Hitachi H 65SD3 User manual

LIST No.
H 65SD3 : F439
Aug. 2016
PRODUCT NAME
Hitachi Demolition Hammer
Model H 65SD3
REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly ----------------------------------------------------------- 1
CONTENTS Page
Overseas Sales Division
H

-1-
Fig. 1 • Disassembly of the armature ass’y
WARNING: Be sure to disconnect the power cord plug from the power supply before conducting
repair. Otherwise, the motor may suddenly turn on, posing a very dangerous situation.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts list and exploded
assembly diagram for the Model H 65SD3.
NOTE: If it is difficult to loosen and remove the fixing bolts, use an appropriate heating device to
heat the bolts to approximately 80°C (176°F).
1. Disassembly of the armature ass’y
(1) Loosen the four Bolts M4 x 8 [81], remove the Cap Cover [82], Cap Rubber [83], Brush Cap [84] and
Carbon Brush [85]. Be careful not to lose any removed parts.
(2) Loosen the four Bolts M8 x 40 [23], and remove the Cylinder Case [19]. Next, loosen the Bolt M8 x 16
[31] and then remove the Connecting Rod Ass’y [28] and the Crank Washer [30]. Leave the Striker
[21] and the Piston [26] as they are.
Disassembly
REPAIR GUIDE
100 mm in dia.
Press the end surface of the
armature with a hand press.
A
rmature shaft
Tubular jig
[42]
[48]
[70]

-2-
Fig. 2 • Disassembly of the crank shaft section
(3) Remove the two Bolts M5 x 16 [59] and five Screws D4 x 25 [90]. Remove handles (A) and (B) of
Handle (A). (B) Set [111], four Bolts M5 [105] and Back Cover [78]. Remove the six Bolts M6 x 40 [54],
Gear Cover [38], and Counter Gear [63]. At this time, be very careful not to damage the mating
surfaces of the Gear Cover [38] and Inner Cover [42]. Insert a flat-blade screwdriver or a similar tool
into the air vent of the Inner Cover [42] and raise the Inner Cover [42]. Then the Inner Cover [42],
Armature Ass’y [70] and Crank Shaft [48] can be removed as a single unit. At this time, be very careful
not to damage the Fan [69].
(4) As illustrated in Fig. 1, support the Inner Cover [42] with an appropriate tubular jig, and push down on
the end surface of the armature shaft with a hand press to separate the Armature Ass’y [70] from the
Inner Cover [42].
2. Disassembly of the crank shaft section
(1) Remove the four Bolts M5 x 16 [47] which fix the Bearing Cover [46]. Then, as illustrated in Fig. 2,
support the lower surface of the Inner Cover [42] with an appropriate tubular jig, align an appropriate
steel rod with the end surface of the Crank Shaft [48], and press down on the steel rod with a hand
press.
(2) Remove the Ball Bearing 6302VV [39], Distance Ring (B) [41], Final Gear [40], Feather Key 4 x 4 x 12
[51], and Crank Shaft [48] from the Inner Cover [42].
(3) Loosen three Bolts M5 x 16 [47], then take out Bearing Cover (A) [65] and Ball Bearing 6203DD [67].
3. Removal of the mouth
(1) Remove six Bolts M8 x 30 [5].
(2) Remove the Front Cover [8] from the Cylinder Case [19].
(3) Remove the Second Hammer [7], Shank Sleeve [13], Damper (A) [11], Mouth [14], Mouth Cover [15],
Mouth Washer (A) [16], and Urethane Ring (A) [17] as a single unit.
NOTE: When the Mouth [14] needs to be replaced with new one, use the new Mouth [14] painted
white.
[48]
Press the end surface of the crank shaft
by fitting a steel rod with a hand press.
Steel rod
[39]
[40]
[41]
[42]
[44]
[45]
Tubular jig

-3-
Fig. 3 • Removal of the O-ring
Fig. 4 • Disassembly of the retainer section
4. Removal of the O-rings
Because the two O-rings [12] are installed inside the Shank Sleeve [13], it may be difficult to remove.
Gently pry the O-rings [12] upward with a small flat-blade screwdriver, while being very careful not to
damage the O-ring surface as illustrated in Fig. 3.
5. Disassembly of the striker section
(1) Remove the four Bolts M8 x 40 [23], and separate the Cylinder Case [19] from the Housing Ass’y [49].
(2) Take out the Striker [21], Piston [26], and Connecting Rod Ass’y [28] in a single body from the
Cylinder Case [19].
(3) Holding the Striker [21] firmly in one hand, grasp the Connecting Rod Ass’y [28] in the other hand and
pull it forcefully to separate it from the Striker [21].
(4) Extract the Piston Pin [25] from the Piston [26] and separate the Piston Pin [25] from the Connecting
Rod Ass’y [28].
6. Disassembly of the retainer section
Remove the two Roll Pins D6 x 55 [1] from the 6 mm dia. holes of the Retainer [2], and then remove the
Lever Pin [3]. The Retainer [2] and two Retainer Dampers (A) [4] can then be removed from the Front
Cover [8].
.
[12]
[13]
Flat-blade screwdriver
[2]
[3]
[1]
[4]
[8]

-4-
Fig. 5 • Grease application positions on the inner cover
Seal ring groove
Apply Hitachi Motor Grease No. 29
to the eight positions.
Reassembly can generally be conducted by reversing the disassembly procedure. However, special
attention should be given to the following items.
1. TB1401 screw locking agent
(1) Before reassembly, all M5 and M6 hexagon socket hd. bolts and machine screws must be coated with
TB1401 screw locking agent.
(2) The following parts must be replaced with new Hitachi genuine parts after being loosened once.
Front Cover [8] fixing bolt: Nylock Hex. Socket Hd. Bolt M8 x 30 [5]
Cylinder Case [19] fixing bolt: Nylock Hex. Socket Hd. Bolt M8 x 40 [23]
Connecting Rod Ass’y [28] fixing bolt: Seal Lock Hex. Socket Hd. Bolt M8 x 16 [31]
CAUTION: Fastening bolts that become loose from vibration could cause serious damage to the
machine. Therefore, be sure to apply TB1401 screw locking agent as directed above
prior to reassembly. Before applying TB1401, carefully clean off any grease or other
foreign matter from the male and female threads with gasoline, thinner or similar
cleaning solvents.
2. Reassembly of the crank shaft section
(1) Press-fit the Ball Bearing 6205DD [45] into the Inner Cover [42], and fasten the Bearing Cover [46]
onto the Inner Cover [42] with the four Bolts M5 x 16 [47].
(2) Use a proper jig to hold the inner race of the Ball Bearing 6205DD [45] and then press-fit the Crank
Shaft [48] into the ball bearing.
(3) Insert Distance Ring (B) [41] and Feather Key 4 x 4 x 12 [51] into the Crank Shaft [48]. Press-fit the
Final Gear [40] and Ball Bearing 6302VV [39] with a hand press.
3. Reassembly of the armature ass’y
Press fit the Ball Bearing 6203DD [67] into the Inner Cover [42], and fasten Bearing Cover (A) [65] onto
the Inner Cover [42] with three Bolts M5 x 16 [47].
4. Mounting the inner cover to the housing ass'y
Use a syringe to apply Hitachi Motor Grease No. 29 to the seal ring groove in eight positions as shown in
Fig. 5 and then secure the Seal Ring [43] to prevent grease leakage due to misalignment of the Seal Ring
[43] at reassembly. Then mount the Inner Cover [42] to the Housing Ass’y [49].
Reassembly

-5-
Fig. 6 • Mounting the striker
Fig. 7 • Mounting oil seal (A)
5. Mounting the striker
The striker can be mounted in either of the following two ways.
• Mount the Connecting Rod Ass’y [28] to the Crank Shaft [48] inside the Housing Ass’y [49]. Mount the
Piston [26] and apply grease for hammer. hammer drill (Code No. 980927) to the inside and outside of
the Striker [21]. Turn the Crank Shaft [48] and move the Connecting Rod Ass’y [28] all the way inside the
Housing Ass’y [49]. Then mount the Striker [21].
• Mount the Piston [26] onto the Connecting Rod Ass’y [28]. Apply grease for hammer. hammer drill
(Code No. 980927) to the inside and outside of the Striker [21]. Mount the Striker [21].
Either of the above two ways requires a pressing force of more than 30 kg.
When a "hissing" sound is heard, the Piston [26] is properly inserted in the Striker [21].
(The "hissing" is the sound of the compressed air escaping from the Striker [21] when the Piston [26]
reaches the respiratory hole in the Striker [21].)
6. Mounting oil seal (A)
When mounting Oil Seal (A) [27] on the Piston [26],
ensure that the lip portion of Oil Seal (A) [27] is
directed toward the rear surface of the Piston [26] as
illustrated in Fig. 7. Before mounting, thoroughly coat
Oil Seal (A) [27] and O-ring (A) [22] with grease for
hammer. hammer drill (Code No. 980927) and
carefully ensure they are not damaged.
[21] (Grooved for identification)
Piston len
g
th 48 mm
[49]
[48]
Press.
[28]
Press.
Respiratory holes [26] Respiratory holes
[22]
[27]
Lip
[26]

-6-
Fig. 8 • Mounting the handle - 1
Fig. 9 • Mounting the handle - 2
7. Mounting the handle
Mount the Handle Stopper [61] to the Gear Cover [38] and secure it with the Back Cover [78]. Be sure to
put the two Handle Dampers [57] in Handle Spring (A) [56] and Handle Spring (B) [55] to prevent
abnormal noise.
Secure handle (A) of Handle (A).(B) Set [111] to the Handle Weight [60] and Handle Shaft [110]. After
wiring, put the switch lever into the lock-ON state and secure handle (B).
NOTE: It is impossible to mount handle (B) without putting the switch lever into the lock-ON state.
[38]
[61]
[78]
[57]
[56]
[55]
While pulling the Switch Lever [109] all the way,
push the pushing button to put into lock-ON state.
After securing handle (B), release the lock-ON state.
[60]
Handle (A)
Handle (B)
[108]
[110]
[109]
Push

-7-
Fig. 10 • Safety precautions on wiring work
8. Safety precautions on wiring work
To prevent breakage and electric shock due to vibration of the Switch [97], the Support [104] elastically
holds the Switch [97] in place. Vinyl Tube (A) (I.D. 7 x T0.5 x 50) [98] covers the internal wire, and the
Vinyl Tube L55 [74] covers the internal wire of the Stator Ass'y [72]. These tubes are provided to protect
the internal wires, therefore, do not forget to attach them.
Handle (A)
[104]
[97]
[98]
[72]
Internal wire of the Stator Ass'y [72]
[49]
[74]
[109]
[93]
[94]

-8-
Fig. 11 • Mounting the retainer
9. Mounting the retainer
(1) Before mounting, apply grease for hammer. hammer drill (Code No. 980927) to the sliding portion
between the Retainer [2] and Retainer Damper (A) [4] of the Front Cover [8], and Lever Pin [3].
(2) Mount two Retainer Dampers (A) [4] to the Front Cover [8],and then mount the Retainer [2].
(3) Insert the Lever Pin [3] into the 20-mm dia. hole of the Retainer [2] facing the recessed portion of the
Lever Pin [3] to the hexagonal hole of the Front Cover [8]. At this time, align the 6-mm dia. hole of the
Retainer [2] with the 7-mm dia. hole of the Lever Pin [3].
(4) Drive the Roll Pin D6 x 55 [1] into the 6-mm dia. hole (side A) of the Retainer [2] approximately 6.3
mm under the end surface of the Retainer [2] as shown in Fig. 11.
Recessed portion
[2]
[3]
6.5 mm dia. hole
[1]
[8]
6.3 mm
7 mm dia. hole
20 mm dia. hole
Side A
[4]

-9-
Fig. 12 • Gear cover filled with Nippeco SEP-3A grease
Fig. 13 • Specified grease (grease for hammer. hammer drill)
Fill specified grease (grease for hammer. hammer drill) to the following parts.
• Fill 41 g of specified grease in the Housing Ass'y [49] on the Crank Shaft [48].
• Fill 41 g of specified grease inside the Cylinder Case [19] (on the machined surface).
Apply specified grease (grease for hammer. hammer drill) to the following parts.
• Apply specified grease to the inside and outside of the Striker [21], sliding portion of the Piston [26],
outside of the Piston Pin [25], O-ring (A) [22] of the Piston [26], and Oil Seal (A) [27].
• Apply specified grease to the inside of the needle bearing in the Connecting Rod Ass'y [28].
• Apply specified grease to the sliding portion of the Second Hammer [7], O-ring (C) [9] of the Front Cover
[8], hexagonal hole of the Front Cover [8], sliding portion of the Retainer [2], sliding portion of the Front
Cover [8], and Lever Pin [3].
Fill Nippeco SEP-3A grease in the following parts.
• Fill 78 g of Nippeco SEP-3A grease in the Gear
Cover [38] so that the gears are greased.
Apply Nippeco SEP-3A grease to the following parts.
• Apply Nippeco SEP-3A grease to the pinion of the Armature Ass'y [70] (including the ball bearing), tooth
surface of the Counter Gear [63], tooth surface of the Final Gear [40], and O-ring [44] inside the ball
bearing chamber on the Crank Shaft [48] side of the Inner Cover [42].
• Apply Nippeco SEP-3A grease to the two O-rings [12] inside the Shank Sleeve [13].
Net weight Code No.
500 g 980927
70 g 308471
30 g 981840
Lubrication points and types of lubricant
500 g 70 g 30 g