Hitachi H 65SD Manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
HAMMER
H 65SD
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. E452 Sep. 1999
H
MODEL
H 65SD

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
MAKITA HM1303B
C-2 MAKITA HM1500B
C-1

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
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
4
5-1. Optional Accessories
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
5
6. COMPARISONS WITH SIMILAR PRODUCTS
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
7
6-1. Specification Comparisons
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
7
6-2. Demolition Performance Comparisons •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
7. PRECAUTIONS IN SALES PROMOTION•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8
7-1. Handling Instructions
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
8
7-2. Caution Plate
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
8
7-3. Grease Replacement
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
9
7-4. O-Ring Replacement
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
9
8. REFERENCE INFORMATION ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10
8-1. Sealed and Dustproof Construction
•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
10
8-2. Vibration-Absorbing Construction •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10
8-3. Tool Retainer •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
9. REPAIR GUIDE •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
9-1. Precautions and Suggestions for Disassembly and Reassembly of the Main Body •••••••••••••••••••••• 12
10. STANDARD REPAIR TIME (UNIT) SCHEDULES •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 19
[ Appendix ]
Assembly Diagram for H 65SD •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 20
Notice for use
Specifications and parts are subject to change for improvement.
Refer to Hitachi Power Tool Technical News for further information.

--- 1 ---
1. PRODUCT NAME
Hitachi Electric Hammer, Model H 65SD
2. MARKETING OBJECTIVE
The Model H 65SD is a grease-sealed and double-insulated electric hammer. It has a tool retainer to permit the
use of 28.5 mm (1-1/8 ") air tool shank tools, standard hexagonal shank tools (combo type), and retaining groove
tools without collar. The Model H 65SD has been developed based on the current Model H 65SB, which features
the use of Hitachi 30 mm hexagonal and round shank tools. Chipping and demolishing capabilities are equivalent
to the Model H 65SB.
3. APPLICATIONS
Demolishing of concrete and similar materials.
Groove and channel digging in concrete.
Groove and channel digging in asphalt and gravel roads.
Tamping/compacting of asphalt and graveled roads.
Cutting of asphalt.
[Typical Applications]
Construction work, piping/wiring work, water supply/drain work, etc.
4. SELLING POINTS
Maker •Model Weight Overall length
HITACHI H 65SD 18.0 kg (39.7 lbs) 823 mm (32-13/32 ")
HITACHI H 65SB 16.0 kg (35.3 lbs) 726 mm (28-37/64 ")
HITACHI H 65 18.0 kg (39.7 lbs) 807 mm (31-49/64 ")
C-1 16.0 kg (35.3 lbs) 823 mm (32-13/32 ")
C-2 19.0 kg (41.9 lbs) 807 mm (31-49/64 ")

--- 2 ---
Highest demolition power in its class
Soft touch and 360 adjustable
side handle for easy operations
4-1. Selling Point Descriptions
4-1-1. Largest demolition power in this class
The powerful impact force of each blow ensures efficient and easy demolishing concrete.
The demolition performance is 1.0 --- 1.3 times more powerful than that of similar products.
4-1-2. Tool retainer accepts 3 types of 28.5 mm (1-1/8 ") hex. shank tools
Three types of shank tools (Fig. 1) can be used in
the Model H 65SD by turning the tool retainer in the
following two methods. Air tool shank tool
Standard hex. shank
tool (combo type)
Retaining groove tool
without collar
Fig. 1
Internal double-insulation construction
with sturdy aluminum frame
Tool retainer accepts 3 types of
28.5 mm (1-1/8 ") hex. shank tools
Vibration-absorbing handle
for less operator fatigue
Maker •Model Ratio of demolished weight (%)
HITACHI H 65SD 100
HITACHI H 65SB 100
HITACHI H 65 97
C-1 80
C-2 90

--- 3 ---
Fig. 2
(1) Mounting air tool shank tools and standard hex. shank tools (combo type)
(2) Mounting standard hex. shank tools (combo type) and retaining groove tools without collars
Fig. 3
4-1-3. Vibration-absorbing handle for less operator fatigue
There are two vibration-absorbing rubber pads, illustrated below, designed to efficiently absorb the vibration from
the main body of the tool and minimize its transmission to the arms of the operator. One is mounted between the
handle and the gear cover; the other is mounted between the handle and the housing.
Fig. 4
Vibration-absorbing rubber
Handle side
Vibration-absorbing rubber

--- 4 ---
5. SPECIFICATIONS
H 65SD
Power source
Voltage (V)
Motor type
Insulation structure
Enclosure
Switch
Type of handles
Full-load current
Power input
Striking speed
Weight
Packaging
Standard accessories
Single-phase AC 50/60 Hz
110, 115, 230, 240
AC single-phase series commutator motor
Double insulation
Materials: Aluminum alloy die casting,
Cast aluminum alloy,
Glass-fiber reinforced plastic resin
Paint: Hammer-net silver green and black
Trigger switch (with stopper)
D-shaped handle and side handle
11.8 A (110 V), 11.4 A (115 V), 5.7 A(230 V), 5.4A (240 V)
1,240 W
1,800/ min.
1,400/ min.
Product: 18.0 kg (39.7 lbs); excluding cord
Packed: 24.5 kg (54.0 lbs)
Corrugated cardboard box with steel tool case
Hex. bar wrench (for M4) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
Hex. bar wrench (for M8) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
Steel tool case ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
Side handle ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
Fig. 5
Hand-grip of urethane resin
Vibration-absorbing side handle
The side handle, made of urethane resin,
reduces vibration transmitted to hands for
reduction of operator fatigue.
Item
No-load
Full-load

--- 5 ---
5-1. Optional Accessories
1. Demolition work
(1) Bull point
2. Grooving and chiseling work
(1) Cold chisel
3. Cutting and stripping work (asphalt cutting, etc.)
(1) Cutter
4. Digging (substitute pick-ax)
(1) Scoop
Overall length
410 mm (16-9/64") Code No. 996372
Overall length
410 mm (16-9/64")
520 mm (20-15/32")
Code No.
996373
985231
Width
75 mm (3")
75 mm (3")
Overall length
410 mm (16-9/64")
520 mm (20-15/32")
Code No.
996374
985232
Overall length
546 mm (21-1/2")
Code No.
985233
+
+
+
+

--- 6 ---
5. Grease for impact drill
500 g (1.1 lbs) Can
Code No. 980927 Code No. 308471
30 g (1 oz) Tube
Code No. 981840
70 g (2.5 oz) Tube
(Note)
Code numbers listed above are subject to change. Please refer to periodic Technical News Bulletins.

--- 7 ---
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons
Maker
Model name
Power input
Full-load impact rate
Dimensions
Striking energy per stroke
Insulation structure
No-load noise level
Weight (without cord)
HITACHI
Length
Height
Width
W
bpm
mm
mm
mm
J
---
dB(A)
kg
H 65SD
1,240
1,400
823
(32-13/32")
235
(9-1/4")
120
(4-23/32")
42
Double
insulation
92
18.0
(39.7 lbs)
H 65SB
1,240
1,400
726
(28-37/64")
235
(9-1/4")
120
(4-23/32")
42
Double
insulation
92
16.0
(35.3 lbs)
H 65
1,240
1,400
807
(31-49/64")
231
(9-3/32")
120
(4-23/32")
39.5
Single
insulation
92
18.0
(39.7 lbs)
C-1
1,300
1,450
823
(32-13/32")
212
(8-11/32")
120
(4-23/32")
39.5
Double
insulation
94
16.0
(35.3 lbs)
C-2
1,430
1,300
807
(31-49/64")
215
(8-15/32")
---
(---)
40.3
Double
insulation
93
19.0
(41.9 lbs)
6-2. Demolition Performance Comparisons
The data shown in Fig. 6 are obtained in actual factory tests, and are for reference only. The demolished amount
may vary in accordance with operating conditions, operator skill, etc.
Fig. 6
H 65SB
Demolished amount
(kg/30 min.)
250
20015010050
187
187
182
150
168
H 65SD
H 65
C-1
C-2
At rated
voltage
Demolished weight for 30 min. (kg)

--- 8 ---
7. PRECAUTIONS IN SALES PROMOTION
In the interest of promoting the safest and most efficient use of the Model H 65SD Electric Hammer by all of our
customers, it is very important that, at the time of sale, the salesperson carefully ensures that the buyer seriously
recognizes the importance of the contents of the Handling Instructions, and fully understands the meaning of the
precautions listed on the Caution Plate attached to each tool.
7-1. Handling Instructions
Although every effort is made in each step of design, manufacture and inspection to provide protection against
safety hazards, the dangers inherent in the use of any electric tool cannot be completely eliminated. Accordingly,
general precautions and suggestions for the use of electric power tools, and specific precautions and suggestions
for the use of the Electric Hammer are listed in the Handling Instructions to enhance the safe, efficient use of the
tool by the customer. Salespersons must be thoroughly familiar with the contents of the Handling Instructions to
be able to offer appropriate guidance to the customer during sales promotion.
7-2. Caution Plate
The Model H 65SD unit is provided with a Caution Plate (illustrated below) which lists basic safety precautions in
its use. Carefully ensure that the customer fully understands and follows these precautions before using the tool.
For the U.S.A. and Canada
Caution Plate on the back of tool case lid
CAUTION
The grease should be exchanged once every six months after the
machine is purchased. The authorized HITACHI power tool repair
shop or the shop from where the tool was bought should be
instructed when it is time to exchange the grease.
Before working on walls, floors, etc., check for buried or hidden
electrical wires and water or gas pipes.
-- WARNING -- To reduce the
risk of injury,
user must read and understand instruction manual.
AVERTISSEMENT Afin de rèduire le risque de
blessures, l'utilisateur doit lire et
bien comprendre le mode d'emploi.
Hitachi Koki

--- 9 ---
To ensure the smooth reciprocating of the striker and the second hammer, special grease (Part No. 980927
or 981840 or 308471 for impact drill) is used in the hammering section. If the hammering section [inside
the cylinder case and housing (crank shaft side)] is disassembled, thoroughly wipe away all old grease
from all parts, and apply 30 g (1 oz) of new grease within the cylinder case and 40 g (1.4 oz) of new grease
within the housing (crank shaft side). Do not exceed the designated amounts of grease. If there is
excessive grease, it may flow between the striker and piston and cause reduced hammering efficiency
and/or increased recoil force.
7-3. Grease Replacement
Different kinds of grease are used in the electro-pneumatic hammering section and the speed-change gear
section. It is not necessary to replenish the grease between 6-month (approx.) change intervals unless the tool is
disassembled or there is grease leakage due to a damage or worn seal.
N.P.C. SEP-3A (Part No. 930035) is used in the speed-change gear section (inside the gear cover). The proper
supply amount is 80 g (2.8 oz). Never use the hammering section special grease in the speed-change section.
The special soft grease would leak into the motor section and cause serious problems.
7-4. O-Ring Replacement
The O-ring mounted on the piston is extremely important to ensure adequate sealing of the air pressure. Although
the O-ring is made of special rubber to ensure a long service life, it does nonetheless become worn and should be
replaced periodically depending on the frequency of tool use. With average use, it is recommended that the
O-ring should be replaced every six months to ensure maximum effectiveness.

--- 10 ---
8. REFERENCE INFORMATION
8-1. Sealed and Dustproof Construction
The cylinder case section and housing (crank case side) are sealed by five (5) O-rings and a seal ring. These
seals serve to prevent leakage of the grease, as well as to prevent dust and dirt from the entering the mechanism.
Fig. 7
8-2. Vibration-Absorbing Construction
There are vibration-absorbing cushions (handle rubbers) provided between the switch handle and the crank case
and motor housing which allow significantly less vibration to transfer from the tool to the arm of the operator than
conventional type hammers.
Vibration-absorbing rubber
As shown in Fig. 8, the main unit and handle are
coupled only by the vibration-absorbing rubber.
As vibration is absorbed by the shearing type
vibration-absorbing construction, the vibration-
absorbing effect is high.
Fig. 8
O-ring (64.4 mm inner dia.)
O-ring (44.4 mm inner dia.)
O-ring
(23.7 mm inner dia.)
O-ring
(59.6 mm inner dia.)
Seal ring
Gear cover
Handle rubber
Switch handle
Cylinder case O-ring
(37.5 mm inner dia.)
Oil cap
Housing
Plate (A)
(connected with the
hammer main body)
Handle rubber
Vibration-absorbing rubber
Plate (B)
(connected with
the handle)
Vibration works in the shearing
direction of the rubber.
Oil cap

--- 11 ---
8-3. Tool Retainer
Three types of shank tools (Fig. 1) can be mounted to
the Model H 65SD by turning the saddle-shaped
retainer.
(1) Mounting air tool shank tool and standard hex.
shank tool
Raise the retainer in A direction and insert the
tool shank into the hexagonal hole of the front
cover as far as it will go (Fig. 9). Put the retainer
back in position to fix the tool shank (Fig. 10).
(2) Mounting standard hex. shank tool and retaining
groove tool without collar
Lower the retainer in B direction and insert the
tool shank into the hexagonal hole of the front
cover as far as it will go facing the recessed
portion of the tool shank to the retainer (Fig. 11).
Turn the retainer in C direction to fix the tool
shank (Fig. 12).
Retainer Front cover
Fig. 9
Fig. 10
Tool shank
Fig. 11 Fig. 12
Tool shank Front cover
Retainer Recessed portion
A
C
B

--- 12 ---
9. REPAIR GUIDE
9-1. Precautions and Suggestions for Disassembly and Reassembly of the Main Body
The [Bold] numbers in the descriptions below correspond to the item numbers in the Parts List and exploded
assembly diagram.
9-1-1. Disassembly
[NOTE] If it is difficult to loosen and remove the fixing bolts, use an appropriate heating device to heat them to
approximately 80 C (176 F).
Disassembly of the Armature Ass'y [74]
(1) Loosen the four M4 x 12 Seal Lock Hex. Socket Hd. Bolts [51], remove the Cap Covers [52], Cap Rubbers
[53] and Brush caps [54], and take out the Carbon Brushes [55]. At this time, be very careful not to lose the
disassembled parts.
(2) Loosen the four M8 x 35 Nylock Hex. Socket Hd. Bolts [25], and remove the Cylinder Case [18]. Next, after
loosening the M8 x 16 Seal Lock Hex. Socket Hd. Bolt [35], the Connecting Rod Ass'y [29] and Crank Washer
[34] can be disassembled. Leave the Striker [22] and Piston [28] as they are.
(3) Loosen the four M5 x 16 Seal Lock Hex. Socket Hd. Bolts [60], and take off Handle (A) [81] and Handle (B)
[86]. Next, loosen the six M6 x 45 Seal Lock Hex. Socket Hd. Bolts [57], and disassemble the Gear Cover
[39] and Counter Gear [62]. Then, by inserting a flat-blade screwdriver or similar tool into one of the air vents
of the Inner Cover [43] and lifting it upwards, the Inner Cover [43], Armature Ass'y [74], Crank Shaft [48], and
related parts can be removed in a single body.
(4) As illustrated in Fig. 13, support the Inner Cover [43] 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 [74] from the Inner Cover [43].
Fig. 13
Disassembly of the Crank Shaft [48] section
First, remove the four M5 x 16 Seal Lock Hex. Socket Hd. Bolts [47] which fix the Bearing Cover [46]. Then,
as illustrated in Fig. 14, support the lower surface of the Inner Cover [43] 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. The 6205DDCM Ball Bearing [45], Distance Ring (B) [42], Final Gear [41], two Woodruff Keys
[64], and Crank Shaft [48] can then be disassembled from the Inner Cover [43].
Inner Cover [43]
Crank Shaft [48]
Armature Ass'y [74]
Press the end surface of the armature shaft
with a hand press
Tubular jig

--- 13 ---
Fig. 14
Press the end surface of the Crank Shaft
by fitting a steel rod with a hand press.
Final Gear [41]
Inner Cover [43]
Crank Shaft [48]
Ball Bearing [40]
Tubular jig
Disassembly of remaining parts from the Inner Cover [43]
Loosen the three M5 x 16 Seal Lock Hex. Socket Hd. Bolts [47], and take out Bearing Cover (A) [70] and the
6203DDCM Ball Bearing [71].
Disassembly of the Mouth [14] and related parts
First, remove the six M8 x 30 Nylock Hex. Socket Hd. Bolts [4], and separate the Front Cover [5] from the
Cylinder Case [18]. The Second Hammer [7], Shank Sleeve [13], Damper (A) [12], Mouth [14], Mouth Cover
[15], Mouth Washer [16], and Urethane Ring [17] can then be taken out.
Removal of O-Ring (E) [10]
As O-Ring (E) [10] is installed in the inner portion of the Shank Sleeve [13], it may be difficult to remove. As
illustrated in Fig. 15, pry O-Ring (E) upward gently with a slender flat-blade screwdriver, being very careful not
to damage the surface of the O-ring.
Removal of the Striker [22] and related parts
Remove the four M8 x 35 Nylock Hex. Socket Hd. Bolts
[25], and separate the Cylinder Case [18] from the Housing
Ass'y [50]. From the Cylinder Case [18], take out the
Striker [22], Piston [28], and Connecting Rod Ass'y [29] in a
single body. Holding the Striker [22] firmly in one hand,
grasp the Connecting Rod Ass'y [29] in the other hand and
pull it forcefully to separate it from the Striker. Finally,
extract the Piston Pin [27] from the Piston [28], and
separate the Piston from the Connecting Rod Ass'y [29].
Disassembly of the Retainer [1] section
Remove the two D6 x 55 Roll Pins [11] from the 6 mm dia. holes of the Retainer [1] and remove the Lever Pin
[2]. The Retainer [1] and two Retainer Dampers [3] can then be removed from the Front Cover [5] (Fig. 16).
Fig. 16
Fig. 15
Shank
Sleeve [13]
O-Ring [10] Slender
flat-blade
screwdriver
Retainer [1]
Retainer dampers [3]
(2 pcs.)
D6 x 55 Roll Pins [11]
(2 pcs.)
Lever Pin [2] Front Cover [5]

--- 14 ---
9-1-2. Reassembly
Reassembly can be accomplished by following the disassembly procedures in reverse. However, special
attention should be given to the following items.
Reassembly of the Crank Shaft [48] section
Press-fit the 6205DDCM Ball Bearing [45] into the Inner Cover [43], and fasten the Bearing Cover [46] onto
the Inner Cover [43] with the four M5 x 16 Seal Lock Hex. Socket Hd. Bolts [47]. Support the inner race of the
6205DDCM Ball Bearing [45] with an appropriate jig, and press-fit the Crank Shaft [48] into the Ball Bearing.
Next, insert Distance Ring (B) [42] and two Woodruff Keys [64] into the Crank Shaft [48], and press-fit the
Final Gear [41] and 6302VVCM Ball Bearing [40] with a hand press.
Reassembly of the Armature Ass'y [74]
Press-fit the 6203DDCM Ball Bearing [71] into the Inner Cover [43], and fasten Bearing Cover (A) [70] onto
the Inner Cover with the three M5 x 16 Seal Lock Hex. Socket Hd. Bolts [47].
Reassembly of the Striker [22] (Two possible methods)
(1) After the Connecting Rod Ass'y [29] has been
assembled into the Housing Ass'y [50], mount the
Piston [28] and press it into the Striker [22].
(2) Mount the Piston [28] onto the Connecting
Rod Ass'y [29], and push down on the
Connecting Rod Ass'y to press the Piston into
the Striker [22].
Fig. 17
Push
Connecting Rod Ass'y [29]
Piston [28]
Respiratory holes
Housing Ass'y [50]
Striker [22]
Push
Either of the two methods described above requires a pressing force of more than 30 kg. When a "hissing"
sound is heard, the Piston is properly inserted in the Striker. (The "hissing" is the sound of the compressed air
escaping from the Striker when the Piston reaches the respiratory chambers within the Striker.)
Respiratory holes
Piston [28]
Connecting Rod Ass'y [29] Striker [22]

--- 15 ---
9-1-3. Screw Locking Agent TB1401
(1) Prior to reassembly, all M5, M6 hexagon socket hd. bolts and machine screws must be coated with screw
locking agent TB1401.
(2) The following parts must be replaced with new Hitachi genuine parts if they are loosened once.
Front cover fixing bolts: M8 x 30 [4]
Cylinder case fixing bolts: M8 x 35 [25]
Fixing bolt on the Connecting Rod Ass'y [29]: M8 x 16 [35]
[CAUTION] If fastening bolts come loose from vibration, it could cause serious damage to the machine.
Ensure without fail that TB1401 screw locking agent is applied as directed above prior to
reassembly. Before applying the TB1401, carefully clean any grease or other foreign matter
from the male and female threads with gasoline, thinner or similar cleaning solvents.
Mounting of Oil Seal (A) [24]
When mounting Oil Seal (A) [24] on the Piston [28], ensure
that the lip portion of the Oil Seal is directed toward the rear
surface of the Piston, as illustrated in Fig. 18. Prior to
reassembly, thoroughly coat Oil Seal (A) [24] and O-Ring
(A) [23] with grease (Grease for Impact Drill, Part No.
980927 or 981840 or 308471 is recommended), and
carefully ensure they are not damaged.
Reassembly of the Retainer [1] section
Before reassembly, apply grease (Doubrex #251 Part No. 980757) to the sliding portion between the Retainer
[1] and the Retainer Damper [3] of the Front Cover [5], and Lever Pin [2]. Mount the two Retainer Dampers
[3] to the Front Cover [5] and then mount the Retainer [1]. Insert the Lever Pin [2] into the 17.5 mm dia. hole
of the Retainer [1] facing the recessed portion of the Lever Pin [2] to the hexagonal hole of the Front Cover
[5]. At this time, align the 6.5 mm dia. hole of the Retainer [1] with the 7 mm dia. hole of the Lever Pin [2].
Drive the D6 x 55 Roll Pin [11] into the 6.5 mm dia. hole of the Retainer [1] approximately 5 mm under the end
surface of the Retainer [1] (Fig. 19).
Fig. 18
O-Ring(A) [23]
Fig. 19
Retainer Damper [3] (2 pcs.)
6.5 mm dia. hole
7 mm dia. hole
Lever Pin [2]
D6 x 55 Roll Pin [11]
(2 pcs.)
Recessed portion
5 mm
Front Cover [5]
17.5 mm dia. hole
Retainer [1]
Oil Seal (A) [24]
Lip
Piston [28]

--- 16 ---
9-1-4. Tightening Torque
(1) M4 hexagon socket hd. bolts 4.41 N•m (45 kgf•cm, 39.1 in-Ibs)
(2) M5 hexagon socket hd. bolts 7.84 N•m (80 kgf•cm, 69.5 in-Ibs)
(3) M6 hexagon socket hd. bolts 9.80 N•m (100 kgf•cm, 86.9 in-Ibs)
(4) M8 hexagon socket hd. bolts 29.4 N•m (300 kgf•cm, 260 in-Ibs)
(5) D4 tapping screw 1.96 N•m (20 kgf•cm, 17.4 in-Ibs)
[NOTE] If above bolts are tightened more than the designated values, it may cause breakage. Without fail,
tighten the bolts and screws according to the above specified values.
9-1-5. Internal Wiring
Wiring diagram of products with noise suppressor
0.5
4.35
Fig. 20
Stator Connector Tube Switch
Armature
Connector
Noise
suppressor
Brown
Tube Plug
Blue
Wiring diagram of products without noise suppressor
Fig. 21
Stator Tube
Switch
Armature
Stator Pillar terminal
Black
Tube
+1.96
0 +20 0 +12.4 0
+1.96
0 +20
0 +17.4 0
+1.96
0 +20 0 +17.4 0
+4.3
0
Stator Pillar terminal
Plug
Tube
White
0.49
0.49

--- 17 ---
Schematic diagram of products with noise suppressor or without noise suppressor
Switch [97]
Support [98]
Vinyl Tube (A)
[102]
Pillar
Terminal [93]
Connectors
Internal
wires Tube [90]
Noise
suppressor Internal Wire
Holder [80]
Cord
With noise suppressor Without noise suppressor
Switch [97]
Support [98]
Vinyl Tube (A)
[102]
Pillar
Terminal [93]
Tube [90]
Internal Wire Holder [80]
Fig. 22
Housing
Ass'y [50]
Noise suppressor
internal wires Stator internal
wires
Internal Wire Holder [80]
Handle (A) [81]