Hitachi H 60MEY User manual

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
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 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>.
(c) Remove the Bolt M8 x 35 <25> and detach the Cylinder Case <24> from the Crank Case [121]{111}.
(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.
(c) Wipe off grease from the Piston <53> side and the First Gear [124]{114} side in the Crank Case
[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>.
(c) Insert the Striker <40> with O-ring <41> into the Cylinder <39> in the direction indicated in the figure.
(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>