[ NEW FEATURES ]
Lightweight and compact
White LED light
Equipped with the new lithium-ion battery
Manual tightening mechanism
Battery level warning lamp
21-stage clutch
Slim and soft-grip handle
Blow-molded case
The Model DB 10DL is a cordless driver drill equipped with a 10.8-V lithium-ion battery. The Model DB 10DL has
the following main features:
(1) Lightweight and compact
(2) White LED light illuminates wide range of work area.
(3) Equipped with the newly developed lithium-ion battery (10.8 V, 1.5 Ah). This battery can be fully charged in
40 minutes.
(4) Manual tightening mechanism. Easy to tighten screws manually with the comfortable handle shape and the
soft grip.
(5) Battery level warning lamp. Easy to check the remaining battery power level.
We aim to ex
p
and our market share with the new Model DB 10DL.
LIST No. G899
Feb. 2008
PRODUCT NAME
Hitachi 10.8 V Cordless Driver Drill
Model DB 10DL
Constructing electric facilities, assembling machines and servicing
Tightening and loosening wood screws and machine screws
Drilling into wood
MARKETING OBJECTIVE
APPLICATIONS
SELLING POINTS
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
D
International Sales Division
REMARK:
For more information about HANDLING INSTRUCTIONS, visit our website at:
http://www.hitachi-koki.com/manual_view_export/
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:
Competitors
Symbols Utilized
Company Name Model Name
B BOSCH GSR10.8V-Li / PS20-2
CONTENTS
Page
SELLING POINT DESCRIPTIONS ----------------------------------------------------------------------------------------- 1
SPECIFICATIONS --------------------------------------------------------------------------------------------------------------4
COMPARISONS WITH SIMILAR PRODUCTS-------------------------------------------------------------------------- 5
1. Specifications comparisons
----------------------------------------------------------------------------------------------------------- 5
2. Drilling and fastening performance comparison per charge
------------------------------------------------------- 6
PRECAUTIONS IN SALES PROMOTION-------------------------------------------------------------------------------- 7
1. Safety Instructions
------------------------------------------------------------------------------------------------------------------------- 7
2. Inherent drawbacks of cordless driver drills requiring particular attention
during sales promotion
------------------------------------------------------------------------------------------------------------------- 9
REPAIR GUIDE---------------------------------------------------------------------------------------------------------------- 10
1. Precautions in disassembly and reassembly
----------------------------------------------------------------------------- 10
2. Precautions in disassembly and reassembly of battery charger
---------------------------------------------- 19
STANDARD REPAIR TIME (UNIT) SCHEDULES-------------------------------------------------------------------- 20
Assembly diagram for DB 10DL
-1-
Lightweight and compact
The Model DB 10DL has the shortest body in the class of 10.8 V cordless driver drill. It is easy to handle
and convenient for operation in narrow spaces.
HITACHI
Model
DB 10DL
B
L x H x W
147 x 197 x 48 166 x 167 x 49
* The height includes battery.
White LED light
The Model DB 10DL incorporates two white LED lights. These two white LED lights illuminate dark places
far and wide by emitting light from the front of the clutch dial.
SELLING POINT DESCRIPTIONS
Illuminating range of the white LED lights
(When illuminating 100 mm away from the object as shown
below)
Illuminating range of
the Model DB 10DL
Illuminating range of B
80 mm
100 mm
100 mm
Pull the trigger switch to light up the light. The light keeps
on lighting while the trigger switch is being pulled. The
light goes out after releasing the trigger switch.
Trigger switch
The illuminating area of the white LED lights is 3 times
larger than B.
-2-
UC 10SFL
BCL 1015
Equipped with the new lithium-ion battery (BCL 1015)
The newly developed Type BCL 1015 lithium-ion battery (10.8 V, 1.5 Ah) can be fully charged by the Model
UC 10SFL charger in about 40 minutes.
The Type BCL 1015 is equipped with the overdischarge protection circuit, overload protection circuit,
battery overheat protection circuit and voltage monitoring circuit for each cell to prevent reduction of the
battery life due to overdischarge (overuse) or overcharge (excessive charging). This battery is safe thanks
to these protection circuits.
Precautions for use of the Type BCL 1015 lithium-ion battery
The Type BCL 1015 lithium-ion battery is equipped with a protective function that automatically stops output
to extend the battery life. The motor may stop automatically in any of the following cases (1), (2) and (3)
even if the switch is depressed continuously during operation. This is because the protective function is
activated. It is not faulty.
Protective
function
Cause of trouble Countermeasure
(1)
Overdischarge
protection circuit
Battery voltage is decreased to about 6 V.
Charge the battery immediately
in such case.
(2)
Overload
protection circuit
Heavy-duty work
Release the switch and eliminate
the cause of the overload problem.
(3)
Battery overheat
protection circuit
Continuous operation
or heavy-duty work
Remove the battery from the tool
and cool it down.
Manual tightening mechanism
The Model DB 10DL is usable as a manual screwdriver. Power off the Model DB 10DL and use it as a
manual screwdriver by turning the main body. Also, when the battery power is out accidentaly, can use it as
a manual screwdriver.
-3-
Battery level warning lamp
The battery level can be checked by pulling the
trigger switch while the power tool is in a no-load
state. The battery level warning lamp lights when
the battery power is very low. If this happens, charge
the battery.
21-stage clutch
Rotate the clutch dial and line up the numbers “1, 3, 5, ... 21” on
the clutch dial, or the black dot, with the triangle mark on the outer
body. Adjust the clutch dial in the weak or the strong torque
direction according to the torque you need.
Slim and Soft-grip handle
The handle is covered with soft elastomer. It is slim, soft, and slip-resistant.
Blow-molded case
The compact blow-molded case is convenient for carrying the tool.
Clutch dial
Drill mark
Triangle mark
Weak
Strong
-4-
Model DB 10DL
Screw driving
Machine screw------------------------------6 mm (1/4")
Wood screw ---------------------------------6 mm dia. x 38 mm (#14 x 1-1/2")
Capacity
Drilling Wood------------------- 18 mm (11/16") [Thickness 18 mm (11/16")]
Tool retainer
6.35 mm (1/4") bit holder
Rotation speed
0 – 400 min
–1
Torque
Slip torque ------ 1.0 – 6.0 N·m (10 – 60 kgf·cm, 9 – 53 in-lbs.) [21 stages]
Max. torque----- 10 N·m (102 kgf·cm, 89 in-lbs.)
Type of motor
DC magnet motor
Type of switch
Trigger switch with pushing button for forward and reverse rotation
changover (with brake)
Enclosure
Body---------------------Glassfiber reinforced polycarbonate resin (black)
and thermoplastic elastomer (green)
Battery ------------------Polycarbonate resin (black)
Charger----------------- ABS resin (black)
Battery Type of battery
Sealed cylindrical lithium-ion storage battery
(Type Nominal voltage
DC 10.8 V
BCL 1015) Nominal life
Charging/discharging: approximately 1000 times
Nominal capacity
1.5 Ah
Charging time
Approx. 40 minutes
(with Charger UC 10SFL at ambient temperature of 20 °C (68 °F))
Charging
temperature
0 °C – 50 °C (32 °F – 122 °F)
Charger
(Model UC 10SFL)
• Overcharge prevention system:
(1) Stop current detection
(2) Battery surface temperature detection (thermostat or therrmistor)
• Input capacity: 35 W
• The maximum allowable temperature of the Type BCL 1015 battery is
50 °C (122 °F).
• Indication method: Pilot lamp indicates the charging state.
• Pilot lamp: On-------------------- During charging
Off -------------------- Charging completed
Weight Net
Main body (including Type BCL 1015 battery) ------------ 0.8 kg (1.8 Ibs.)
Charger unit (including cord) 0.35 kg (0.8 Ibs.)
Gross DB 10DL (2LCSK) (including Type BCL 1015 battery) 3.0 kg (6.6 Ibs.)
Standard accessories
Charger (UC 10SFL) ---------------------------------------------------------------1
Battery (Type BCL 1015) ----------------------------------------------------------2
Phillips plus driver bit (No. 2) -----------------------------------------------------1
Case ------------------------------------------------------------------------------------1
SPECIFICATIONS
-5-
1. Specifications comparisons
(Superior specifications:
)
Maker HITACHI
Model name DB 10DL
B (EURO)
B (U.S.A.)
Steel
˂
6 mm (1/4")
Drilling
Wood 18 mm (23/32") 18 mm (23/32”)
Wood screw 6 mm dia. x 38 mm (#14 x 1-1/2") 6 mm dia. (#14)
Max.
capacity
Screw
driving
Machine screw 6 mm (1/4") 6 mm (1/4”)
Rotation speed 0 - 400 min
-1
0 - 400 min
-1
Max. torque 10 N·m (102 kgf·cm) (89 in-lbs.) 18 N·m (183 kgf·cm) (160 in-lbs.)
Max. torque (hard)
(actually measured value)
24.7 N·m (252 kgf·cm)
(219 in-lbs.)
16.7 N·m
*1)
(170 kgf·cm)
(148 in-lbs.)
[21 stages] [10 stages]
Slip torque
1.0 – 6.0 N·m
10 – 60 kgf·cm
(9 – 53 in-lbs.)
2.0 – 6.0 N·m
20 – 60 kgf·cm
(18 – 53 in-lbs.)
Spindle lock function Equipped Equipped
LED light Equipped Equipped
Battery level warning lamp Equipped None
Soft-grip handle Equipped Equipped
Battery type Li-ion Li-ion
Nominal capacity 1.5 Ah 1.3 Ah
Nominal voltage 10.8 V 10.8 V
Battery
Charging time
*
2)
40 min. (Model UC 10SFL) 30 min.
Overall length 147 mm (5-3/4") 166 mm (6-1/2")
Overall height 197 mm (7-3/4") 167 mm (6-1/2")
Dimensions
Width 48 mm (1-7/8") 49 mm (1-7/8")
Weight 0.8 kg (1.8 lbs.) 0.8 kg (1.8 lbs.)
*1): The clutch function is worked even at the drill mode setting.
*2): Charging time may vary depending on the type of charger to be used.
COMPARISONS WITH SIMILAR PRODUCTS
-6-
2. Drilling and fastening performance comparison per charge
(Superior specifications:
)
The above table shows an example of test data. The batteries used in this test are as follows:
Model DB 10DL: 1.5 Ah
B: 1.3 Ah
*: Number of machine screws fastened per charge
*1: Number of holes or fasteners per charge
The above table shows an example of test data obtained using the battery which is standard for this tool.
As actually measured values listed in the above table may vary depending on the sharpness of the drill bit,
workpiece hardness (particularly in wood materials), moisture content of wood, charging condition, operator
skill, etc. This data should be used as a comparative guide only.
Drilling
Type of work
Maker
Model
0 *200 *400 *600 *800
speed
0 100 200 300 400
(sec./pc.)
1.4
1.5
3.6
3.7
2.4
2.4
HITACHI
DB 10DL
3.5
3.5
B
38 mm (1-1/2")
142
146
131
141
157
196
T18 (11/16")
18 mm dia. (11/16")
Wood boring
A
merican
pine
Machine screw
6mm dia.
(
#14
)
w
ith pilot hole Ɏ4
A
merican
p
ine
Wood screw
A
merican
pine
38 mm
(
1-1/2"
)
Wood screw
3.8 mm dia.
(#7)
12 mm
(
15/32"
)
*576
*714
6 mm (1/4")
HITACHI
DB 10DL
B
HITACHI
DB 10DL
B
HITACHI
DB 10DL
B
Working capacity (*1)
-7-
1. Safety instructions
In the interest of promoting the safest and most efficient use of the Model DB 10DL cordless driver drill 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 and Name Plate attached to each
tool.
A. Handling instructions
Salespersons must be thoroughly familiar with the contents of the Handling Instructions in order to give
pertinent advice to the customer. In particular, they must have a thorough understanding of the precautions
for use of the cordless tools which are different from those of ordinary electric power tools.
(1) Before use, ensure that the battery is fully charged.
New battery is not fully charged. Even if the battery was fully charged at the factory, long periods of
inactivity, such as during shipping, cause the storage battery to lose its charge. Customers must be
instructed to fully charge the battery prior to use.
(2) When charging storage battery, use only the exclusive Model UC 10SFL charger provided with
the tool.
Because of the designed rapid-charging feature (about 40 minutes), use of other battery chargers is
hazardous.
(3) Connect the charger to an AC power outlet only.
Use of any other power source (DC outlet, fuel powered generator, etc.) will cause the charger to
overheat and burn out.
(4) Do not use any voltage increasing equipment (transformer etc.) between the power source and
the charger.
If the charger is used with voltage higher than that indicated on the unit, it will not function properly.
(5) Conduct battery charging at an ambient temperature range of 0°C - 40°C (32°F - 104°F).
Special temperature sensitive devices are employed in the charger to permit rapid charging. Ensure that
customers are instructed to use the charger at the indicated ambient temperature range. At temperature
under 0°C (32°F) the thermostat will not function properly, and the storage battery may be overcharged.
At temperature over 40°C (104°F), the storage battery cannot be sufficiently charged. The optimum
temperature range is 20°C - 25°C (68°F - 77°F).
(6) The battery charger should not be used continuously.
At high ambient temperature, if over three storage batteries are charged in succession, the temperature
of the coils on the transformer will rise and there is a chance that the temperature fuse inserted in the
interior of the transformer will inadvertently melt. After charging one battery, please wait about 15
minutes before charging the next battery.
(7) Do not attempt to disassemble the storage battery or the charger.
Special devices, such as a thermostat, are built into the storage battery and the charger to permit rapid
charging. Incorrect parts replacement and/or wiring will cause malfunctions which could result in fire or
other hazards. Instruct the customer to bring these units to an authorized service center in the event
repair or replacement is necessary.
PRECAUTIONS IN SALES PROMOTION
-8-
(8) Disposal of the storage battery (Type BCL 1015)
Ensure that all customers understand that the Type BCL 1015 storage battery should be returned to the
Hitachi power tool sales outlet or the authorized service center when they are no longer capable of
being recharged or repaired. If thrown into a fire, the battery may explode.
B. Caution plate
(1) The following cautions are listed on the Name Plate attached to the Type DB 10DL main body.
[ For the U.S.A. and Canada ]
Warning
To reduce the risk of injury, user must read Instruction Manual.
Risk of fire, burn or explosion. Use only with battery BCL 1015.
AVERTISSEMENT
Afin de reduire le risque de blessures, I’utilisateur doit lire le mode d’emploi.
(2) The following cautions are listed on the Name Plate attached to the Type BCL 1015 storage battery.
[ For Europe ]
[ For the U.S.A. and Canada ]
(3) The following cautions are listed on the Name Plate attached to the Type UC 10SFL storage battery.
[ For the U.S.A. and Canada ]
-9-
2. Inherent drawbacks of cordless driver drills requiring particular
attention during sales promotion
The cordless driver drill offers many advantages; it can be used in places where no power source is
available, the absence of a cord allows easy use, etc. However, any cordless tool has certain inherent
drawbacks. Salespersons must be thoroughly familiar with these drawbacks in order to properly advise the
customer in the most efficient use of the tool.
A. Suggestions and precautions for the efficient use of the tool
(1) Use the cordless driver drill for comparatively light work.
Because they are battery driven, the output of the motor in cordless driver drills is rather low in
comparison with conventional electric power tools. Accordingly, they are not suitable for continuous
drilling of many holes in succession, or for drilling into particularly hard materials which creates a heavy
load. Salespersons should recommend conventional electric power tools for such heavy work.
(2) Do not insert a foreign object into body.
A foreign object inserted through a hole may cause a failure. Please instruct customers to never insert a
foreign object into body.
(3) Avoid "Locking" of the motor.
Locking of the motor will cause an overload current that could result in burning of the motor and/or rapid
deterioration of the battery. Salespersons should advise the customer to immediately release the switch
and stop operation if the motor becomes locked. (A jammed drill bit can be disengaged from the
workpiece material by setting the switch to reverse rotation, or by manually turning the main body of the
tool.)
(4) Variation in amount of work possible per charge
Although the nominal chargeable capacity of the storage battery used with the Model DB 10DL is 1.5 Ah,
the actual capacity may vary within 10% of that value depending on the ambient temperature during use
and charging, and the number of times the batteries have been recharged. It should be noted that other
factors which may have a bearing on the amount of work possible per charge are the working conditions
(ambient temperature, type and moisture content of the workpiece, sharpness of the drill bit, etc.) and
the operational skill of the user.
B. Suggestions and precautions for the efficient use of the charger and storage
battery
If the Type BCL 1015 storage battery is exposed to direct sunlight for an extended period or if the tool has
just been operated for a long time, charging may not be possible if the temperature of the battery is above
50°C (122°F). In such a case, the customer should be advised to place the battery in a shaded area with a
good airflow, and allow sufficient cooling before recharging. This phenomenon is common to all existing
batteries and chargers which employ temperature sensitive overcharge protection devices. The cooling
time required before recharging can be accomplished varies from a few minutes to about 40 minutes,
depending on the load, duration of use, and ambient temperature.
-10-
Be sure to remove the storage battery (BCL 1015) from the main body before servicing. Inadvertent
triggering of the switch with the storage battery connected will result in danger of accidental turning of the
motor.
1. Precautions in disassembly and reassembly
The [Bold] numbers in the description below correspond to the item numbers in the Parts List and the
exploded assembly diagram for the Model DB 10DL.
1. Removal of the housing
Remove the seven Tapping Screws (W/Flange) D3 x 16 (Black) [36]. Holding the battery chamber of
Housing (A).(B) Set [31], open Housing (A).(B) Set [31] gently. After opening Housing (A).(B) Set [31], all
the internal parts can be removed separately or in an assembled status. Lift the Motor [30] and the Clutch
Dial [6] from Housing (A).(B) Set [31]. Then all the internal parts can be removed easily. The internal parts
are separated into the drive unit (Gear Box Ass’y [1]), power supply unit (Motor [30], DC-Speed Control
Switch [35] and Controller (B) [39]) and Pushing Button (A) [34].
2. Removal of the drive unit from the power supply unit
Hold the Motor Spacer [29] and the Motor [30] of the Gear Box Ass’y [1] and pull it in the axial direction.
Then the drive unit can be removed from the power supply unit.
3. Disassembly of the drive unit
(a) Disassembly of the deceleration mechanism
Twist the Motor Spacer [29] counterclockwise to remove it from the Gear Case [12]. Remove Washer
(A) [28] then remove the First Ring Gear [27], Planet Gear (A) Set (3 pcs.) [26] and Pinion (B) [25] in
order. Remove the two Needles [13] inserted through the side of the Gear Case [12]. Remove Washer
(B) [24], Planet Gear (B) Set (3 pcs.) [23], Pinion (C) [22], Washer (C) [21], Planet Gear (C) Set (3 pcs.)
[17], Carrier [19], Ring Gear [20], Needle Roller Set (6 pcs.) [16], six Steel Balls D4 [15], Pin Set (6
pcs.) [14] and Lock Ring [18] in order.
NOTE: Do not lose the small parts. Especially be careful not to lose the Needle Roller Set (6 pcs.)
[16], six Steel Balls D4 [15] and Pin Set (6 pcs.) [14] because they are apt to roll.
(b) Removal of guide sleeve (A)
Remove the Retaining Ring [2], Washer (D) [3], Guide Spring [4] and Guide Sleeve (A) [5] in order
following the procedure shown in Fig. 1. One side of the gap of the Retaining Ring [2] is raised. Slowly
raise the other side of the gap with a small flat-blade screwdriver to remove the Retaining Ring [2].
Avoid quickly raising the Retaining Ring [2] or it may fly out forcefully. Do not lose the Steel Ball D3.5
[11] in the socket hole.
(c) Disassembly of the clutch mechanism
Remove the Clutch Dial [6] and the Click Spring [7]. (Remove Guide Sleeve (A) [5].)
Turn the Nut [8] counterclockwise and remove it from the Gear Case [12]. Then remove the Spring [9]
and Washer (D) [10] in order.
NOTE: Do not remove the Gear Case [12].
Disassembl
y
REPAIR GUIDE
-11-
Fig. 1-1 Hold the body and adjust the gap of the
Retaining Ring [2] to the groove of socket, then insert a
small flat-blade screwdriver into the groove at an angle.
Guide Sleeve (A) [5]
Socket
Retaining Ring [2]
Small flat-blade
screwdriver
Washer (D)
[3]
Fig. 1
4. Disassembly of the power supply unit
Unsolder the Internal Wire (Black) [32] and the Internal Wire (Red) [33] of the Motor [30] with a soldering
iron and disconnect them from the Motor [30]. Disconnect the Internal Wire (Black) [32] and the Internal
Wire (Red) [33] of the Motor [30] from the DC-Speed Control Switch [35] with a soldering iron in the same
manner.
The internal wires of the DC-Speed Control Switch [35] (two LEDs are connected with the internal wires)
and the Controller (B) [39] are soldered to each terminal.
Unsolder the internal wire (red) ((B+) terminal side of the DC-Speed Control Switch [35]), internal wire
(white) ((B-) terminal side of the DC-Speed Control Switch [35]) and internal wire (blue) of the DC-Speed
Control Switch [35] with a soldering iron and disconnect them from the DC-Speed Control Switch [35].
Before unsoldering the internal wire (blue), be sure to remove the heat shrinkable tube.
NOTE: Do not remove the DC-Speed Control Switch [35] and the Controller (B) [39].
Fig. 1-2 Press down Washer (D) [3] with the small
flat-blade screwdriver.
Fig. 1-3 Slide the small flat-blade screwdriver under
one side of the gap of the Retaining Ring [2].
Fig. 1-4 Slowly raise the Retaining Ring [2] using the
end face of Guide Sleeve (A) [5] as a fulcrum.
-12-
Fig. 2
Motor Spacer [29]
Internal Wire (Red) [33]
Internal Wire (Black) [32]
Internal wire (black)
Internal wire (white)
Terminal on the switch (B
-
) side
Controller (B) [39]
Motor [30]
DC-Speed Control Switch [35]
Internal wire (blue)
Internal wire (red)
Terminal on the switch (B+) side
Protect the soldered portion with
the insulating tape.
Reassembly can be accomplished by following the disassembly procedure in reverse. However, special
attention should be given to the following items.
1. Wiring of the power supply unit
(a) Perform wiring according to the wiring diagram (Fig. 2). Be careful of the color of the internal wires and
the terminals to be soldered.
(b) Be careful of the polarity of the Motor [30] when soldering the Internal Wire (Black) [32] and the Internal
Wire (Red) [33] to the Motor [30]. The (+) terminal of the Motor [30] has a red mark for distinction
(Fig. 3).
(c) Be careful of the polarity and the mounting direction when soldering the Internal Wire (Black) [32] and
the Internal Wire (Red) [33] to the terminals of the DC-Speed Control Switch [35] (Fig. 4 (A)).
(d) Be careful of the color of the internal wires and the soldering direction when mounting Controller (B) [39]
to the DC-Speed Control Switch [35]. Solder the internal wire (blue) of the DC-Speed Control Switch
[35] to the internal wire (black) of Controller (B) [39]. After soldering, protect the soldered portion with
the insulating tape (Fig. 4 (B), (C)).
Reassembl
y
-13-
Fig. 3
Fig. 4
(+) terminal
Red mark
(
-
) terminal
Internal wire (red) of
Controller (B) [39]
Internal wire (white)
Internal wire (red)
Internal wire (black) of Controller (B) [39]
Protect the soldered portion with the insulating tape.
Internal wire (blue)
Internal wire (black)
Internal wire (red) of Controller (B) [39]
Internal wire (white) of Controller (B) [39]
Internal wire (red)
(A)
(B) (C)
-14-
Fig. 6
Fig. 5
Spring [9]
Y surface
Nut [8]
Gear Case [12]
Z surface
Spring [9]
Washer (D) [10]
Y surface Z surface
Gear Case [12]
Nut [8]
Washer (D) [10]
Register mark Protrusion
Notch (3 pcs.)
Gear Case [12]
Protrusion
Click Spring [7]
2. Reassembly of the drive unit
(a) Mount Washer (D) [10] and the Spring [9] to the Gear Case [12] in order.
(b) Screw the Nut [8] in aligning its protrusion with the register mark on the Gear Case [12].
Turn the Nut [8] about 1 turn clockwise so that the register mark on the Nut [8] is aligned with the
register mark on the Gear Case [12]. Check that the Y surface of the Nut [8] is almost aligned with the Z
surface of the Gear Case [12] (Fig. 5).
(C) Mount the Click Spring [7] to the notch of the Gear Case [12] aligning the register mark on the Gear
Case [12] with the protrusion of the Click Spring [7]. Mount the Click Spring [7] in the proper direction as
shown in Fig. 6.
Protrusion of the Nut [8]
Register mark of the
Gear Case [12].
Register mark of the Nut [8]
Register mark of the
Gear Case [12].
Screw-in start position
Screw-in end position
-15-
Flat portion of
the Lock Ring [18]
Protrusion
Opening of the Gear Case [12]
Fig. 8
3. Reassembly of the manual tightening
mechanism
(a) Mount the Lock Ring [18] to the Gear Case [12]
so that the protrusion of the Lock Ring [18] aligns
with the concave portion of the Gear Case [12].
At this time, mount the Lock Ring [18] so that its
flat portion faces the opening of the Gear Case
[12] as shown in Fig. 7.
(b) Mount the Needle Roller Set (6 pcs.) [16].
NOTE: Do not apply grease to the Lock Ring [18]
and the Needle Roller Set (6 pcs.) [16].
Otherwise, the manual tightening
mechanism may operate poorly.
4. Reassembly of the deceleration mechanism
(a) Apply grease (Hitachi Motor Grease No. 29) to the engaging portions of each gear, Pin Set [14] and the
contacting surface of the Ring Gear [20] with the Steel Ball D4 [15] properly.
(b) Mount the parts from the Pin Set (6 pcs.) [14], Steel Ball D4 [15], Ring Gear [20], Carrier [19] and
Planet Gear (C) Set [17] to the part assembled in the above (3). Then mount the parts up to Washer (A)
[28] in order (Fig. 8).
Mount the Pin Set (6 pcs.) [14] first then mount the Steel Ball D4 [15].
Pay attention to the mounting direction of the Ring Gear [20], Carrier [19], Pinion (C) [22] and Pinion
(B) [25] (Fig. 8).
Check that the Needle [13] is mounted between Washer (B) [24] and the First Ring Gear [27].
Fig. 7
Needle Roller Set (6 pcs.) [16]
Lock Ring [18]
Flat portion
Stepped portion
Steel Ball D3.5 [11]
Gear Case [12]
Needle [13] Pin Set (6 pcs.) [14]
Steel Ball D4 [15]
Needle Roller Set [16]
Planet Gear (C) Set [17]
Lock Ring [18] Carrier [19]
Ring Gear [20]
Washer (C) [21]
Pinion (C) [22]
Planet Gear (B) Set [23]
Washer (B) [24]
Pinion (B) [25]
Planet Gear (A) Set [26]
First Ring Gear [27]
Washer (A) [28]
-16-
Fig. 9
Fig. 10
Fig. 11
5. Mounting the power supply unit to the drive unit
(a) Mount the Motor Spacer [29] to the Motor [30] fitting its cylindrical protrusion in the hole of the Motor
[30] as shown in Fig. 9.
(b) Fit the protrusions of the Motor Spacer [29] in the concave portions of the Gear Case [12] and turn it
clockwise to secure. Pay attention to the mounting direction of the Motor [30] and the Gear Case [12]
when mounting the Motor [30] to the Gear Box Ass’y [1]. Mount the Motor [30] so that the red mark on
the Motor [30] is positioned to the top when mounted to the housing (Fig. 10).
6. Mounting the clutch dial
The Nut [8] has three protrusions. One of these protrusions is wider than the others. The Clutch Dial [6]
has three concave portions inside. One of these concave portions is wider than the others. Mount the Nut
[8] to the Clutch Dial [6] aligning the wider protrusion of the Nut [8] with the wider concave portion of the
Clutch Dial [6]. The wider concave portion in the Clutch Dial [6] is at the position indicated with "1" on the
outside of the Clutch Dial [6] (Fig. 11).
Cylindrical protrusion
Motor Spacer [29]
Hole
Motor [30]
Do not insert in these holes.
Motor [30]
Motor Spacer [29]
Gear Case [12]
Red mark
Wider concave portion
Protrusion
Nut [8]
Concave portion
Wider protrusion
Clutch Dial [6]
Indicated with “1”
Protrusion
Concave portion
Protrusion
Protrusion
Cylindrical protrusion
-17-
Fig. 12
Fig. 13
7. Reassembly of the housing
(a) Mount the LED to housing (A) of Housing (A).(B) Set [31] without twisting the LED internal wire attached
to the DC-Speed Control Switch [35]. Put the LED connected with the internal wire (red) in the space
provided on the DC-Speed Control Switch [35] side and the LED connected with the internal wire (blue)
in the space provided on the upper side of housing (A) of Housing (A).(B) Set [31]. Mount these two
LEDs positioning the chamfered side as shown in Fig. 12.
(b) Mount the assembly of the Motor [30] and the Gear Box Ass’y [1] to housing (A) of Housing (A).(B) Set
[31]. At this time, fit the protrusions of the Gear Case [12] and the Motor Spacer [29] in the concave
portions of housing (A) of Housing (A).(B) Set [31] and the protrusion of the Clutch Dial [6] in the
concave portion of housing (A) of Housing (A).(B) Set [31]. Align the two Needles [13] protruded from
the Gear Case [12] with the two holes of housing (A) of Housing (A).(B) Set [31]. Be careful not to
pinch the internal wires of the LED (Fig. 13).
Internal wire (blue)
Space for the LED
Housing (A).(B) Set [31]
LED light
Chamfered side
LED
Chamfered side
LED
Internal wire (red)
A-A
B-B
Clutch Dial [6] mounting position
Gear Case [12] mounting position
Needle [13] mounting position
Motor Spacer [29] mounting position
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