HiKOKI DH45MA Rotary Hammer Instruction Manual

HiKOKI DH45MA Rotary Hammer

GENERAL POWER TOOL SAFETY WARNINGS

WARNING

Read all safety warnings and all instructions
Failure to follow the warnings and instructions may result in electric shock, fi re 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.

Work area safety

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

Electrical safety

• 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. Unmodifi ed plugs and matching outlets will reduce the risk of electric shock.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• 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.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. The use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. The use of an RCD reduces the risk of electric shock.

Personal safety

• 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 infl uence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks, non-skid safety shoes, hard hats, or hearing protection used for appropriate conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off position before connecting to a power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your fi nger on the switch or energizing power tools that have the switch on invites accidents.
• 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.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
• 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.

Power tool use and care

• 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.
• 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.
• 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.
• 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.
• Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may aff ect the power toolʼs operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• 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.

Service

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

CAUTION
Keep children and infi rm persons away. When not in use, tools should be stored out of reach of children and infi rm persons.

ROTARY HAMMER SAFETY WARNINGS

1. Wear ear protectors. Exposure to noise can cause hearing loss.
2. Use auxiliary handle(s), if supplied with the tool. Loss of control can cause personal injury.
3. Hold power tool by insulated gripping surfaces, when performing an operation where the cutting accessory 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.

ADDITIONAL SAFETY WARNINGS

1. Do not touch the bit during or immediately after the operation. The bit becomes very hot during operation and could cause serious burns.
2. Before starting to break, chip, or drill into a wall, fl door, or ceiling, thoroughly confi rm that such items as electric cables or conduits are not buried inside.
3. Always hold the body handle and side handle of the power tool fi rmly. Otherwise, the counterforce produced may result in inaccurate and even dangerous operations.
4. Wear a dust mask. Do not inhale the harmful dust generated in drilling or chiseling operations. The dust can endanger the health of yourself and bystanders.
5. Mounting the tool
   • To prevent accidents, make sure to turn the switch off and disconnect the plug from the receptacle.
   • When using tools such as bull points, drill bits, etc., make sure to use the genuine parts designated by our company.
   • Clean the shank portion of the drill bit. Then smear the shank portion with the grease or machine oil.
6. The rotation speed cannot be changed by pressing the rotation speed selector switch while the motor is rotating. To change speeds, switch off the tool fi first.
7. RCD The use of a residual current device with a rated residual current of 30 mA or less at all times is recommended.

SYMBOLS

WARNING
The following show symbols used for the machine. Be sure that you understand their meaning before use.

SPECIFICATIONS

STANDARD ACCESSORIES

See the list below to check the accessories for DH45MA.

OPTIONAL ACCESSORIES (sold separately)

1. Through-hole drilling (Rotation + Hammering)
   • Drill bit (SDS max shank)

1. Anchor hole drilling (Rotation + Hammering)

2. Large dia. hole boring (Rotation + Hammering)

3. Drilling holes ………….. For drilling metal and wooden materials

4. Bolt placing operation with Chemical Anchor (Rotation + Hammering)
   Square dimensions of the side of the socket installation| Code No.
   ---|---
   12.7 mm| 313469
   19.0 mm| 313470

5. Crushing (Hammering)

6. Groove digging and edging (Hammering)

7. Asphalt cutting (Hammering)

8. Digging Code No. 313476

9. Surface Roughing (Hammering)

10. Tamping (Hammering)

11. Rammer
    Code No. 313478

12. Shank
    Overall length| Code No.
    ---|---
    220 mm| 313479

13. Syringe (for chip removal)

14. Hammer grease A 500 g (in a can) Code No. 980927 70 g (in a tube) Code No. 308471

NOTE
Specifi cations are subject to change without any obligation on the part of the HiKOKI.

APPLICATIONS
Rotation and hammering function

• Drilling anchor holes
• Drilling holes in concrete

Hammering only function

• Crushing concrete, chipping, digging, and squaring (by applying optional accessories)

PRIOR TO OPERATION

1. Power source Ensure that the power source to be utilized conforms to the power requirements specifi ed on the product nameplate.
2. Power switch Ensure that the power switch is in the OFF position. If the plug is connected to a receptacle while the power switch is in the ON position, the power tool will start operating immediately, which could cause a serious accident.
3. Extension cord When the work area is removed from the power source, use an extension cord of sufficient thickness and rated capacity. The extension cord should be kept as short as practicable.
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 faulty receptacle is used, it may cause overheating, resulting in a serious hazard.
5. Confirming condition of the environment Confi rm that the work site is placed under appropriate conditions conforming to prescribed precautions.
6. Installing the Side Handle
7. Check that you have all the parts of the Side Band Handle bolt Handle. (Fig. 1)
8. Place the band over the band attachment area and fi t the band’s two holes onto the “T” portion of the handle bolt. (Fig. 2, 3)
9. As you hold the band to make sure the handle bolt won’t come loose, insert the handle bolt into the mount. (Fig. 4)
10. Adjusting the band to a position that is suitable for the task, turn the side handle to fasten the band. Make sure that the band is securely fastened. (Fig. 5)
11. How to install the tool

CAUTION
For tools such as a drill bit and a bull point, use only HiKOKI genuine parts.

1. Clean, then smear the tool shank with the grease provided in the green tube.
2. To attach the tool (SDS max shank), insert it into the hole Tool until it contacts the innermost end of the hole as illustrated in Fig. 6. 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. Pull the tool to make sure it is locked completely.
4. To remove the tool, fully pull the grip in the direction of the arrow and pull out the tool.

HOW TO USE

1. How to drill holes (Fig. 7)
2. Pull the switch trigger after applying the drill bit tip to the drilling position.
3. It is unnecessary to forcibly press the rotary hammer’s 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 slip 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.

1. How to chisel or crush (Fig. 8) By applying the tooltip to the chiseling or demolishing position, operate the rotary hammer by utilizing its empty weight. Forcible pressing or thrusting is unnecessary.
2. 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”
2. Turn the selector lever.
3. Align the selector lever and of the crank cover as illustrated in Fig. 9.

NOTE
Turn the selector lever to check if it is completely locked and make sure that it does not turn.

1. When chipping and chiseling at “hammering”:

CAUTION

• 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.
• 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 position of ”hammering”.

Switching to “hammering”

• Turn the selector lever.
• Align the selector lever and the crank cover as illustrated in Fig. 10.

NOTE
Turn the selector lever to check if it is completely locked and make sure that it does not turn.

1. When fi xing working positions of tools such as cold chisel, etc.,

   • Turn the selector lever. Align the selector lever and of the lever holder as illustrated in Fig. 11.
   • Turn the grip or the tool as illustrated in Fig. 12 and fi x the tool to the desired working direction.
   • Switch the selector lever to “hammering” according to the procedures mentioned in the above item (1) and secure the position of the tool.

2. Install the stopper (Fig. 13)

3. Loosen the wing bolt, and insert the stopper into the mounting hole on the side handle.

4. Adjust the stopper position according to the depth of the hole and tighten the wing bolt securely.

5. Warming up (Fig. 14)
   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.

7. Install drill bit with taper shank in the taper shank adaptor. (Fig. 15)

8. Turn the power on and drill a base hole.

9. After cleaning out dust with a syringe, attach the plug to the anchor tip and drive in the anchor with plug to the anchor tip and drive in the anchor with a manual hammer.

10. 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. 16)

USING DRILL CHUCK, CHUCK ADAPTER

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

WARNING
During operation, be sure to grip the handle and the side handle fi rmly 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 26.

2. Attaching chuck adapter to drill chuck (Fig. 17)

3. Attach the chuck adapter to the drill chuck. The SDS max shank of the chuck adapter is equivalent to the drill bit. Therefore, follow the same procedure as [7. How to install tool] in page 25 for attaching and detaching.

4. Drilling

5. 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 e fficiency and shortened life of this machine.

6. 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 holes use the core bit. At that time use with the center pin and the core, bit shank were provided as optional accessories.

Mounting

CAUTION
Be sure to turn the power OFF and disconnect the plug from the receptacle.

1. Mount the core bit to the core bit shank (Fig. 18). Lubricate the thread of the core bit shank to facilitate disassembly.
2. Mount the core bit shank to the rotary hammer (Fig. 19).
3. Insert the center pin into the guide plate until
4. it stops. Engage the guide plate with the core bit, and turn the guide plate to the left or the right so that it does not fall even if it faces downward (Fig. 20).

How to bore (Fig. 21)

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 5 mm in depth the position of the hole will be established. Bore after that removing the center pin and the guide plate from the core bit.

4. The application of excessive force will not only expedite the work but will deteriorate the tip edge of the drill bit, resulting in the 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.

5. Dismounting (Fig. 22)
   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.

GREASE REPLACEMENT

This Rotary Hammer is of full air-tight construction to protect against dust and to prevent lubricant leakage. Therefore, this Rotary Hammer 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 authorized Service Center.

MAINTENANCE AND INSPECTION

WARNING
Be sure to switch the 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 degrade efficiency, replace the drill bit with new ones or resharpen them 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. Failure to do so could result in serious hazards.

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. 23) Wear limit The motor employs carbon brushes which are No. of carbon brush consumable parts. When they become worn to or near the “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 No.86: 7 mm both carbon brushes with new ones which have the 17 mm same carbon brush Nos. shown in the fi sure. In addition, always keep carbon brushes clean Fig. 23 ensure that they slide freely within the brush holders.
   CAUTION
   Using this Rotary Hammer with a carbon brush that is worn in excess of the wear limit will damage the motor.

   • Replacing carbon brushes:
     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 by securely tightening two set screws.

5. Replacing supply cord If the replacement of the supply cord is necessary, this has to be done by the manufacturer of this agent in order to avoid a safety hazard.

CAUTION
In the operation and maintenance of power tools, the safety regulations and standards prescribed in each country must be observed.

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