Hitachi H 45MEY User manual

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
H

-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}.
(c) Disassembly of the vibration reduciton mechanism (Model H 45MEY only):
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}.
(c) Disconnect the connector of the Panel [98]{95} from the Controller [53]{50}. Remove the Bolt M6 x
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.
(c) Insert the Striker <35> mounted with O-ring (I.D 27.2) <36> into the Cylinder <33>. Mount the
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.
(c) Mount the Back Cover [64]{61} to the Crank Case [91]{88} and secure them with the Bolt M5 x 16
[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}