502
23
5