DH 38YE2 - Drill METABO - Free user manual and instructions

USER MANUAL DH 38YE2 METABO

SAFETY INSTRUCTIONS AND INSTRUCTION MANUAL

Read and understand all of the safety precautions, warnings and operating instructions 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 metabo HPT.

MEANINGS OF SIGNAL WORDS

WARNING indicates a potentially hazardous situations which, if ignored, could result in death or serious injury. CAUTION indicates a potentially hazardous situations which, if not avoided, may result in minor or moderate injury, or may cause machine damage. NOTE emphasizes essential information. SAFETY

Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) 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 of fumes. c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2) Electrical safety

a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. 01Eng_DH38YE2_US 4/21/10, 4:26 PM34 English A moment of inattention while operating power tools may result in serious personal injury. b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non- skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

4) Power tool use and care

a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Exposure to noise can cause hearing loss.

2. Use auxiliary handles, if supplied with the tool.

Loss of control can cause personal injury.

3. Hold power tools by insulated gripping surfaces,

when performing an operation where the cutting tool may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

4. NEVER touch the tool bit with bare hands after

5. NEVER wear gloves made from materials likely to

roll up such as cotton, wool, cloth or string, etc.

6. ALWAYS attach the side handle and securely grip

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

8. 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.

than those specified. NEVER use a power tool for applications other than those specified in the Instruction Manual.

11. 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.

12. Keep all screws, bolts and covers tightly in place.

Keep all screws, bolts, and plates tightly mounted. Check their condition periodically.

13. 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.

14. Blades and accessories must be securely mounted

to the tool. Prevent potential injuries to youself or others. Blades, cutting implements and accessories which have been mounted to the tool should be secure and tight.

15. 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.

16. 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.

17. NEVER use a tool which is defective or operating

abnormally. If the tool appears to be operating unusually, making strange noises, or otherwise appears repairs by a metabo HPT authorized service center.

18. NEVER leave tool running unattended. Turn power

off. Don’t leave tool until it comes to a complete stop. 19 Carefully handle power tools. Should a power tool be dropped or struck against hard materials inadvertently, it may be deformed, cracked, or damaged.

20. Do not wipe plastic parts with solvent.

Solvents such as gasoline, 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.

21. ALWAYS wear eye protection that meets the

requirement of the latest revision of ANSI Standard Z87.1.

22. ALWAYS be careful with buried object such as an

OPERATION To ensure safer operation of this power tool, metabo HPT 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 “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:

Only metabo HPT AUTHORIZED SERVICE CENTER should disassemble or assemble this power tool, and only genuine metabo HPT replacement parts should be installed.

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. 01Eng_DH38YE2_US 4/21/10, 4:26 PM56 English

CAVE THESE INSTRUCTIONS

AND OWNERS OF THIS TOOL! 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. NEVER operate, or attempt any maintenance on the tool unless you have first read and understood all safey instructions contained in this manual. Some illustrations in this Instruction Manual may show details or attachments that differ from those on your own power tool.

5. Confirming condition of the environment:

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

6. How to install dust cover (Fig. 2)

Always install the dust cover on the drill bit or the taper shank adaptor. Insert the dust cover until it lies flush in the groove. NOTE: For a thick drill bit, insert the dust cover from drill rear.

7. How to install tool

CAUTION: For tools such as a drill bit and a bull point, use only metabo HPT genuine parts. (1) Clean, then smear the tool shank with the grease or oil. (2) Pull the tool holder in the direction of arrow

and rotate it in the direction of arrow

(counterclockwise). Fully insert the tool shank into the hexagonal hole of the front cover. (Fig. 3) (3) Return the tool holder to fix the tool. (4) Pull the tool to make sure it is locked completely. SPECIFICATIONS Motor Single-Phase, Series Commutator Motor. Power Source Single-Phase, 120 V 60 Hz Current 8.4 A Capacity Drill Bit: 1-1/2" (38 mm) Core Bit: 4-13/64" (105 mm) No-Load Speed 620/min Full-load Blow 2,800/min Weight 14.1 lbs (6.4 kg)

ASSEMBLY AND OPERATION

APPLICATIONS Rotation and hammering function

Drilling anchor holes

Drilling holes in concrete Hammering function only

Demolishing 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. The extension cord should be kept as short as practicable.

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. Fig. 2 Insert up to the groove Dust cover

NOTE: Ensure that the wing bolt in the side handle is properly tightened before using the tool.

1. How to drill holes (Fig. 4)

(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 demolish (Fig. 5)

By applying the tool tip to the chiseling or demolishing position, operate the rotary hammer by utilizing its empty weight. Forcible pressing or thrusting is unnecessary.

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) Push the button, release lock and turn the selector lever clockwise. (b) Align ▲ of the selector lever and of the lever holder as illustrated in Fig. 6. (c) Release the button to lock the selector lever. NOTE: Turn the selector lever (do not push the button) to check if it is completely locked and make sure that it does not turn.

4. When chipping and shredding at “hammering”:

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. (1) Switching to “hammering” (a) Push the button, release lock and turn the selector lever counterclockwise. (b) Align ▲ of the selector lever and of the lever holder as illustrated in Fig. 7. (c) Release the button to lock the selector lever. Fig. 5 Fig. 7 Fig. 4 Side handle Fig. 6 Selector lever Lever holder Button Lever holder Selector lever Button 01Eng_DH38YE2_US 4/21/10, 4:26 PM89 English NOTE: Turn the selector lever (do not push the button) to check if it is completely locked and make sure that it does not turn.

5. Warming up (Fig. 8)

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.

6. 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. (Fig. 9) (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. 10)

7. Using the stopper (Fig. 11)

(1) Loosen the wing bolt, and insert the stopper into the mounting hole on the side handle. (2) Adjust the stopper position according to the depth of the hole and tighten the wing bolt securely.

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. 12) Lubricate the thread of the core bit shank to facilitate disassembly. Fig. 8 Fig. 9 Drill bit (Taper shank) Taper shank adaptor Fig. 10 Fig. 12 Fig. 11 Taper shank adaptor Cotter Support Core bit Core bit shank Stopper Mounting hole Wing bolt Side handle 01Eng_DH38YE2_US 4/21/10, 4:26 PM910 English CAUTION: When removing the center pin and the guide plate, turn OFF the switch and disconnect the plug from the receptacle.

3. Dismounting (Fig. 16)

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. (2) Mount the core bit shank to the Rotary Hammer. (Fig. 13) (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. 14)

2. How to bore (Fig. 15)

(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. (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. Fig. 13 Fig. 14 Center pin Core bit Core bit tip Guide plate Fig. 15 Core bit shank Fig. 16 01Eng_DH38YE2_US 4/21/10, 4:26 PM1011 English NOTE: Use metabo HPT carbon brush No. 43 indicated in Fig. 17

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.

Grease replacement period After purchase, replace grease after every 6 months of usage. Ask for grease replacement at the nearest metabo HPT Authorized Service Center. Proceed for replacement of grease.

Grease replenishment CAUTION: Before replenishing the grease, turn the power off and pull out the power plug. (1) Remove the crank cover and wipe off the grease inside. (Fig. 18) (2) Apply 2.0 oz (60 g) of metabo HPT Electric Hammer Grease A (optional accessory, contained in tube) to the crank case. (3) After replenishing the grease, install the crank cover securely. NOTE: The metabo HPT Electric Hammer Grease A is of the lower viscosity type.

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 screws

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

Using this Rotary Hammer with loosen screws is extremely dangerous.

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. 17)

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.

Be sure to switch power OFF and disconnect the plug from the receptacle during maintenance and inspection. Fig. 17 Wear limit No. of carbon brush 0.28" (7 mm) 0.67" (17 mm)

1. Through-hole drilling (Rotation + Hammering)

(1) Drill bit (Spline shank)

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 metabo HPT AUTHORIZED SERVICE CENTER, ONLY.

Repair, modification and inspection of metabo HPT Power Tools must be carried out by a metabo HPT Authorized Service Center. This Parts List will be helpful if presented with the tool to the metabo HPT Authorized Service Center when requesting repair or other maintenance. In the operation and maintenance of power tools, the safety regulations and standards prescribed in each country must be observed. MODIFICATIONS: metabo HPT Power Tools are constantly being improved and modified to incorporate the latest technological advancements. Accordingly, some parts may be changed without prior notice. ACCESSORIES

ALWAYS use Only authorized metabo HPT replacement parts and accessories. NEVER use replacement parts or accessories which are not intended for use with this tool. Contact metabo HPT if you are not sure whether it is safe to use a particular replacement part or accessory with your tool. 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 metabo HPT.

(38 mm) A-taper B-taper Taper shank adaptor formed A-taper or B-taper is provided as optional accessory, but drill bit for it is not provided Code No. 985377 Code No. 985378 (1) Center pin Code No.

(3) Core bit shank (Spline shank) (Guide plate) Code No.

(2) Core bit External dia. 2" (50 mm) 4-1/8" (105 mm) (3) Cotter (Code No. 944477) (2) Taper shank adaptor (Spline shank) (1) Drill bit (Taper shank) (2) Taper shank adaptor 01Eng_DH38YE2_US 4/21/10, 4:26 PM1213 English

4. Crushing (Hammering)

5. Groove digging and edging (Hammering)

8. Syringe (for chip removal)

44 SLIP CLUTCH ASS'Y 1

90 BEARING HOLDER 1 91 TAPPING SCREW (W/FLANGE) D5 x 20 4 92 NAME PLATE 1 93 HANDLE 1 94 CORD ARMOR 1 95 TERMINAL M4.0 1 96 SWITCH (C) 1 97 PILLAR TERMINAL 1 98 TAPPING SCREW (W/FLANGE) D4 x 25 2 99 HANDLE COVER 1 100 CORD CLIP 1 101 TAPPING SCREW (W/FLANGE) D4 x 16 2 102 CORD 1 501 DUST COVER 1 502 CASE 1 503 STOPPER ROD 1 03Spa_DH38YE2_US 4/21/10, 4:39 PM39WARNING: 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.

Code No. C99184361 F Printed in China 04Back_DH38YE2_US 9/29/14, 9:52 AM2 Issued by Shinagawa Intercity Tower A, 15-1, Konan 2-chome, Minato-ku, Tokyo 108-6020, Japan Distributed by 1111 Broadway Ave, Braselton, Georgia, 30517 3405 American Drive, Units 9-10, Mississauga, ON, L4V 1T6