DH 40MA - Drill HITACHI - Free user manual and instructions

USER MANUAL DH 40MA HITACHI

INSTRUCTION MANUAL AND SAFETY INSTRUCTIONS

English Français Español3 English IMPORTANT INFORMATION Read and understand all of the operating instructions, safety precautions and warnings in the Instruction Manual before operating or maintaining this power tool. Most accidents that result from power tool operation and maintenance are caused by the failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing a potentially hazardous situation before it occurs, and by observing appropriate safety procedures. Basic safety precautions are outlined in the “SAFETY” section of this Instruction Manual and in the sections which contain the operation and maintenance instructions. Hazards that must be avoided to prevent bodily injury or machine damage are identified by WARNINGS on the power tool and in this Instruction Manual. Never use this power tool in a manner that has not been specifically recommended by HITACHI, unless you first confirm that the planned use will be safe for you and others.

MEANINGS OF SIGNAL WORDS

WARNING indicates a potentially hazardous situations which, if ignored, could result in serious personal injury. CAUTION indicates a hazardous situations which, if ignored, could result in moderate personal injury, or could cause machine damage. NOTE emphasizes essential information.4 English SAFETY

GENERAL SAFETY RULES

WARNING: Read and understand all instructions.

Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

(1) Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. (2) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes. (3) Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.

2. Electrical Safety

(1) Double Insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double Insulation eliminates the need for the three wire grounded power cord and grounded power supply system. (2) Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. (3) Don’t expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. (4) Do not abuse the cord. Never use the cord to carry the tools or pull the plug from a receptacle. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock. (5) When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of electric shock.

(1) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. (2) Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.5 English (3) Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents. (4) Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury. (5) Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. (6) Use safety equipment. Always wear protective glasses. Dust mask, non-skid safety shoes, hard hat, or ear plugs must be used for appropriate conditions.

4. Tool Use and Care

(1) Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. (2) Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. (3) Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired. (4) Disconnect the plug form the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. (5) Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users. (6) Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control. (7) Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. (8) Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

(1) Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. (2) When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instruction may create a risk of electric shock or injury.

6. Never touch moving parts.

Never place your hands, fingers or other body parts near the tool’s moving parts.

7. Never operate without all guards in place.

Never operate this tool without all guards or safety features in place and in proper working order. If maintenance or servicing requires the removal of a guard or safety feature, be sure to replace the guard or safety feature before resuming operation of the tool.6 English

Don’t force small tool or attachment to do the job of a heavy-duty tool. Don’t use tool for purpose not intended — for example — don’t use circular saw for cutting tree limbs or logs.

9. Never use a power tool for applications other than those specified.

Never use a power tool for applications other than those specified in the Instruction Manual. 10.Handle tool correctly. Operate the tool according to the instructions provided herein. Do not drop or throw the tool. Never allow the tool to be operated by children, individuals unfamiliar with its operation or unauthorized personnel. 11.Keep all screws, bolts and covers tightly in place. Keep all screws, bolts, and plates tightly mounted. Check their condition periodically. 12.Do not use power tools if the plastic housing or handle is cracked. Cracks in the tool’s housing or handle can lead to electric shock. Such tools should not be used until repaired. 13.Blades and accessories must be securely mounted to the tool. Prevent potential injuries to yourself or others. Blades, cutting implements and accessories which have been mounted to the tool should be secure and tight. 14.Keep motor air vent clean. The tool’s motor air vent must be kept clean so that air can freely flow at all times. Check for dust build-up frequently. 15.Operate power tools at the rated voltage. Operate the power tool at voltages specified on its nameplate. If using the power tool at a higher voltage than the rated voltage, it will result in abnormally fast motor revolution and may damage the unit and the motor may burn out. 16.Never use a tool which is defective or operating abnormally. If the tool appears to be operating unusually, making strange noises, or otherwise appears defective, stop using it immediately and arrange for repairs by a Hitachi authorized service center. 17.Never leave tool running unattended. Turn power off. Don’t leave tool until it comes to a complete stop. 18.Carefully handle power tools. Should a power tool be dropped or struck against hard materials inadvertently, it may be deformed, cracked, or damaged. 19.Do not wipe plastic parts with solvent. Solvents such as gasolie, thinner, benzine, carbon tetrachloride, and alcohol may damage and crack plastic parts. Do not wipe them with such solvents. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.7 English

SPECIFIC SAFETY RULES AND SYMBOLS

1. Hold tools by insulated gripping surfaces when performing an operation where

the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

2. Wear ear plugs when using the tool for extended periods. Prolonged exposure

to high intensity noise can cause hearing loss.

3. NEVER touch the tool bit with bare hands after operation.

4. NEVER wear gloves made of stuff liable to roll up such as cotton, wool, cloth or

5. ALWAYS attach the side handle and securely grip the Rotary Hammer.

6. ALWAYS be careful with buried object such as an underground wiring.

Touching these active wiring or electric cable with this tool, you may receive an electric shock. Comfirm if there are any buried object such as electric cable within the wall, floor or ceiling where you are going to operate here after.

7. Definitions for symbols used on this tool

To ensure safer operation of this power tool, HITACHI has adopted a double insulation design. “Double insulation” means that two physically separated insulation systems have been used to insulate the electrically conductive materials connected to the power supply from the outer frame handled by the operator. Therefore, either the symbol “ ” or the words and “Double insulation” appear on the power tool or on the nameplate. Although this system has no external grounding, you must still follow the normal electrical safety precautions given in this Instruction Manual, including not using the power tool in wet environments. To keep the double insulation system effective, follow these precautions: 䡬 Only HITACHI AUTHORIZED SERVICE CENTER should disassemble or assemble this power tool, and only genuine HITACHI replacement parts should be installed. 䡬 Clean the exterior of the power tool only with a soft cloth moistened with soapy water, and dry thoroughly. Never use solvents, gasoline or thinners on plastic components; otherwise the plastic may dissolve.

SAVE THESE INSTRUCTIONS

OTHER USERS OF THIS TOOL!9

English FUNCTIONAL DESCRIPTION NOTE: The information contained in this Instruction Manual is designed to assist you in the safe operation and maintenance of the power tool. Some illustrations in this Instruction Manual may show details or attachments that differ from those on your own power tool.

APPLICATIONS Rotation and hammering function 䡬 Drilling anchor holes 䡬 Drilling holes in concrete Hammering function only 䡬 Crushing concrete, chipping, digging, and squaring (by applying optional accessories)

Ensure that the power source to be utilized conforms to the power source requirements specified on the product nameplate.

Ensure that the switch is in the OFF position. If the plug is connected to a receptacle while the switch is in the ON position, the power tool will start operating immediately and can cause serious injury.

When the work area is far away from the power source, use an extension cord of sufficient thickness and rated capacity (refer to page 9). The extension cord should be kept as short as practicable.

WARNING: Damaged cord must be replaced or repaired.

4. Check the receptacle

If the receptacle only loosely accepts the plug, the receptacle must be repaired. Contact a licensed electrician to make appropriate repairs. If such a fautly receptacle is used, it may cause overheating, resulting in a serious hazard.

5. Confirming condition of the environment:

Confirm that the work site is placed under appropriate conditions conforming to prescribed precautions.

6. How to install tool

CAUTION: For tools such as a drill bit and a bull point, use only Hitachi genuine parts. (1) Clean, then smear the tool shank with the grease provided in the green tube.11 English (2) To attach the tool (SDS max shank), insert it into the hole until it contacts the innermost end of the hole as illustrated in Fig. 2. If you continue to turn the tool with slight pressure, you can feel a spot where there is a hitch. At that spot, pull the grip to the direction of an arrow mark and insert the tool all the way until it hits the innermost end. Releasing the grip reverts the grip and secures the tool in place. (3) To remove the tool, fully pull the grip in the direction of the arrow and pull out the tool.

1. How to drill holes (Fig. 3)

(1) Pull the switch trigger after applying the drill bit tip to the drilling position. (2) It is unnecessary to forcibly press the rotary hammer main body. It is sufficient to slightly press the rotary hammer to an extent that clips are freely discharged. CAUTION: Although this machine is equipped with a safety clutch, if the drill bit becomes bound in concrete or other material, the resultant stoppage of the drill bit could cause the machine body to turn in reaction. Ensure that the main handle and side handle are gripped firmly during operation.

2. How to chisel or crush (Fig. 4)

By applying the tool tip to the chiseling or crushing position, operate the rotary hammer by utilizing its empty weight. Forcible pressing or thrusting is unnecessary. Front Cap Tool Fig. 2 Part of SDS max Shank Grip Fig. 3 Fig. 412 English

3. When drilling at “rotation +

hammering” CAUTION: If you switch the selector lever during motor rotation, the tool can start to rotate abruptly, resulting in unexpected accidents. Be sure to switch the selector lever when the motor is at a complete stop. (1) Switching to “rotation + hammering” (a) Pull the selector lever, release lock and turn it clockwise. (b) Align ▲ of the selector lever with ▲ on the side of the undercover as illustrated in Fig. 5. (c) Push in the selector lever to lock it. NOTE: Turn the selector lever (do not pull it up) to check if it is completely locked and make sure that it does not turn.

4. When chipping and shredding at “hammering”:

CAUTION: 䡬 If the selector lever is switched during motor rotation, the tool can start to rotate abruptly, resulting in unexpected accidents. Make sure to switch the selector lever when the motor is at a complete stop. 䡬 If the bull point or cold chisel is used at the position of “rotation + hammering”, the tool can start to rotate, resulting in unexpected accidents. Make sure that they are used at the positon of “hammering”. (1) Switching to “hammering” (a) Pull the selector lever, release lock and turn it counterclockwise. (b) Align ▲ of the selector lever with ▲ on the side of the undercover as illustrated in Fig. 6. (c) Push in the selector lever to lock it. NOTE: Turn the selector lever (do not pull it up) to check if it is completely locked and make sure that it does not turn. Fig. 5 Selector Lever Undercover

Selector Lever13 English (2) When fixing working positions of tools such as cold chisel, etc., (a) Pull the selector lever, release lock and turn it. Align ▲ of the selector lever and of the undercover as illustrated in Fig. 7. (b) Push in the selector lever to lock it. (c) Turn the grip as illustrated in Fig. 8 and fix the working position of the tool. (d) Switch the selector lever to “hammring” according to the procedures mentioned in the above item (1) and secure the position of the tool.

5. Install the stopper (Fig. 9)

(1) Loosen the side handle and insert the straight portion of the stopper into the handle bolt hole from the front cover. (2) Loosen the side handle, move the stopper to the specified position and rotate the grip of the side handle clockwise to fix the stopper.

6. Warming up (Fig. 10)

The grease lubrication system in this unit may require warming up in cold regions. Position the end of the bit so makes contact with the concrete, turn on the switch and perform the warming up operation. Make sure that a hitting sound is produced and then use the unit. CAUTION: When the warming up operation is performed, hold the side handle and the main body securely with both hands to maintain a secure grip and be careful not to twist your body by the jammed drill bit. Grip Fig. 8 Stopper Side Handle Fig. 9

7. How to use the drill bit (taper shank)

and the taper shank adaptor. (1) Install drill bit with taper shank in the taper shank adaptor. (2) Turn the power on and drill a base hole. (3) After cleaning out dust with a syringe, attach the plug to the anchor tip and drive in the anchor with a manual hammer. (4) To remove the drill bit with taper shank, insert a cotter into the slot of the taper shank adaptor, place supports under the rotary hammer and tap the cotter with a manual hammer. (Fig. 12)

USING DRILL CHUCK, CHUCK ADAPTOR

Note that this machine can be used at “rotation only” if separately sold parts such as drill chuck and chuck adaptor are attached. Use it with the selector lever positioned at “rotation + hammering”.

During operation, be sure to grip the handle and the side handle firmly to prevent your body from swaying. (1) Switching to “rotation + hammering” For switching to “rotation + hammering”, follow the same procedures mentioned in [3. When drilling at “rotation + hammering”] in Page 12. (2) Attaching chuck adaptor to drill chuck (Fig. 13) (a) Attach the chuck adaptor to the drill chuck. (b) The SDS max shank of the chuck adaptor is equivalent to the drill bit. Therefore, follow the same procedure as [6. How to install tool] in Page 10 for attaching and detaching. Fig. 11 Taper Shank Adaptor Cotter Support Fig. 12 Drill Bit (Taper shank) Taper Shank Adaptor Drill Chuck Grip Fig. 13 SDS max Shank Chuck Adaptor15 English (3) Drilling (a) Even if you apply more-than-required pressure to the machine body, drilling can never be performed as quickly as you expect. Applying more force or pressure to the machine body than what is needed, on the contrary, damages the drill tip, resulting in the declined working efficiency and shortened life of this machine. (b) A drill can snap sometimes when drilling is almost finished. It is important to relax your thrusting pressure when drilling is nearing the end.

HOW TO USE THE CORE BIT

When boring penetrating large hole use the core bit. At that time use with the center pin and the core bit shank provided as optional accessories.

CAUTION: Be sure to turn power OFF and disconnect the plug from the receptacle. (1) Mount the core bit to the core bit shank. (Fig. 14) Lubricate the thread of the core bit shank to facilitate disassembly. (2) Mount the core bit shank to the rotary hammer. (Fig. 15) (3) Insert the center pin into the guide plate until it stops. (4) Engage the guide plate with the core bit, and turn the guide plate to left or right so that it does not fall even if it faces downward. (Fig. 16)

2. How to bore (Fig. 17)

(1) Connect the plug to the receptacle. (2) A spring is installed in the center pin. Push it lightly to the wall or the floor straight. Connect all over the surface of the core bit tip and start operating. (3) When boring about 3/16" (5 mm) in depth the position of the hole will establish. Bore after that removing the center pin and the guide plate from core bit. Fig. 14 Core Bit Core Bit Shank Fig. 16 Center Pin Core Bit Core Bit Tip Fig. 15 Guide Plate16 English (4) Application of excessive force will not only expedite the work, but will deteriorate the tip edge of the drill bit, resulting in reduced service life of the rotary hammer. CAUTION: When removing the center pin and the guide plate, turn OFF the switch and disconnect the plug from the receptacle.

3. Dismounting (Fig. 18)

Remove the core bit shank from the rotary hammer and strike the head of the core bit shank strongly two or three times with a manual hammer holding the core bit, then the thread becomes loose and the core bit can be removed. Fig. 17 Core Bit Shank Fig. 1817 English

MAINTENANCE AND INSPECTION

WARNING: Be sure to switch power OFF and disconnect the plug from the

receptacle during maintenance and inspection.

1. Inspecting the drill bits

Since use of a dull tool will cause motor malfunctioning and degraded efficiency, replace the drill bit with a new one or resharpening without delay when abrasion is noted.

2. Inspecting the mounting screws

Regularly inspect all mounting screws and ensure that they are properly tightened. Should any of the screws be loose, retighten them immediately.

WARNING: Using this rotary hammer with loosen screws is extremely

3. Maintenance of the motor

The motor unit winding is the very “heart” of the power tool. Exercise due care to ensure the winding does not become damaged and/or wet with oil or water.

4. Inspecting the carbon brushes: (Fig. 19)

The motor employs carbon brushes which are consumable parts. When they become worn to or near “wear limit”, it could result in motor trouble. When an auto-stop carbon brush is equipped, the motor will stop automatically. At that time, replace both carbon brushes with new ones which have the same carbon brush Nos. shown in the figure. In addition, always keep carbon brushes clean and ensure that they slide freely within the brush holders. CAUTION: Using this rotary hammer with a carbon brush which is worn in excess of the wear limit will damage the motor. NOTE: Use HITACHI carbon brush No.73 indicated in Fig. 19 Wear limit No. of carbon brush 0.28" (7 mm) 0.67" (17 mm)

Fig. 1918 English 䡬 Replacing carbon brushes: (For parts name, refer to Fig. 1) Loosen the two set screws and remove the tail cover. Remove the brush caps and carbon brushes. After replacing the carbon brushes, tighten the brush caps securely and to install the tail cover with securely tightening two set screws.

5. How to replase grease

This machine is full air-tight construction to protect against dust and to prevent lubricant leakage. Therefore, the machine can be used without lubrication for long periods. Replace the grease as described below. 䡬 Grease replacement period After purchase, replace grease after every 6 months of usage. Ask for grease replacement at the nearest HITACHI Authorized Service Center. Proceed for replacement of grease. 䡬 Grease replenishment CAUTION: Before replenishing the grease, turn the power off and pull out the power plug. (1) Remove the crank case cover and wipe off the grease inside. (2) Apply 0.7 oz (20 g) of HITACHI Electric Hammer Grease A (standard accessory, contained in tube) to the crank case. As the tube contains 1 oz (30 g) of grease, supply 2/3 of the contained grease. (3) After replenishing the grease, install the crank case securely. NOTE: The HITACHI Electric Hammer Grease A is of the lower viscosity type. When the supplied grease tube is consumed, purchase from a HITACHI Autorized Service Center.

6. Service and repairs

All quality power tools will eventually require servicing or replacement of parts because of wear from normal use. To assure that only authorized replacement parts will be used, all service and repairs must be performed by a HITACHI AUTHORIZED SERVICE CENTER, ONLY. Crank Case Cover Fig. 2019 English ACCESSORIES

WARNING: Accessories for this power tool are mentioned in this Instruction

• Manual. The use of any other attachment or accessory can be dangerous and could cause injury or mechanical damage. NOTE: Accessories are subject to change without any obligation on the part of the HITACHI. STANDARD ACCESSORIES (1) Case (Molded plastic) (Code No. 313097) p. 1
• (2) Side Handle (Code No. 313078) p. 1
• (3) Stopper (Code No. 971786) p. 1
• (4) Allen Wrench 4 mm (Code No. 944458) p. 1
• (5) Allen Wrench 5 mm (Code No. 944459) p. 1
• (6) Hammer Grease A (Code No. 981840) OPTIONAL ACCESSORIES sold separately For accessories in detail please call HITACHI AT 1-800-59-TOOLS p. 1

1. Through-hole drilling (Rotation + Hammering)

Adaptor for SDS-plus shank bit

3. Large-dia. hole boring (Rotation + Hammering)

4. Drilling holes....For drilling metals and wooden materials

5. Bolt plaching operation with Chemical Anchor (Rotation + Hammering)

6. Crushing (Hammering)

(Guide plate) Code No.

(3) Core bit shank (SDS max shank) Code No.

(3) Chuck wrench Code No. 930515 (Standard socket on the market) (1) Chemical Anchor Adaptor (SDS max shank) Square dimensions of the side of the socket installation 1/2" (12.7 mm) 3/4" (19.0 mm) Code No.

(2) Adaptor for SDS-plus shank bit (SDS max shank) Code No. 313465 (1) Drill Bit (SDS-plus shank) (1) Bull point Overall length Code No. 11" (280 mm) 313471 15-3/4" (400 mm) 31347221 English

7. Groove digging and edging (Hammering)

12. Syringe (for chip removal)

Grease (A) For Hammer, Hammer Drill 503 Allen Wrench 4MM 504 Allen Wrench 5MM Parts are subject to change without any obli- gation on the part of the HITACHI due to im- provement. Item No. Part Name Item No. Part Name63 Español101 Code No. C99076564 N Printed in Japan

Some dust created by power sanding, sawing, grinding, drilling, and other construc- tion activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: ● Lead from lead-based paints, ● Crystalline silica from bricks and cement and other masonry products, and ● Arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.