Hitachi DV 22V User manual

Hitachi
Brand
Hitachi
Model
DV 22V
Type
User manual

This manual is also suitable for

PRODUCT NAME
Hitachi 22 mm Impact Drill
Model DV 22V
Hitachi 20 mm Impact Drill
Model DV 20VD
DV 22V
Overseas Sales Division
REPAIR GUIDE ---------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly ----------------------------------------------------------- 1
STANDARD REPAIR TIME (UNIT) SCHEDULES ------------------------------------------------------------------ 14
CONTENTS
Page
LIST Nos.
DV 22V: F431
DV 20VD: F430
Jul. 2015
-1-
WARNING: Be sure to disconnect the power cord plug from the power supply before conducting
repair. Otherwise, the motor may suddenly turn on, posing a very dangerous situation.
1. Precautions on disassembly and reassembly
[Bold] numbers in the description below correspond to the item numbers in the parts lists and exploded
assembly diagrams for the Models DV 22V and DV 20VD.
1. Removal of the drill chuck
The Drill Chuck [3] is secured to Spindle (A) [4] with the 1/2”-20 UNF right-handed screw and Flat Hd.
Screw (A) (Left Hand) M6 x 25 [1]. At first, fully open the chuck jaws and loosen Flat Hd. Screw (A) (Left
Hand) M6 x 25 [1] by turning it clockwise.
(1) Hold the drill so that only the Drill Chuck [3] rests firmly and squarely on the edge of a solid bench.
Insert a hex. bar wrench into the Drill Chuck [3]. Turn the Drill Chuck [3] until the wrench is positioned
at an angle of about 30° with respect to the bench top, and then sharply strike the wrench with a
hammer so that the Drill Chuck [3] turns counterclockwise. (Fig. 1)
If the Drill Chuck [3] cannot be removed by striking the wrench, do not strike the wrench forcibly and
try another way as described in step (2).
Disassembly
REPAIR GUIDE
Fig. 1 • Removal of the drill chuck
[1]
Loosen
Hex. bar wrench
-2-
(2) Hold Spindle (A) [4] with an open-end wrench secured to the vise as shown in Fig. 2. Mount a pipe
onto the hex. bar wrench. Turn the hex. bar wrench counterclockwise to loosen the Drill Chuck [3].
(3) This step is only for the keyed chuck.
Secure the tip of the Drill Chuck [3] with the J-78 ring and J-78 ring ass’y (disassembly tools). Then
secure these disassembly tools with a vise to prevent from turning. Fit the J-140 wrench ass'y
(disassembly tool) to Spindle (A) [4], and turn it counterclockwise to loosen the Drill Chuck [3]. (Fig. 3)
2. Removal of handle cover (B)
(1) Loosen the Screws D4 x 20 [51] and remove Handle Cover (B) [49].
3. Removal of the brush holder
(1) Insert the tip of a small flat-blade screwdriver into the clearance between Housing (B) [43] and Click
Plate [44], and then pry the arm of the Click Plate [44] off as shown in Fig. 4-1.
(2) Lift up the end of the Spring [47] with a small flat-blade screwdriver to release it from the Carbon Brush
[46], and hitch it on the Brush Holder [52] as shown in Fig 4-2 .Then pull out the Carbon Brush [46]
from the Brush Holder [52].
(3) Remove the Brush Holder [52] from Housing (B) [43].
Fig. 2 • Removal of the drill chuck
Hex. bar wrench
Pipe
Turn it counterclockwise.
Vise
Open-end wrench
Fig. 3 • Removal of the drill chuck
Vise
Turn it counterclockwise.
J-140 wrench ass'y
Drill chuck
J-78 ring ass’y
J-78 ring
-3-
Fig. 4-1 • Removal of the click plate
[44]
Insert the tip of a flat-blade screwdriver
into the clearance between Housing
(B) [43] and Click Plate [44], and pry
the arm of the Click Plate [44] off.
Small flat-blade screwdrive
r
[
43
]
[52]
Fig. 4-2 • Removal of the carbon brush
Small flat-blade screwdriver
[46]
Lift up the end of the Spring [47] to release it from the
Carbon Brush [46], and hitch it on the Brush Holder [52].
[47]
[43]
[52]
-4-
4. Removal of the carbon brush
Cut the Band [45] that binds the Internal Wire [54] or [56] to the pigtail of the Carbon Brush [46] with
nippers. Then disconnect the terminal of the Carbon Brush [46] from the terminal of the Brush Holder [52],
and take out the Carbon Brush [46]. (Fig. 5)
5. Removal of gear cover (A) ass'y and inner cover (A)
Loosen the Bolt M5 x 45 [11] and remove Gear Cover (A) Ass'y [12] from Housing (B) [43]. Then remove
Inner Cover (A) [20] together with the Armature [35] from Housing (B) [43].
6. Removal of the stator
Insert a small flat-blade screwdriver into the windows near the terminals and pull out the internal wires
from the Switch [55]. Tap the end of Housing (B) [43] slightly with a wooden hammer. Then remove the
Stator Holder [40] and Stator [38] from Housing (B) [43].
7. Removal of the armature
Place Inner Cover (A) [20] on a cylindrical jig and push down on the top of the pinion of the Armature [35]
as shown in Fig. 6.
8. Disassembly of gear cover (A) ass’y
(1) Removal of spindle (A)
Remove the Retaining Ring For D35 Hole [5]. Place Gear Cover (A) Ass'y [12] on a cylindrical jig of
inside diameter 38 mm or larger, and push down on the rear end of Spindle (A) [4] lightly. Remove
Spindle (A) [4] together with Oil Seal (A) [6], Ball Bearing 6003DD [7], Ratchet (D) [8], and Spring (A)
[9] as shown in Fig. 7-1.
(2) Removal of the shift lever ass'y
Position the Shift Lever Ass'y [21] as shown in Fig. 7-2. Push both ends of the Retaining Ring (E-type)
for D15 Shaft [27] with a pair of long-nose pliers until a clearance about 1 to 2 mm is made. Keeping
the clearance, turn the Shift Lever Ass'y [21] by 180 degrees together with the Retaining Ring (E-type)
for D15 Shaft [27]. Insert a flat-blade screwdriver into the clearance and pry the Retaining Ring
(E-type) for D15 Shaft [27] off upward.
Fig. 5 • Removal of the carbon brush
[45]
Pigtail of the Carbon Brush [46]
[54] or [56]
-5-
Fig. 6 • Removal of the armature
Fig. 7-1 • Disassembly of the gear cover section
Fig. 7-2 • Removal of the shift lever ass'y
Pinion of the armature
Push.
[35]
Cylindrical Jig (73 mm in dia.)
[20]
[4]
Push.
[7]
[9]
[12]
[6]
[8]
Cylindrical Jig (38 mm in dia.)
Push.
[21]
[27]
Turn 180°.
[12]
Clearance
-6-
Fig. 8 • Reassembly of gear cover (A) ass’y (with slip clutch)
Reassembly can generally be conducted by reversing the disassembly procedure. However, special
attention should be given to the following items.
1. Internal wire arrangement
(1) Perform wiring of the internal wires according to Fig. 11 to Fig. 16.
(2) Be careful not to get the internal wires caught between handle covers (A) and (B).
2. Reassembly of gear cover (A) ass’y
NOTE: Never reuse Ratchet (D) [8] removed from Spindle (A) [4]. If reused, the tightening torque
between Ratchet (D) [8] and Spindle (A) [4] will be excessively low and Spindle (A) [4] may
run idle in the IMPACT mode.
(1) Mount the Washer [28] to Ratchet (D) [8] securely before mounting the Low Speed Gear [29].
(2) Mount the Shift Arm [31] and High Speed Gear [30] in the specified direction as shown in Fig. 8 to Fig.
10.
(3) Insert the Shift Pin [22] into the slotted hole of the Shift Arm [31] securely as shown in Fig. 10.
Reassembly
[30]
[4]
[26]
[5]
[24]
[9]
[8]
[7]
[6]
[29]
[21]
[32]
[31]
[14]
[15]
[28]
[13]
-7-
Fig. 9 • Reassembly of gear cover (A) ass’y (without slip clutch)
Fig. 10 • Reassembly of gear cover (A) ass’y
Apply Cosmo Molybdenum No. 2 grease to the following parts.
• Gear teeth of the Armature [35]
• Gear teeth and both engaging portions with the needle bearing of Second Pinion (A) [15] or Second
Pinion (B) [15]
• Engaging portions with the bearings and the Low Speed Gear [29], and splined portion of Spindle (A)
[4]
• Gear teeth and both end surfaces of the Low Speed Gear [29] and High Speed Gear [30]
• Outer circumference of the Shift Pin [22] and O-ring [23] of the Shift Lever Ass'y [21]
• Both end surfaces and inner circumference of the Distance Piece [14]
• Marked surface of the needle bearing inserted in Inner Cover (A) [20] and Gear Cover (A) Ass'y [12]
• Inner circumference of the metal inserted in Inner Cover (A) [20]
[30]
[4]
[5]
[24]
[9]
[8]
[7]
[6]
[21]
[32]
[31]
[14]
[15]
[28]
[13]
[26]
[29]
[22]
[31] [30]
[32]
[4]
Lubrication points and type of lubricant
-8-
• Outer circumference of the Pin D5 [32]
• Lip portion of Oil Seal (A) [6]
• Both end surfaces of Spring (A) [9]
• Both surfaces of the Washer [28]
• Both surfaces of Washer (B) [13]
Fill 10 grams of Cosmo Molybdenum No. 2 grease in the following part.
• Inside of Gear Cover (A) Ass'y [12]
Apply Power Lite WR No. 1 grease to the following parts.
• Hole for inserting the Steel Ball D6.35 [10] in Spindle (A) [4] (Before inserting the Steel Ball D6.35
[10])
• Outer circumference of the O-ring of the Change Shaft [19]
• Steel Ball D6.35 [10]
• Teeth of Ratchet (C) [24] inserted in Gear Cover (A) Ass'y [12] and Ratchet (D) [8]
Fill 2 grams of Power Lite WR No. 1 grease in the following part.
• Space between Ratchet (C) [24] and Ratchet (D) [8]
• Flat Hd. Screw (A) (Left Hand) M6 x 25 [1] ······························ 4.9 ± 0.5 N•m (50 ± 5 kgf•cm)
• Tapping Screw (W/Flange) D4 x 20 (Black) [51] ························ 2.0 ± 0.5 N•m (20 ± 5 kgf•cm)
• Hex. Socket Hd. Bolt (W/Flange) M5 x 45 [11] ·························· 4.9 ± 1.0 N•m (50 ± 10 kgf•cm)
• Drill Chuck 13VLRB-D [3] ···················································· 34.3 ± 0.49 N•m (350 ± 50 kgf•cm)
• Drill Chuck 13VLRE-N [3] (Keyless Type) ································ 34.3 ± 0.49 N•m (350 ± 50 kgf•cm)
• Tapping Screw (W/Flange) D4 x 16 [60] ·································· 2.0 ± 0.50 N•m (20 ± 5 kgf•cm)
• Screw for connecting the Cord [62] to the Switch [55] ················ 0.6 ± 0.2 N•m (6 ± 2 kgf•cm)
On completion of reassembly after repair, measure the insulation resistance and conduct the dielectric
strength test.
Insulation resistance: 7 Mȍ or more with a 500 VDC megohm tester
Dielectric strength: 4,000 VAC/minute, with no abnormalities ······ 220 V to 240 V (110 V for UK products)
2,500 VAC/minute, with no abnormalities ······ 110 V to 127 V (except for UK products)
After no-load operation for 30 minutes, the no-load current values should be as follows:
Voltage 110 V 120 V 127 V 220 V 230 V 240 V
Current
max.
DV 22V
4.0 A 2.0 A 1.9 A 1.9 A
DV 20VD
3.8 A 3.1 A 3.2 A 1.8 A 1.7 A 1.7 A
Screw tightening torque
Insulation test
No-load current value
-9-
Connecting diagrams
Fig. 11 • Circuit diagram for the Models DV 22V and DV 20VD with noise suppressor and ferrite core
Cord
Ferrite core
Speed control switch Reversing switch
Noise suppressor
Bl
ac
k
o
r
b
r
o
wn
Whit
e
o
r
b
l
R
ed
Bl
ac
k
R
ed
Bl
ue
Whi
te
Y
e
ll
o
w
3
2
14
M2
C2
C1
M1
1
Ļ
2
Ļ
Stator
Stator
Fig. 12 • Circuit diagram for the Models DV 22V and DV 20VD without noise suppressor and ferrite core
Cord
Speed control switch Reversing switch
Black or brown
White or blue
Red
Black
Red
Blue
WhiteYellow
3
2
14
M2
C2
C1
M1
1Ļ
2Ļ
Stator
Stator
-10-
Fig. 13 • Wiring diagram for the Models DV 22V and DV 20VD with noise suppressor and ferrite core
Cord clip mounting direction
Cord Armor [58]
Ferrite Core [57]
Noise Suppressor [61]
Switch [55]
Stator [38] (White internal wire)
Internal Wire [56] (Blue)
Cord [62] (White or blue internal wire)
Cord [62] (Black or brown internal wire)
Stator [38] (Red internal wire)
Stator [38] (Yellow internal wire)
Internal Wire [56] (Red)
Stator [38] (Black internal wire)
Spring [47]
Carbon Brush [46]
-11-
Fig. 14 • Wiring diagram for the Models DV 22V and DV 20VD without noise suppressor and ferrite core
Cord clip mounting direction
Cord diameter: Under 8.5 mm
Cord diameter: 8.5 mm and over
Cord Armor [58]
Switch [55]
Spring [47]
Carbon Brush [46]
Stator [38] (White internal wire)
Stator [38] (Black internal wire)
Cord [62] (White or blue internal wire)
Cord [62] (Black or brown internal wire)
Internal Wire [56] (Blue)
Stator [38] (Red internal wire)
Stator [38] (Yellow internal wire)
Internal Wire [56] (Red)
-12-
Fig. 15 • Wiring diagram for the Models DV 22V and DV 20VD
Internal wire (blue)
(1)
(3)
(2)
(4)
Stator (white)
Internal wire (red)
Stator (black)
Stator (yellow)
Stator (red) (M2)
Cord (black or brown)
(1Ļ)
Cord (white or blue)
(2Ļ)
(C1)
(C2)
Noise suppressor
Wiring of the reversing switch
Wiring of the speed control switch
-13-
Fig. 16 • Wiring diagram for the Models DV 22V and DV 20VD
The Models DV 22V and DV 20VD
intended for the specified destinations
are not equipped with the noise
suppressor and ferrite core.
Fit the internal wire in the groove of the handle cover.
Position the rotational change lever
of the switch between the protrusions
of the Brush Holder [52].
Be careful not to catch the red and yellow
internal wires passed under the switch.
-14-
Model
Variable
Fixed
10 20 30 40 50 60 min.
DV 22V
DV 20VD
General Assembly
Fan
Guide (B)
Stator
Holder
Armature
Ball Bearing
(607VV)
Ball Bearing
(608DD)
Inner Cover
(A)
Change
Shaft
Second
Pinion
Spindle (A)
Ball Bearing
(6003DD)
Ratchet (D)
Ratchet (C)
Gear Cover
(A) Ass’y
Low Speed
Gear
High Speed
Gear
Shift Lever
Ass’y
Shift Arm
Housing (B)
Stator
Work Flow
Switch
Cord Armor
Cord
Handle
Cover (B)
Handle
Cover (A)
Brush Holder
Brush Cover
STANDARD REPAIR TIME (UNIT) SCHEDULES
Model DV 22V
IMPACT DRILL
LIST NO. F431
2015 · 7 · 6
(E1)
52
24
1
2
3
3
4
5
6
7
8
9
10
11
12
13
13
14
15
17
18
19
20
25
26
27
29
31
32
33
34
35
36
37
38
39
40
41
42
43
50
44
46
53
48
49
51
54
55
56
57
58
59
60
61
62
30
21
23
22
28
47
16
45
502
501
508
504
507
506
505
503
PART
S
DV 22V
DESCRIPTION REMARKS
1 995344 FLAT HD. SCREW (A) (LEFT HAND) M6 X 25 1
* 2 987576 CHUCK WRENCH FOR 13VLB-D,13VLR-D 1 FOR SIN,MAL,UAE,CHN
* 3 321814 DRILL CHUCK 13VLRB-D 1 INCLUD.1,2 FOR SIN,MAL,UAE,CHN
* 3 319546 DRILL CHUCK 13VLRE-N (KEYLESS TYPE) 1
4 338738 SPINDLE (A) 1
5 939556 RETAINING RING FOR D35 HOLE (10 PCS.) 1
6 971745 OIL SEAL (A) 1
7 6003DD BALL BEARING 6003DD 1
8 338771 RATCHET (D) 1
9 984101 SPRING (A) 1
10 959150 STEEL BALL D6.35 (10 PCS.) 1
11 338764
HEX. SOCKET HD. BOLT (W/FLANGE) M5 X 45 4
12 338769 GEAR COVER (A) ASS'Y 1 INCLUD.24
13 322852 WASHER (B) 2
14 338744 DISTANCE PIECE 1
15 338743 SECOND PINION (A) 1
16 339222 PACKING 1
17 338746 CHANGE LEVER 1
18 338747 CHANGE COVER 1
19 338748 CHANGE SHAFT 1
20 338745 INNER COVER (A) 1
21 338737 SHIFT LEVER ASS'Y 1 INCLUD.22,23
22 322848 SHIFT PIN 1
23 878885 O-RING (S-18) 1
24 338770 RATCHET (C) 1
25 981328 SPRING (H) 1
26 335299 STEEL BALL D3.5 (10 PCS.) 1
27 323048 RETAINING RING (E-TYPE) FOR D15 SHAFT 1
28 339223 WASHER 1
29 338740 LOW SPEED GEAR 1
30 338741 HIGH SPEED GEAR 1
31 338742 SHIFT ARM 1
32 984104 PIN D5 1
33 LABEL (SLIP CLUTCH) 1
34 608DDM BALL BEARING 608DD 1
* 35 361002B ARMATURE 110V 1
* 35 361002D ARMATURE 220V 1
* 35 361002E ARMATURE 230V 1
* 35 361002F ARMATURE 240V 1
36 338754 FAN GUIDE (B) 1
37 338755 RUBBER BUSH 2
* 38 340905B STATOR 110V 1
* 38 340905D STATOR 220V 1
* 38 340905E STATOR 230V-240V 1
39 338751 DUST SEAL 1
40 338750 STATOR HOLDER 1
41 607VVC BALL BEARING 607VV 1
42 931701 BEARING LOCK 1
43 338749 HOUSING (B) 1
44 338761 CLICK PLATE 2
- 2 - 7 - 15 *ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.
PART
S
DV 22V
DESCRIPTION REMARKS
45 331759 BAND 2
46 999088 CARBON BRUSH (1 PAIR) 2
47 339292 SPRING 2
48 338760 BRUSH COVER 1
49 338753 HANDLE COVER (B) 1
50 NAME PLATE 1
51 301653
TAPPING SCREW (W/FLANGE) D4 X 20 (BLACK) 7
52 338759 BRUSH HOLDER 1
53 338752 HANDLE COVER (A) 1
54 338758 INTERNAL WIRE L100 1
55 338756 SWITCH 1
56 338757 INTERNAL WIRE L180 1
* 57 334379 FERRITE CORE 1 EXCEPT FOR SIN,MAL,UAE
* 58 953327 CORD ARMOR D8.8 1
* 58 938051 CORD ARMOR D10.1 1
59 937631 CORD CLIP 1
60 984750 TAPPING SCREW (W/FLANGE) D4 X 16 2
* 61 997174 NOISE SUPPRESSOR 1 EXCEPT FOR SIN,MAL,UAE
* 62 500409Z CORD 1 (CORD ARMOR D8.8)
* 62 500505Z CORD 1 (CORD ARMOR D8.8) FOR MAL,UAE (230V),
GBR (230V)
* 62 323974 CORD 1 (CORD ARMOR D10.1) FOR SIN,UAE (110V)
* 62 500461Z CORD 1 (CORD ARMOR D8.8) FOR GBR (110V)
* 62 500439Z CORD 1 (CORD ARMOR D8.8) FOR AUS
* 62 500408Z CORD 1 (CORD ARMOR D8.8) FOR NZL
* 62 500468Z CORD 1 (CORD ARMOR D8.8) FOR CHN
DESCRIPTION REMARKS
*
501 338762 CASE 1
502 338768 SIDE HANDLE 1
503 303709 DEPTH GAUGE 1
* 504 402539 SYSTEM CASE 2 1 INCLUD.505-507
* 505 336472 LATCH 4
* 506 336473 HANDLE 1
* 507 336474 HINGE 2
* 508 338763 INNER TRAY 1
7 - 15 Printed in Japan - 3 -
(150706N)
*ALTERNATIVE PARTS
STANDARD ACCESSORIES
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.
Model DV 20VD
IMPACT DRILL
LIST NO. F430
2015 · 7 · 6
(E1)
502
24
1
2
3
3
4
5
6
7
8
9
10
11
12
13
13
14
15
17
18
19
20
22
25
26
28
33
34
35
36
37
38
39
40
41
42
43
50
44
46
52
48
49
51
54
56
57
58
59
60
61
62
501
508
55
29
31
32
30
504
507
506
505
503
16
53
47
27
21
23
45
PART
S
DV 20VD
DESCRIPTION REMARKS
1 995344 FLAT HD. SCREW (A) (LEFT HAND) M6 X 25 1
* 2 987576 CHUCK WRENCH FOR 13VLB-D,13VLR-D 1 EXCEPT FOR NZL,GBR,SAF,RUS,EUROPE
* 3 321814 DRILL CHUCK 13VLRB-D 1 INCLUD.1,2
* 3 319546 DRILL CHUCK 13VLRE-N (KEYLESS TYPE) 1 FOR NZL,GBR,SAF,RUS,EUROPE
4 338738 SPINDLE (A) 1
5 939556 RETAINING RING FOR D35 HOLE (10 PCS.) 1
6 971745 OIL SEAL (A) 1
7 6003DD BALL BEARING 6003DD 1
8 338771 RATCHET (D) 1
9 984101 SPRING (A) 1
10 959150 STEEL BALL D6.35 (10 PCS.) 1
11 338764
HEX. SOCKET HD. BOLT (W/FLANGE) M5 X 45 4
12 338769 GEAR COVER (A) ASS'Y 1 INCLUD.24
13 322852 WASHER (B) 2
14 338744 DISTANCE PIECE 1
* 15 338767 SECOND PINION (B) 1
* 15 338743 SECOND PINION (A) 1 FOR SLIP CLUTCH
16 339222 PACKING 1
17 338746 CHANGE LEVER 1
18 338747 CHANGE COVER 1
19 338748 CHANGE SHAFT 1
20 338745 INNER COVER (A) 1
21 338737 SHIFT LEVER ASS'Y 1 INCLUD.22,23
22 322848 SHIFT PIN 1
23 878885 O-RING (S-18) 1
24 338770 RATCHET (C) 1
25 981328 SPRING (H) 1
26 335299 STEEL BALL D3.5 (10 PCS.) 1
27 323048 RETAINING RING (E-TYPE) FOR D15 SHAFT 1
28 339223 WASHER 1
29 338740 LOW SPEED GEAR 1
30 338741 HIGH SPEED GEAR 1
31 338742 SHIFT ARM 1
32 984104 PIN D5 1
* 33 LABEL (SLIP CLUTCH) 1 FOR SLIP CLUTCH
34 608DDM BALL BEARING 608DD 1
* 35 361003B ARMATURE 110V 1
* 35 361003C ARMATURE 120V-127V 1
* 35 361003U ARMATURE ASS'Y 120V 1 INCLUD.34,39,41
* 35 361003D ARMATURE 220V 1
* 35 361003E ARMATURE 230V 1
* 35 361003F ARMATURE 240V 1
36 338766 FAN GUIDE (B) 1
37 338755 RUBBER BUSH 2
* 38 340906B STATOR 110V 1
* 38 340906C STATOR 120V-127V 1
* 38 340906D STATOR 220V 1
* 38 340906E STATOR 230V 1
* 38 340906F STATOR 240V 1
39 338751 DUST SEAL 1
- 2 - 7 - 15 *ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.
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Hitachi DV 22V User manual

Hitachi
Brand
Hitachi
Model
DV 22V
Type
User manual
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