Hitachi DH 40SR Instruction manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
ROTARY HAMMER
DH 40SR
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. E471 Apr. 2003
D
MODEL
DH 40SR

REMARK:
Throughout this TECHNICAL DATA AND SERVICE MANUAL, symbols
are used in the place of company names and model names of our
competitors. The symbols utilized here are as follows:
Symbols Utilized Competitors
Company Name Model Name
MAKITA HR3811
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 .............................................................................. 9
6-1. Specification Comparisons ............................................................................................................. 9
6-2. Drilling Speed Comparisons ......................................................................................................... 10
6-3. Chiseling Performance Comparison ..............................................................................................11
7. PRECAUTIONS IN SALES PROMOTION ....................................................................................11
7-1. Handling Instructions .....................................................................................................................11
7-2. Caution Plate .................................................................................................................................11
8. REFERENCE INFORMATION ...................................................................................................... 12
8-1. Grease Replacement.................................................................................................................... 12
8-2. O-Ring Replacement .................................................................................................................... 12
8-3. Structure of the Model DH 40SR Rotary Hammer........................................................................ 13
9. REPAIR GUIDE ............................................................................................................................ 17
9-1. Disassembly ................................................................................................................................. 17
9-2. Reassembly .................................................................................................................................. 20
9-3. Screw Locking Agent TB1401....................................................................................................... 25
9-4. Tightening Torque ......................................................................................................................... 25
9-5. Internal Wiring............................................................................................................................... 25
9-6. Insulation Tests ............................................................................................................................. 26
9-7. No-load Current Value .................................................................................................................. 26
10. STANDARD REPAIR TIME (UNIT) SCHEDULES ..................................................................... 27
Assembly Diagram for DH 40SR

--- 1 ---
1. PRODUCT NAME
Hitachi Rotary Hammer, Model DH 40SR
2. MARKETING OBJECTIVE
The Model DH 40SR is an upgraded version of the current Model DH 40SA, which features the use of Hitachi
13 mm hexagonal tools. The performance, durability and operability are greatly improved. With this competitive
Model DH 40SR, we aim to enhance the share of Hitachi 13 mm hexagonal shank 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 control
(5) Soft-touch grip for easier handling
(6) Ahighly reliable mechanism for prevention of idle hammering and shock-absorbing mechanism results in
prolonged service life and comfortable operation.
(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
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
A highly reliable mechanism for prevention of idle
hammering and shock-absorbing mechanism results
in prolonged service life and comfortable operation.
Constant speed control

--- 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.
Even so, the Model DH 40SR 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 40SR
100
118
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 40SA and the working tool smoothly penetrates into the workpiece with a light pressing
force. The Model DH 40SR realizes quicker self-drilling with better impact feeling.
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 and DH 40MR).
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 40SR 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.
4-1-4. Constant speed control
The Model DH 40SR is equipped with a built-in electronic control circuit that can keep constant speed in either no-
load operation or actually loaded operation. The Model DH 40SR provides better operability and stable, efficient
drilling performance even if the load varies because the constant speed control minimizes changes in speed and
number of hammering.
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.
Full-load noise level dB (A)
No-load noise level dB (A)
8.0
95
79
HITACHI
DH 40SA
72
118
8.0
95
88
C
72
120
10.2
96
87
* Each product used a 25-mm dia. drill bit for the above measurement.

--- 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): 120 mm (4-3/4")
AC single phase 50 Hz or 60 Hz
950 W
Trigger switch
D-shaped handle and side handle
No load and full load: 2,800 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
Voltage 110 V
10 A 230 V
4.8 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: 510 min-1
4-1-6. A highly reliable mechanism for prevention of idle hammering and shock-absorbing mechanism results in
prolonged service life and comfortable operation
Conventional mechanism for prevention of idle hammering is to open and close the air holes according to the
movement of the striker. The Model DH 40SR has air holes located at the position unaffected by the rebound of
the striker at no load. The air holes are opened and closed by the movement of slide sleeve (A) provided around
the cylinder that interlocks with the tool and the second hammer to prevent to idle hammering. This mechanism
securely prevents idle hammering even if the striker rebounds heavily when drilling holes using a large-diameter
drill bit. The Model DH 40SR has prolonged service life and improved operability even in the operation that
requires care not to destroy the surroundings.
At the instance of releasing the working tool from the workpiece by moving the main body up, the second hammer
contacts driver then the cushion (damper (B)) provided between driver holder and front cover absorbs the striking
force of the second hammer. Thus the Model DH 40SR has greater durability than the similar products.
4-1-7. Needle-pin type slip clutch
The Model DH 40SR is equipped with a needle-pin type slip clutch for higher slip torque accuracy and enhanced
safety (same as the Model DH 40SA).

--- 4 ---
5-2. Optional Accessories
1. Drilling work for through-holes (rotation + hammering)
+
+
(1) Drill bit (taper shank) (2) Taper shank adapter
(3) Cotter
(1) Drill bit (hexagon shaft)
Outer diameter (mm)
16 (5/8")
18 (11/16")
19 (3/4")
20 (25/32")
22 (7/8")
25 (1")
28 (1-1/8")
30 (1-3/16")
32 (1-1/4")
35 (1-3/8")
38 (1-1/2")
40 (1-9/16")
280 (11")
Code No.
985721
985724
985727
985730
985733
985736
985739
313322
Outer length (mm)
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 985750
(3) Cotter
Code No.
944477
400 (15-3/4")
Code No.
985720
985723
985726
985729
985732
985735
985738
505 (19-7/8")
Code No.
985722
985725
991334
985728
985731
985734
985737
985740
550 (21-5/8")
Code No.
991330
991331
991332
991333
991335
991336
991337
991338
991339
991340
991341
21.5 (7/8") 944464 Morse taper No. 2 985751

--- 5 ---
985754
985755
Taper shank adapters for A-taper or
B-taper shanks are provided as optional
accessories. Taper shank drill bits are
not provided.
A-taper
B-taper
9.7 mm (3/8") x 1/20 Taper (A)
12.9 mm (1/2") x 1/20 Taper (B)
For Australia
K-taper shank adapter 992813
+
(1) Drill bit (ratio shank) (2) Ratio shank adapter
+
Code No. 985761
A ratio shank adapter is provided as an optional accessory, but corresponding drill bits are not provided.
3. Boring work for large-dia. holes (rotation + hammering)
(1) Guide plate (2) Center pin (3) Core bit (4) Core bit shank
+
+
(1) Guide plate
Core bits with outer diameter of 32, 35, 38, 45, 54, 64, 79, 94, 105, 120 mm (1-1/4", 1-3/8", 1-1/2", 1-3/4",
2-1/8", 2-2/1", 3-1/8", 3-1/16", 4-1/8", 4-3/4")
[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, 54, 64, 79, 94, 105, 120 mm
(1-1/2", 1-3/4", 2-1/8", 2-1/2", 3-1/8", 3-11/16", 4-1/8", 4-3/4")
[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 (in.)
25 mm (1")
29 mm (1-1/8")
32 mm (1-1/4")
35 mm (1-3/8")
38 mm (1-1/2")
45 mm (1-3/4")
Code No.
955994
955995
955996
955998
956000
955154
Outer diameter (in.)
54 mm (2-1/8")
64 mm (2-1/2")
79 mm (3-1/8")
94 mm (3-11/16")
105 mm (4-1/8")
120 mm (4-3/4")
Code No.
955155
986002
955157
956004
955159
956006
+
(4) Core bit shank
Code No. 956008 for core bits with outer diameter of 25, 29, 32, 35 mm (1", 1-1/8", 1-1/4", 1-3/8")
Code No. 955163 for core bits with outer diameter of 38, 45, 54, 64, 79, 94, 105, 120 mm
(1-1/2", 1-3/4", 2-1/8", 2-1/2", 3-1/8", 3-11/16", 4-1/8", 4-3/4")

--- 6 ---
(1) Anchor size
W1/4" (No. 20)
W5/16" (No. 25)
W3/8" (No. 30)
W1/2" (No. 40)
W5/8" (No. 50)
Code No.
985756
985757
985758
985759
985760
+
+
(1) Anchor adapter (for rotation + hammering)
Anchor size W1/4" (No. 20), W5/16" (No. 25), W3/8" (No. 30),
W1/2" (No. 40), W5/8" (No. 50)
(5) Core bit for efficient drilling
Center pin (C)
Outer diameter (in)
65 mm (9-2/16")
80 mm (3-5/32")
90 mm (3-1/2")
100 mm (3-15/16")
105 mm (4-1/8")
Code No.
903901
Core bit (with guide plate)
Code No.
992819
Core bit shank
Code No.
992814
992815
992816
992817
992818
4. Anchor work for self-drilling anchors (rotation + hammering)
++
+
(2) Drift key (Code No. 944574)
5. Anchor work for self-drilling anchors (hammering)
++
(1) Anchor adapter (for hammering)
Anchor size: W3/8" (No. 30), W1/2" (No. 40)
W5/8" (No. 50)
(2) Turning handle (Code No. 944573)
(3) Drift key (Code No. 944574)
(1) Anchor size
W3/8" (No. 30)
W1/2" (No. 40)
W5/8" (No. 50)
Code No.
981929
981930
981931

--- 7 ---
+
(1) Bull point
6. Demolition work (hammering)
280 mm
450 mm
Overall length Code No.
981922
981923
7. Grooving and edging work (hammering)
+
(1) Cold chisel
280 mm
450 mm
Overall length Code No.
981925
981926
+
(1) Cutter
280 mm (11")
Width
45 mm (2")
8. Cutting and stripping (asphalt cutting, etc.) (hammering)
Code No.
981924
9. Digging work (substitute pick-ax) (hammering)
+
(1) Scoop
405 mm (16")
Overall length Code No.
956126
Overall length: 280 mm (11"), 450 mm (17-3/4")
Overall length: 280 mm (11"), 450 mm (17-3/4")
Overall length
10. Roughing surface work (hammering)
+
(1) Bushing tool
+
(2) Shank
250 mm (10")
Overall length Code No.
955186
Code No. 955183