Hitachi DH 40MR User manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
ROTARY HAMMER
DH 40MR
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. E467 Sep. 2002
D
MODEL
DH 40MR

REMARK:
Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s)
is(are) used in the place of company name(s) and model name(s) of our
competitor(s). The symbol(s) utilized here is(are) as follows:
Symbols Utilized Competitors
Company Name Model Name
BOSCH GBH5-40DE
B
HILTI TE55
D
MAKITA HR4000C
C

Page
CONTENTS
1. PRODUCT NAME...........................................................................................................................1
2. MARKETING OBJECTIVE .............................................................................................................1
3. APPLICATIONS..............................................................................................................................1
4. SELLING POINTS ..........................................................................................................................1
4-1. Selling Point Descriptions .............................................................................................................. 2
5. SPECIFICATIONS ..........................................................................................................................3
5-1. Specifications................................................................................................................................. 3
5-2. Optional Accessories ..................................................................................................................... 4
6. COMPARISONS WITH SIMILAR PRODUCTS ..............................................................................8
6-1. Specification Comparisons ............................................................................................................ 8
6-2. Drilling Speed Comparisons .......................................................................................................... 9
6-3. Chiseling Performance Comparison ............................................................................................ 10
6-4. Comparison of Drilling Speed Change by Pushing Force ........................................................... 10
6-5. Drilling Speed and Quantity of Body Jumping ..............................................................................11
7. PRECAUTIONS IN SALES PROMOTION ...................................................................................11
7-1. Handling Instructions ....................................................................................................................11
7-2. Caution Plate ............................................................................................................................... 12
8. REFERENCE INFORMATION ......................................................................................................12
8-1. Grease Replacement................................................................................................................... 12
8-2. O-Ring Replacement ................................................................................................................... 12
8-3. Structure of DH 40MR Rotary Hammer ....................................................................................... 13
9. REPAIR GUIDE ............................................................................................................................18
9-1. Disassembly ................................................................................................................................ 18
9-2. Reassembly ................................................................................................................................. 20
9-3. Screw Locking Agent TB1401...................................................................................................... 23
9-4. Tightening Torque ........................................................................................................................ 23
9-5. Internal Wiring.............................................................................................................................. 24
9-6. Insulation Tests ............................................................................................................................ 25
9-7. No-load Current Value ................................................................................................................. 25
10. STANDARD REPAIR TIME (UNIT) SCHEDULES .....................................................................26
Assembly Diagram for DH 40MR

--- 1 ---
1. PRODUCT NAME
Hitachi Rotary Hammer, Model DH 40MR
2. MARKETING OBJECTIVE
The Model DH 40MR is an upgraded version of the current Models DH 40MA and DH 40MB, which feature the
use of SDS-max shank tools. The performance, durability and operability are greatly improved. With this
competitive Model DH 40MR, we aim to enhance the share of SDS-max type rotary hammers.
The main specifications are as follows:
(1) High drilling speed with low vibration and noise level
(2) Self-drilling (Good feeling)
(3) Internal double-insulation construction with sturdy aluminum frame
(4) Constant speed with variable speed control
(5) Soft-touch grip for easier handling
(6) Variabel lock mechanism for easy working-angle adjustment of chisels etc.
(7) Avery original design
3. APPLICATIONS
Drilling holes in concrete and drilling anchor holes
Demolishing and chiseling of concrete. Edging, gravel road digging, compacting and tamping, grooving,
cutting, stripping and roughing, etc.
[Application examples]
Air conditioning Piping and wiring Electric fixtures
Sanitary facilities Interior finishing Other building, construction and repair work
4. SELLING POINTS
Needle-pin type slip clutch
Internal double-insulation construction
with sturdy aluminum frame Constant speed with
variable speed control
Soft-touch grip handle
for easier handling
Soft-touch grip side-handle
for easier handling
High drilling speed with low vibration and noise level
Self-drilling (Good feeling)
A very original design
Change lever for switching between "Rotation +
Hammering" (for drilling), "Neutral" (for positioning
the tool tip) and "Hammering only" (for chiseling
and chipping)

--- 2 ---
4-1. Selling Point Descriptions
4-1-1. High drilling speed with low vibration and noise level
The drilling speed is 10 % faster than that of similar products thanks to efficient striking energy transmission and
speed setting. Even so, the Model DH 40MR produces lower vibration and noise levels than those of similar
products.
Maker •Model
Ratio of drilling speed %
Full-load vibration level dB (VL)
m/s2
HITACHI
DH 40MR
100
116.8
4-1-2. Self-drilling (Good feeling)
Thanks to the computer-simulated optimum striking characteristics, the quantity of body jumping is less than that
of the current Model DH 40MA and the working tool smoothly penetrates into the workpiece with a light pressing
force. The Model DH 40MR realizes quicker self-drilling with better impact feeling.
4-1-4. Dial type, constant speed with variable speed control
The Model DH 40MR is equipped with a built-in electronic control circuit
that can adjust the number of hammering steplessly between 1320 and
2650 min-1 with the dial. Even though the load varies, the Model
DH 40MR provides better operability and stable and efficient drilling
performance because the constant speed control minimizes changes in
number of rotation and hammering.
Impact efficiency
Maximum compressed air force (piston force)
Quantity of body jumping
About 10 % up
About 50 % down
About 25 % down
Full-load noise level dB (A)
No-load noise level dB (A)
6.9
92.4
79.5
HITACHI
DH 40MA/MB
64
118.0
7.9
94.6
89.4
B
85
119.8
9.8
93.7
85.0
D
64
116.1
6.4
93.2
83.0
C
74
118.5
8.4
93.5
80.3
* Ratio of drilling speed: A28-mm dia. drill bit is used.
Full-load vibration and noise levels: A 20-mm dia. drill bit is used.
4-1-3. Internal double-insulation construction with sturdy aluminum frame
The aluminum die-cast outer frame is very sturdy (same as the Models H 45MR/H 45SR). In addition, a plastic
internal S holder is adopted to realize double-insulation construction. Thus the housing has greater rigidity and
the double-insulated motor has greater durability. The Model DH 40MR is heavy-duty and the service life of the
carbon brush is greatly prolonged (1.5 times longer than the conventional one) minimizing disconnection of the
armature, deviation of the core and grease leakage.
4-1-5. Soft-touch grip for easier handling
The double-layer molded handle consists of a nylon resin base covered with a soft plastic layer to ensure a soft
touch and firm, non-slip grip of the handles.
Speed-adjust dial

--- 3 ---
5. SPECIFICATIONS
5-1. Specifications
Capacity
Power source
Current
Power input
Switch
Type of handles
Impact rate
Weight
Packaging
Standard accessories
Drill bit (Max. diameter): 40 mm (1-9/16")
Core bit (Max. diameter): 105 mm (4-1/8")
AC single phase 50 Hz or 60 Hz
950 W
Trigger switch
D-shaped handle and side handle
No load and full load: 1,320 to 2,650 min-1
Product: 6.5 kg (14.3 lbs.); excluding cord and side handle
Packed: 10.0 kg (22.1 lbs.)
Corrugated cardboard box with plastic tool case
•Plastic case ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Side handle •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Hex. bar wrench (for M6) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Hex. bar wrench (for M5) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Hex. bar wrench (for M4) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Stopper ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
•Grease (A) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
4-1-6. Change lever for switching between "Rotaion + Hammering", "Neutral" and "Hammering only"
The Model DH 40MR provides three functions, "rotation + hammering"
function (for drilling), "neutral" function (for positioning the tool tip) and
"hammering only" function (for chiseling and chipping).
These function modes can be easily switched by using the change lever.
The tool angle can be easily changed in 12 steps by turning the grip
with the change lever positioned at "Neutral".
4-1-7. Needle-pin type slip clutch
The Model DH 40MR is equipped with a needle-pin type slip clutch for higher slip torque accuracy and enhanced
safety (same as the Model DH 40MA).
Voltage 110 V
10 A
120 V
9.2 A 220 V
5 A 230 V 4.8 A 240 V 4.6 A
Enclosure
Motor type AC single-phase series commutator motor
Materials: Aluminum alloy die casting
Nylon resin (Handle, handle cover, tail cover and crank cover)
Paint : Silver green metallic, black
Double insulation
Insulation structure
Rotation rate No load and full load: 240 to 480 min-1

--- 4 ---
5-2. Optional Accessories
1. Drilling work for through-holes (Rotation + Hammering)
+
+
(1) Drill bit (taper shank) (2) Taper shank adapter
(SDS max shank)
(3) Cotter
(1) Drill bit (SDS max shank)
Outer diameter
(mm)
16 (5/8")
19 (3/4")
22 (7/8")
25 (1")
28 (1-1/8")
32 (1-1/4")
38 (1-1/2")
40 (1-9/16")
Over length
(mm)
340 (13-3/8")
340 (13-3/8")
320 (12-5/8")
320 (12-5/8")
370 (14-9/16")
370 (14-9/16")
370 (14-9/16")
370 (14-9/16")
Code No.
313448
313449
313450
313451
313452
313453
313454
313455
Outer diameter
(mm)
16 (5/8")
19 (3/4")
22 (7/8")
25 (1")
28 (1-1/8")
32 (1-1/4")
38 (1-1/2")
40 (1-9/16")
Over length
(mm)
540 (21-1/4")
540 (21-1/4")
520 (20-15/32")
520 (20-15/32")
570 (22-7/16")
570 (22-7/16")
570 (22-7/16")
570 (22-7/16")
Code No.
313456
313457
313458
313459
313460
313461
313462
313463
2. Drilling work for anchor holes (Rotation + Hammering)
1 Drill bit (Taper shank)
+
(1) Drill bit (Taper shank)
Outer diameter (mm)
11 (7/16")
12.3 (15/32")
12.7 (1/2")
14.3 (9/16")
14.5 (9/16")
17.5 (11/16")
Code No.
944460
944461
993038
944462
944500
944463
(2) Taper shank adapter
Taper dimension Code No.
Morse taper No. 1 313464
(3) Cotter
Code No.
944477
2 SDS-plus shank bit adapter
+
(1) Drill bit (SDS-plus shank) (2) SDS-plus shank
bit adapter
(SDS max shank)
Code No. 313465
+

--- 5 ---
3. Boring work for large-diameter holes (Rotation + Hammering)
(1) Guide plate
(2) Center pin
(3) Core bit (4) Core bit shank
(SDS max shank)
+
++
(1) Guide plate
Core bits with outer diameter of 32, 35, 38, 45, 50, 54, 60, 64, 70, 75, 79, 94, 100, 105 mm (1-1/4", 1-3/8",
1-1/2", 1-3/4", 2", 2-1/8", 2-3/8", 2-2/1", 2-3/4", 2-15/16", 3-1/8", 3-1/16", 3-15/16", 4-1/8")
[Guide plate is not used with core bits with outer diameter of 25 mm (1") and 29 mm (1-1/8")]
(2) Center pin
Code No. 956009 for core bits with outer diameter of 32, 35 mm (1-1/4", 1-3/8")
Code No. 955165 for core bits with outer diameter of 38, 45, 50, 54, 60, 64, 70, 75, 79, 94, 100, 105 mm
(1-1/2", 1-3/4", 2", 2-1/8", 2-3/8", 2-1/2", 2-3/4", 2-15/16", 3-1/8", 3-11/16", 3-15/16", 4-1/8")
[Center pin is not used with core bits with outer diameter of 25 mm (1") and 29 mm (1-1/8").]
(3) Core bit
Outer diameter (mm)
25 (1")
29 (1-1/8")
32 (1-1/4")
35 (1-3/8")
38 (1-1/2")
45 (1-3/4")
Code No.
955994
955995
955996
955998
956000
955154
Outer diameter (mm)
50 (2")
54 (2-1/8")
60 (2-3/8")
64 (2-1/2")
70 (2-3/4")
75 (2-15/16")
Code No.
959706
955155
959707
956002
959708
959709
Outer diameter (mm)
79 (3-1/8")
94 (3-11/16")
100 (3-15/16")
105 (4-1/8")
Code No.
955157
956004
959710
955159
4. Hole drilling .................................... For drilling steel and wood
+
(1) 13 mm drill chuck
(13VLA)
+
(2) Chuck adapter
(SDS max shank)
(3) Chuck wrench
+
(1) 13 mm drill chuck (13VLA) (2) Chuck adapter (3) Chuck wrench
Code No. 950272 Code No. 313468 Code No. 930515
(4) Core bit shank (SDS max shank)
Code No. 313466 for core bits with outer diameter of 25, 29, 32, 35 mm (1", 1-1/8", 1-1/4", 1-3/8")
Code No. 313467 for core bits with outer diameter of 38, 45, 50, 54, 60, 64, 70, 75, 79, 94, 100, 105 mm
(1-1/2", 1-3/4", 2", 2-1/8", 2-3/8", 2-1/2", 2-3/4", 2-15/16", 3-1/8", 3-11/16", 3-15/16", 4-1/8")

--- 6 ---
(Socket) (1) Chemical anchor adapter
(SDS max shank)
+
+
(1) Bull point (SDS max shank)
12.7 mm (1/2")
19.0 mm (3/4")
Socket square size Code No.
313469
313470
5. Chemical anchor holes drilling work (Rotation + Hammering)
+
6. Demolition work (Hammering)
280 mm (11")
400 mm (15-3/4")
Overall length Code No.
313471
313472
7. Grooving and edging (Hammering)
+
(1) Cold chisel (SDS max shank)
280 mm (11")
400 mm (15-3/4")
Overall length Code No.
313473
313474
+
(1) Cutter (SDS max shank)
400 mm (15-3/4")
Overall length Width
50 mm (2")
8. Cutting and stripping (Asphalt cutting etc.) (Hammering)
Code No.
313475
9. Digging (Substitute pick-ax) (Hammering)
+
(1) Scoop (SDS max shank)
400 mm (15-3/4")
Overall length Code No.
313476

--- 7 ---
10. Surface roughing work (Hammering)
+
(1) Bushing tool
+
(2) Shank (SDS max shank)
220 mm (8-21/32")
Overall length Code No.
313479
313477
Code No.
11. Tamping work (Hammering)
+
(1) Rammer
+
(2) Shank (SDS max shank)
220 mm (8-21/32")
Overall length Code No.
313479
313478
150 mm x 150 mm
Code No.
500 g (1.1 lbs.) Can
12. Syringe (for chip removal)
Code No. 944575
Code No. 980927
70 g (2.5 oz) Tube
Code No. 308471
30 g (1 oz) Tube
Code No. 981840
13. Impact drill grease
(Note)
Code numbers listed above are subject to change without noitce. Please refer to periodic Technical News
Bulletins.