PRODUCT NAME
Hitachi 36 V Cordless Hedge Trimmer
Model CH 36DL
REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 1
1. Precautions on disassembly and reassembly ------------------------------------------------------------- 1
2. Precautions on disassembly and reassembly of battery charger ------------------------------------ 8
STANDARD REPAIR TIME (UNIT) SCHEDULES---------------------------------------------------------------------- 9
CONTENTS
Page
LIST No.
CH 36DL: J840
Jan. 2013
C
Sales Division
-1-
1. Precautions on disassembly and reassembly
[Bold] numbers in the descriptions below correspond to item numbers in the Parts List and the exploded
assembly diagram for the Model CH 36DL.
Before conducting any repair, make sure to remove the battery (Type BSL 3620, BSL 3626 or BL 36200)
from the product. Otherwise, the motor will suddenly start to run. This is very dangerous.
1. Removing the bottom cover ass’y
(1) Remove the Bottom Cover Ass’y [38] by removing four Tapping Screws (W/Flange) D5 x 20 (Black)
[40] that secure the Bottom Cover Ass’y [38] to the main unit.
(2) Slide the Cam Rod Holder [39] in the direction of the blade. Then remove the Washer [33] (bottom
cover), Cam Rod [34] (bottom cover), Gear [35], First Gear [37], Cam Rod [34] (housing), and Washer
[33] (housing). Lastly, remove the Cam Rod Holder [39].
2. Removing the blade ass’y
Be sure to attach the Blade Case [48] before removing the Blade Ass’y [47].
(1) Raise the Blade Ass’y [47] imbedded into the housing toward the bottom cover. Then remove the
Cushion [29], Spacer [30], and Blade Ass’y [47]. If the Blade Ass’y [47] is too tightly imbedded and
cannot be removed, loosen the Tapping Screw (W/Flange) D4 x 20 (Black) [26] securing the housing in
place near the Blade Ass’y [47], and then remove the Blade Ass’y [47].
3. Removing the blade and the spacer
Remove two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [31] and two Nylon Nuts M6 [28]. Then remove
the Spacer [30]. Two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [31] on the edge of the blade can be
loosened by inserting a hexagonal wrench through the holes at the top and bottom of the blade.
4. Removing the sub handle ass’y
Remove two Machine Screws (W/Washers) M5 x 30 [10]. Then pull the Sub Handle Ass’y [1] outward to
disengage it from Housing (A).(B) Set [23].
5. Removing housing (B)
(1) Remove twelve Tapping Screws (W/Flange) D4 x 20 (Black) [26] so that housing (B) can be removed with
all internal parts stored in housing (A).
(2) Grip the Motor DC 36 V [16] and lift housing (A) so that the power supply section (Motor DC 36 V [16],
Switch [8], Controller (W/Ferrite Core) [19], and Battery Terminal [22]) can be removed in its entirety.
(3) Remove the Rubber Cushion [25], Trigger [21], and Push Pin [13] while making sure that Spring (B) [20] on
Trigger [21] and Spring (D) [9] on Push Pin [13] are not mislaid.
6. Disassembling the power supply section
(1) When disconnecting the internal wire (black) for the Motor DC 36V [16] from the Switch [8], remove
the solder with a soldering iron. When disconnecting the internal wire (red) from the Connector 50092
[5], cut the Connector 50092 [5] connection with nippers.
(2) The Controller (W/Ferrite Core) [19] is soldered to the Battery Terminal [22] and two Switches [8] with
internal wires.
Disassembl
y
REPAIR GUIDE
-2-
Ɣ Connection diagram
Connector 50092 [5]
Battery Terminal [22]
Switch [8]
Internal wire (Black)
Internal Wire (Black) [7]
Internal wire (Black)
Internal Wire (Red) [6]
Internal wire (White)
Internal wire (Red)
Controller (W/Ferrite Core) [19]
Motor DC 36 V [16]
Internal wire (Red)
Internal wire (Red)
Internal wire (White)
Internal wire (Black)
Switch [8]
Internal wire (Red)
Internal wire (Black)
Internal Wire (Red) [12]
Diode [17]
Panel Sheet [18]
Ferrite Core [15]
Ferrite Core [15]
(3) When disconnecting the two internal wires (red), two internal wires (black), and one internal wire
(white) for the Switch [8], and when disconnecting two internal wires (red) and three internal wires
(black) for the other Switch [8], remove the solder with a soldering iron.
(4) When disconnecting the internal wire (red), internal wire (black) and internal wire (white) for the Battery
Terminal [22], remove the solder with a soldering iron.
NOTE: Do not disassemble the Switch [8] and the Controller (W/Ferrite Core) [19].
Conduct reassembly by doing the disassembly procedure in reverse. Note the following:
1. Connecting the power supply section
(1) Make sure all connections are made by referring to the connecting diagram. Always pay attention to
the color of the internal wires and the terminals to be soldered.
Reassembl
y
Switch [8]
(Red) Wound once
Internal Wire (Red) [6]
Controller
(W/Ferrite Core) [19]
B
attery
T
erm
i
na
l
[22]
Diode [17]
(Red)
(Black)
Internal Wire (Black) [7]
Internal Wire (Red) [12]
Switch [8]
LED
circuit
board
(Black) Wound once
(White) Not wound
Ferrite Core [15]
(Red)
Wound twice
(Black)
Wound twice
Ferrite Core [15]
(Red)
Wound once
(Black)
Wound once
Ferrite Core [15]
-3-
Ɣ Attaching spring (B)
(2) Pay attention to the soldering direction when soldering two Switches [8] and internal wires.
(3) Pay attention to the polarity of the Diode [17] when attaching it.
(4) Pay attention to the soldering direction when soldering the Controller (W/Ferrite Core) [19] to two
Switches [8] and the Battery Terminal [22].
(5) Attach the Motor DC 36 V [16] and the assembly of the Controller (W/Ferrite Core) [19], two Switches
[8], and Battery Terminal [22] onto housing (A) of Housing (A).(B) Set [23]. Ensure indented portions
on the Motor DC 36 V [16] are placed on protruding portions of housing (A).
(6) Attach the Trigger [21], Spring (B) [20], Push Pin [13], Spring (D) [9], and Rubber Cushion [25] to the
correct locations on Housing (A).(B) Set [23]. Ensure Spring (B) [20] is attached at right angle to the
Switch [8]. Spring (B) [20] is securely fastened and is not bent or misaligned.
Ɣ Wiring diagram
Diode [17]
Motor DC 36 V [16]
Switch [8]
Trigger [21]
Battery Terminal [22]
Internal Wire (Red) [12]
Internal wire (White)
Internal wire (White)
LED circuit board
Internal wire (Black)
Internal wire (Red)
Controller (W/Ferrite Core) [19]
Spring (B) [20]
Connector 50092 [5]
Internal wire (Black)
Internal wire (red)
Internal Wire (Black) [7]
Internal Wire (Red) [6]
Internal wire (Red)
Push Pin [13]
Internal wire (Black)
Spring (D) [9]
Rubber Cushion [25]
Switch [8]
A
Switch [8]
Trigger [21]
Spring (B) [20]
-4-
Ɣ Attaching the protector and packing (A)
2. Reassembling the housing section
(1) Ensure internal wires do not sag and are not pinched when covering with housing (B) of Housing
(A).(B) Set [23]. Also, ensure Spring (B) [20] is securely fastened and is not bent or misaligned.
(2) Press Protector [11] into Housing (A).(B) Set [23] while firmly holding packing (A).
(3) Align housing (B) of Housing (A).(B) Set [23], and tighten twelve Tapping Screws (W/Flange) D4 x 20
(Black) [26] after inserting the Ball Bearing 626ZZC2 PS2-L [36] and the Ball Bearing 608DDC2PS2L
[32] into the ball bearing chambers on the housing. (Tighten the screw “A” shown on the wiring
diagram first and ensure the internal wires are not pinched.)
(4) Pass Shaft (D) [4] through the hole on the Push Pin [13]. Make sure the protruding portions on the Sub
Handle Ass’y [1] are aligned with the indented portions on Housing (A).(B) Set [23]. Then tighten two
Machine Screws (W/Washers) M5 x 30 [10]. Make sure the two Nuts M5 (Black) [14] do not fall off.
(5) Insert the felt flange into the groove on Housing (A).(B) Set [23].
3. Attaching the blade and gear
(1) Pass two Hex. Socket Hd. Bolts (W/Button) M6 x 25 [31] on the edge of the blade through the Spacer
[30]. Then pass a hexagonal wrench through the holes at the top and bottom of the blade and tighten
the two Nylon Nuts M6 [28]. The protruding portion of the Spacer [30] must be facing the edge of the
blade.
(2) Attach the blade to Housing (A).(B) Set [23]. If the Cushion [29] is too tight and cannot be inserted,
loosen the Tapping Screws (W/Flange) D4 x 20 (Black) [26] around the Cushion [29] and then attach it.
Retighten the Tapping Screws (W/Flange) D4 x 20 (Black) [26]. Replace the Cushion [29] if it is
scratched or cracked.
(3) Apply grease (Shell Alvania Grease RL3) to the inside of the Cam Rod Holder [39] and pass it through
the blade. Make sure the wedge-shaped joint on the Cam Rod Holder [39] faces toward the HITACHI
logo on housing (A) at this time.
(4) When attaching the First Gear [37], apply grease (Shell Alvania Grease RL3) to the tooth surface on
the First Gear [37] and insert the Ball Bearing 626ZZC2 PS2-L [36].
(5) Apply grease (Shell Alvania Grease RL3) to both sides of the Cam Rod [34] (on the housing side), and
the inner diameter of the cam alignment hole and the interlocking hole on the blade pin. Then press
them onto the housing blade's pin. Ensure the Cam Rod [34] is attached with the shear droop surface
Protector [11]
Packing (A)
Insert the felt flange into the hole.
Housing (A).(B) Set [23]
-5-
Ɣ Attaching the blade attachment, cam rod holder and cam rod
facing the Gear [35] on the blade.
(6) Apply grease (Shell Alvania Grease RL3) to the tooth surface on the Gear [35], sliding portion on the
Cam Rod [34], and the cam. Place the Washer [33] on top of the Ball Bearing 608DDC2PS2L [32],
and insert the shaft of the Gear [35] into the Ball Bearing 608DDC2PS2L [32]. Ensure the Cam Rod
[34] and the Gear [35] are interlocked.
(7) Apply grease (Shell Alvania Grease RL3) to both sides of the Cam Rod [34] (bottom cover), inner
diameter of the cam alignment hole, and interlocking hole on the blade pin. Then press them onto the
blade pin and the Gear [35] cam. Place the Washer [33] on the shaft of the Gear [35]. Ensure the
Cam Rod [34] is attached with the shear droop surface facing the Gear [35] (on the blade).
(8) Slide the Cam Rod Holder [39] toward the Gear [35] so that it sandwiches the two Cam Rods [34] and
the blades (upper and lower).
Washer [33]
Cam Rod Holder [39]
First Gear [37]
Cam Rod [34]
Sandwich the two Cam
Rods [34] and the upper
and lower blades inside
the Cam Rod Holder [39].
-6-
ƔOrientation of the cam rod holder and cam rod
Ɣ Attaching the spacer
Pass a hexagonal wrench through the hole in the
blade and tighten the Hex. Socket Hd. Bolts
(W/Button) M6 x 25 [31] and the Nylon Nuts M6 [28].
Cushion [29]
Face the protruding portion of the
Spacer [30] to the edge of the blade.
Face the indented portion of the Spacer
[30] to the blade ass'y [47].
Blade Ass'y [47]
Face the wedge-shaped joint to the
HITACHI logo on housing (A).
Cam Rod Holder [39]
Face the shear droop surface of the Cam
Rod [34] inward (toward the Gear [35]).
Cam Rod [34]
Cam Rod [34]
Gear [35]
-7-
Ɣ Attaching the bottom cover ass’y
Ɣ Positioning the cam rod holder
4. Reassembly of the bottom cover ass’y
(1) Slide the Cam Rod Holder [39] toward the Gear [35] and align the edge of the Cam Rod Holder [39]
with the edge of ribs on Housing (A).(B) Set [23].
(2) Cover the Bottom Cover Ass’y [38] while making sure the Cam Rod Holder [39] is correctly placed
inside the cam rod holder's storage ribs. Then tighten four Tapping Screws (W/Flange) D5 x 20 (Black)
[40].
Slide the Cam Rod Holder [39]
toward the Gear [35].
A
lignment ribs
A
lign the edge of the Cam Rod Holde
r
[39] with the edge of the alignment ribs.
Cam rod holder storage ribs
Bottom Cover Ass'y [38]
Cam Rod Holder [39]
-8-
Ɣ Motor DC 36 V [16]: 0.5 g of Shell Alvania Grease RL3
Ɣ First Gear [37] tooth surface: 0.5 g of Shell Alvania Grease RL3
Ɣ Gear [35] tooth surface and sliding portin with the cam and the Cam Rod [34]:
3 g of Shell Alvania Grease RL3
Ɣ Blade pin outer circumference and sliding portion with the Cam Rod [34]:
2 g of Shell Alvania Grease RL3
Ɣ Housing (A).(B) Set [23] gear chamber: 7 to 10 g of Shell Alvania Grease RL3
Ɣ Tapping Screw (W/Flange) D4 x 20 (Black) [26] ······························· 3.1 to 3.6 N•m {30 to 35 kgf•cm}
Ɣ Tapping Screw (W/Flange) D5 x 20 (Black) [40] ······························· 2.9±0.5 N•m {30±5 kgf•cm}
Ɣ Machine Screw (W/Washers) M5 x 30 [10] ····································· 2.4±0.5 N•m {25±5 kgf•cm}
Ɣ Nylon Nut M6 [28] ····································································· 9.8±2.0 N•m {100±20 kgf•cm}
Ɣ Hex. Socket Hd. Bolt (W/Flange) M5 x 8 [45] ································· 5.9±1.5 N•m {60.2±15.3 kgf•cm}
2. Precautions on disassembly and reassembly of battery charger
Refer to the Service Manual for precautions on disassembly and reassembly of the Model UC 36YRSL
Battery Charger.
Screw ti
g
htenin
g
tor
q
ue
Lubrication
-9-
MODEL
Variable
Fixed
10 20 30 40 50 60 min.
CH 36DL
General assembly
Housing
(A).(B) Set
Switch x 2
Push Pin
Motor
Controller
Trigger
Work Flow
Bottom Cover
Ass’y
First Gear
Ball Bearing
(626ZZC2)
x 2
Gear
Ball Bearing
(608DDC2)
x 2
Cam Rod x 2
Cam Rod
Holder
Blade Ass’y
Cushion x 2
Spacer
Guard Plate
STANDARD REPAIR TIME
(
UNIT
)
SCHEDULES
Model CH 36DL
CORDLESS HEDGE TRIMMER
LIST NO. J840
2013 · 1 · 8
(E1)
18
17
45
46
15
15
15
23
1
4
10
11
24
8
21
12
19
16
7
8
9
13
14
25
26
41
27
29
30
28
32
33
34
35
36
37
33
31
31
29
40
38
43
44
42
48
34
20
6
5
2
3
36
32
47
501
22
39
PART
S
CH 36DL
DESCRIPTION REMARKS
1 335-015 SUB HANDLE ASS'Y 1 INCLUD. 2, 3
2 333-341 SPRING (C) 1
3 335-347 COLLAR 2
4 335-019 SHAFT (D) 1
5 959-141 CONNECTOR 50092 (10 PCS.) 1
6 335-345 INTERNAL WIRE (L96) 1
7 335-344 INTERNAL WIRE (L186) 1
8 335-018 SWITCH 2
9 333-344 SPRING (D) 1
10 880-561 MACHINE SCREW (W/WASHERS) M5 X 30 2
11 335-010 PROTECTOR 1
12 335-343 INTERNAL WIRE (L204) 1
13 333-343 PUSH PIN 1
14 302-012 NUT M5 (BLACK) 2
15 334-379 FERRITE CORE 3
16 335-016 MOTOR DC 36 V 1
17 335-346 DIODE 1
18 335-342 PANEL SHEET 1
19 335-341 CONTROLLER (W/FERRITE CORE) 1
20 324-307 SPRING (B) 1
21 333-761 TRIGGER 1
22 331-399 BATTERY TERMINAL 1
23 335-012 HOUSING (A).(B) SET 1
* 24 334-998 BATTERY BSL 3620 (EUROPE, AUS, NZL) 1
* 24 334-997 BATTERY BSL 3620 (USA, CAN) 1
25 332-668 RUBBER CUSHION 1
26 301-653
TAPPING SCREW (W/FLANGE) D4 X 20 (BLACK) 12
27 NAME PLATE 1
28 669-8766 NYLON NUT M6 2
29 335-021 CUSHION 2
30 335-020 SPACER 1
31 669-9113
HEX. SOCKET HD. BOLT (W/BUTTON) M6 X 25 2
32 608-DDM BALL BEARING 608DDC2PS2L 2
33 335-022 WASHER 2
34 669-8987 CAM ROD 2
35 335-014 GEAR 1
36 335-669 BALL BEARING 626ZZC2 PS2-L 2
37 335-013 FIRST GEAR 1
* 38 335-017 BOTTOM COVER ASS'Y 1 INCLUD. 32, 36
* 38 335-676 BOTTOM COVER ASS'Y 1 INCLUD. 32, 36
39 335-677 CAM LOD HOLDER 1
40 302-089
TAPPING SCREW (W/FLANGE) D5 X 20 (BLACK) 4
41 669-8108 CARBURETOR GASKET 5
42 669-9114 WASHER (A) 5
43 669-9111 WASHER M7 5
44 669-9109 SHOULDER BUTTON BOLT M5 5
45 669-9065
HEX. SOCKET HD. BOLT (W/FLANGE) M5 X 8 1
46 669-9062 GUARD PLATE 1
47 669-9061 BLADE ASS'Y 1 INCLUD. 31, 41-44
48 335-011 BLADE CASE 1
- 2 - 1 - 13
*ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
CH 36DL
DESCRIPTION REMARKS
501 CHARGER (MODEL UC 36YRSL) 1
1 - 13 - 3 -
*ALTERNATIVE PARTS
STANDARD ACCESSORIES
NO.
USED
CODE NO.
ITEM
NO.
CH 36DL
DESCRIPTION REMARKS
- 4 - Printed in Japan 1 - 13
(130108N)
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.
/