DC 120VA

POWER TOOLS

DIAMOND CORE DRILL

TECHNICAL DATA AND SERVICE MANUAL

LIST No. 0192

Jun. 2000
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
Notice for use Specifications and parts are subject to change for improvement. Refer to Hitachi Power Tool Technical News for further information. CONTENTS

[ Business Section ]

1. PRODUCT NAME
2. MARKETING OBJECTIVE 3. APPLICATIONS

4. SELLING POINTS

4-1. Selling Point Descriptions

5. SPECIFICATIONS

5-1. Main Specifications

5-2. Optional Accessories

6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons

7. PRECAUTIONS IN SALES PROMOTION

7-1. Safety Precautions

8. PRECAUTIONS IN USAGE

8-1. Drilling with Diamond Core Bits

[ Service Section ]
9. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY
9-1. Disassembly 9-2. Reassembly 9-3. Lubrication

9-4. Tightening Torque 9-5. Internal Wiring
10. CONFIRMATION AFTER REASSEMBLY

10-1. Insulation Tests

10-2. No-Load Current Value
11. STANDARD REPAIR TIME (UNIT) SCHEDULES
[ Appendix ] Assembly Diagram for DC 120VA
Hitachi Diamond Core Drill (with slip clutch function), Model DC 120VA

2. MARKETING OBJECTIVE

The diamond core drill market is showing growth due to increase of demands for reform applications and comfortable operation (low noise and vibration). Especially, a core drill capable of drilling various types of materials efficiently is demanded. To meet such demand, the Model DC 120VA was developed as an advanced version of the current dry-type Model DC 120V in efficiency and operability. The key features are as follows: (1) 1400 W high-power motor for fast drilling (110 V product: 1250 W) (2) Various drilling applications thanks to the speed control system with 2-speed transmission, dial-type stepless variable speed control and constant speed control (3) High slip torque mechanism for powerful drilling (4) Synchronized gear shift mechanism for easy speed switching (5) Easy-to-use rotary type side handle (6) Vibration-isolating handle for reduced operator fatigue

3. APPLICATIONS

The Model DC 120VA can drill various workpieces using the appropriate bit or accessory tool. Tool Capacity Workpiece
Autoclaved lightweight concrete Chloroethylene material

External wall material

Gypsum board

Fiber reinforced plastic

Reinforced concrete

Mortar

Diamond core bit (Hitachi) Hole saw for metal (Commercial) Hole saw for wood (Commercial) Drill bit for steel (Hitachi) Drill bit for wood (Hitachi) <Typical applications> Air conditioning
27 mm to 120 mm (available in 10 sizes) Up to 60 mm Up to 120 mm Up to 13 mm Up to 30 mm

Installation of air conditioners and water coolers Electric, gas and water supply work Installation of electrical fixtures Anchoring Construction of terrace, garage, etc. --- 1 ---
Piping and wiring Electrical fixtures Reinforcing

Residencial facilities

Stainless

Stable gripping and powerful drilling thanks to long side handle and high slip torque mechanism
Fast drilling with 1400 W high-power motor (110 V product: 1250 W)
Synchronized gear shift mechanism for easy speed switching Vibration-isolating handle reduces operator fatigue
Various drilling applications, thanks to the speed control system with 2-speed transmission and variable 5-speed dial
* Shown with an optional core bit.

--- 2 ---

4-1. Selling Point Descriptions 4-1-1. Powerful motor with a power input of 1400 W Although the motor has the same dimensions as the Model DC 120V, the motor of the Model DC 120VA is more powerful thanks to the larger-diameter motor coil.
4-1-2. Faster drilling speed
The Model DC 120VA can drill holes in various materials using diamond core bits of up to 120 mm in diameter which are generally used for hand-held drills, or tools (hole saws) corresponding to specific materials, thanks to the optimum design. The drilling speed is about 30 % faster than the Model DC 120V and equivalent to C.
Drilling speed comparison of dry-type drills
(Test conditions) Power requirements: 230 V, 50 Hz Concrete compression strength: 2.5 x 105 MPa Test material: Concrete reinforced with 10-mm diameter bars (drilling depth 150 mm) Orientation: Horizontal drilling

Drilling speed (mm/min.)

(Hitachi) DC 120VA (Hitachi) DC 120V C

Core bit diameter (mm)

* Drilling performance varies depending on the operating conditions such as strength of concrete, diameter and number of reinforcing bars. The test results shown above should be used as a reference only.

--- 3 ---

4-1-3. High slip torque mechanism for powerful drilling
The table below shows the factory test results on slip-mechanism life cycles. The Model DC 120VA is superior to the Model DC 120V and C.
Test conditions: Repeated cycle of 2 seconds slip and 13 seconds rest. Model Hitachi DC 120VA Hitachi DC 120V C Slip torque after testing 2.2 kgf-m after 5000 cycles 1.6 kgf-m after 5000 cycles 0.8 kgf-m after 500 cycles Influence on operation No problem No problem but slipped frequently Drilling impossible

(Test conditions)

Repeated
cycle of 2 seconds slip and 13 seconds rest. (Hitachi) DC 120VA

(34 Nm)

(Hitachi) DC 120V C

Slip torque (N m)

(27 Nm)

(22 Nm) (16 Nm)

(18 Nm)
3000 Slip life (cycles) 6000
<Slip clutch mechanism> DC 120VA: A claw clutch, which is the same as that of the Model DC 120V, is provided to increase the service life. C: A friction-plate clutch with a belleville spring, which is the same as that of 6300T, is provided.
4-1-4. Synchronized gear shift mechanism for easy speed switching
A synchronized gear shift mechanism is provided to permit automatic shifting between the low- and high-speed ranges just by turning the shift lever. This eliminates the need to turn the drill chuck by hand while making the changeover. Model Hitachi DC 120VA Hitachi DC 120V C Synchronized gear shift mechanism Provided 2-speed transmission is not provided Not provided

--- 4 ---

4-1-5. Constant speed electronic control with stepless variable speed for stable drilling efficiency
The Model DC 120VA contains an electronic control circuit which allows the number of revolutions to be steplessly adjustable on the dial. The number of revolutions in the low-speed range is from 400 min-1 to 1,000 min-1, and the high-speed range from 800 min-1 to 2,000 min-1. The constant speed control minimizes the change in the number of revolutions even if the load fluctuates, thus providing ease of use and increased service life of drill bits. The graph below shows the relationship between load and speed.

Dial No. E

Number of revolutions of high-speed gear (min-1)

Dial No. D

Dial No. C Dial No. B

Dial No. A

Load current (A)
4-1-6. Easy-to-use rotary type side handle
For ease of operation, the side handle can be secured in any position over 360 in increments of 45 to suit the operating position.
4-1-7. Vibration-isolating handle reduces operator fatigue
For safety, the handle and the housing are rubber-isolated to reduce vibrations transmitted to the operator's hand.
4-1-8. Unique body design
The ergonomically designed, unique styling ensures excellent operability.

--- 5 ---

5-1. Main Specifications Capacity (with dry-type diamond core bit) Brick, block * Mild steel Wood Drill chuck Power source 152 mm (5 --- 63/64") 13 mm (1/2") 30 mm (1 -- 1/8") -
Capacity 1.2 mm (0.047") -- 13 mm (1/2") 100 V 230 V 240 V

12 A 6.4 A 6.2 A

Type of motor Enclosure Type of switch Type of handle Full-load current
Single-phase series commutator motor Housing, handle Inner cover, gear cover

Nylon resin Aluminum alloy die casting
Trigger switch with stopper D-type handle 100 V 230 V 240 V 100 V 230 V 240 V
12 A 6.4 A 6.2 A 1250 W 1400 W 1400 W 400 -- 1000 /min. 800 -- 2000 /min. 400 -- 860 /min. 800 -- 1920 /min. -

Power consumption

Rotation speed
No-load: No-load: Full-load: Full-load: 380 W
Low speed gear High speed gear Low speed gear High speed gear
Full-load output Weight Packaging Weight after packaging Cord
4.0 kg (without cord and side handle) (8.8 lbs.) Corrugated cardboard box 5.2 kg (11.4 lbs.) Type: 2-core cabtire cord Nominal sectional area: 0.75 mm2 Length: 2.5 m (8.3 ft.) Chuck wrench Side handle

Standard accessories

* Drilling may not be possible with some very hard brick and block materials.

--- 6 ---

5-2. Optional Accessories (1) Diamond core bits Dia. bit 22 mm (7/8") 28 mm (1-7/64") 38 mm (1-1/2") 48 mm (1-57/64") 52 mm (2-3/64") 65 mm (2-9/16") 78 mm (2-1/16") 91 mm (3-37/64") 107 mm (4-7/32") 117 mm (4-39/64") 127 mm (5") 152 mm (64/64") 150 mm (5 -- 29/32") Length 300 mm (11 -- 11/16") -
(2) Adapter packs & extension rods Adapter pack Adapter for dia. 38 -- 152 mm (1-1/2 " -- 6 ") core bits Pilot spigot Ejector drift

Extension rod

(length 250 mm (9-27/32 "))
(3) Dust extraction range

Dust sucker - Large

Dust sucker - Small

--- 7 ---

6-1. Specification Comparisons Maker, Model Item HITACHI DC 120VA 152 (5-63/64") 13 (1/2") 30 (1-1/2") 230/50 Hz 6.4 1400
C 152 (5-63/64") 13 (1/2") 30 (1-1/2") 230/50 Hz 6.Low-speed) 900 --- 2000 High-speed) 1800 --- 4000 4.2 (9.2 lbs.) Low-speed) 900 --- 2000 High-speed) 1800 --- 4000
HITACHI DC (5-63/64") 13 (1/2") 30 (1-1/2") 230/50 Hz 4.600 -- 1400 3.1 (6.8 lbs.) 580 -- 1410 -

Capacity

Brick, block Mild steel Wood
Diameter Diameter Diameter

mm mm mm V A W min

Values listed on catalogs
Voltage Current Power consumption No-load rotation speed
Low-speed) 400 --- 1000 High-speed) 800 --- 2000 4.0 (8.8 lbs.)
Weight (without cord) Characteristics No-load rotation speed of motor (measured Full-load current values) Full-load rotation speed Full-load torque Maximum output Locked torque Slip torque Insulation structure Full-load noise level Standard accessories
min-1 Low-speed) 450 --- 1050 High-speed) 850 --- 2000 A min-1 6.4 Low-speed) 400 --- 1020 High-speed) 760 --- 1920
4.0 Low-speed) 900 --- 1600 High-speed) 1700 --- 3200 (Low-speed) 3 (High-speed) 1.(Low-speed) 46 (High-speed) Double insulation 88
890 5.Double insulation 88
kg-m (Low-speed) 4 (High-speed) 2 W 1560
kg-m (Low-speed) 70 (High-speed) 35 kg-m 34 Double insulation dB 86 Chuck wrench Side handle
Chuck wrench Side handle Rubber gloves
Chuck wrench Side handle Plastic case

1 pair

--- 8 ---
7-1. Safety Precautions In the interest of promoting the safest and most efficient use of the Models DC 120VA Diamond Core 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 attached to each tool. (1) Handling Instructions: Although every effort is made in each step of design, manufacture and inspection to provide protection against safety hazards, the dangers inherent in the use of any electric power tool cannot be completely eliminated. Accordingly, general precautions and suggestions for the use of electric power tools, and specific precautions and suggestions for the use of the Diamond Core Drill are listed in the Handling Instructions to enhance the safe, efficient use of the tool by the customer. Salespersons should ensure that the customer thoroughly reads and understands these precautions, with particular attention to the following. 1 Check the power source voltage: Ensure that the power source voltage conforms with the power specifications listed on the nameplate. (2) Cautions on nameplate: 1 Each tool is provided with a nameplate which lists the following basic safety precautions in the use of the tool.

For Europe

CAUTION
Read thoroughly HANDLING INSTRUCTIONS before use.

For Germany

ACHTUNG
Bedienungsanleitung vor Inbetriebnahme lesen.

For France

TRES IMPORTANT: Lire avec attention la notice

d'utilisation.

--- 9 ---
8-1. Drilling with Diamond Core Bits (1) Ensure that the Side Handle is firmly secured before attempting to operate the tool. The side handle is separated from the main body of the tool when it is shipped from the factory. Carefully instruct the customer to loosen the grip portion of the side handle by turning it as shown in the right figure, install it on the gear cover portion, and fix it securely in the desired position before operating the tool.

Gear cover

Side handle
(2) Diamond core bits: Diamond core bits applicable to the Model DC 120VA and DC 120V are dry-type diamond core bits for drilling brick, concrete block and similar materials. Instruct the customer not to apply water during the drilling operation. In addition, the customer should be advised that drilling may not be possible in bricks and blocks which are particularly high in hardness and density.
(3) Rotation speed during drilling: If you exceed the standard values (optimum speed of rotation) given in Table 1 in the Handling Instructions or engage in continued work for an extended period of time or perform a drilling job on soft materials, the motor may be subjected to an unreasonable load and may result in burnout. Especially, avoid any abnormal use where the drill stops during the drilling work. Adjust the number of rotations so that a smooth drilling job can be done at all times. Make absolutely certain that you never use any tool or bit beyond its maximum capacity as otherwise the service life of the main unit may be extremely shortened.

Table 1

Shift lever indication

1 [Low speed gear] Dial

2 [High speed gear]
ters A B C D E A B C D E No load Materials to be drilled Types of drills speed (min-1) 27 Diamond Brick, block 65 core bit Autoclaved lightweight Hole saw concrete t3.Hole saw Steel SPCC t3.15 Hole saw Stainless steel t1.27 Hole saw Wood tDrill Steel SPCC t3.Drill Wood t50
: Standard values (optimum speed of rotation)

Drill d

--- 10 ---
(4) Pressure: Drilling will NOT be accelerated by placing heavy pressure on the drill. Such action will only result in a damaged drill bit, decreased drilling efficiency, and/or shortened service life of the drill.
(5) When drilling completely through the material: When the drill bit bores completely through the material, careless handling often results in broken drill bit or damage to the drill body itself due to the sudden movement of the drill. Always be alert and ready to release pushing force when drilling through the material.

--- 11 ---

The [Bold] numbers in the descriptions below correspond to the item numbers in the Parts List and exploded assembly diagram. 9-1. Disassembly
9-1-1. Handle cover section and carbon brush
(1) Loosen the Tapping Screw (W/Flange) D4 x 20 [48] and remove Handle (B) [49]. (2) Remove the Tapping Screw (W/Flange) D4 x 20 [48] from the Cord Clip [56] and remove the Cord [59] together with the Cord Armor [57]. (3) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52] on the Switch [53] and remove the Noise Suppressor [54]. (4) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52] on the Switch [53] and remove the internal wire with terminal. Remove the Switch [53]. (5) Remove the Carbon Caps [36] with a flat-blade screwdriver to remove the Carbon Brushes [37].
9-1-2. Armature and stator ass'y
(1) Loosen the Tapping Screw (W/SP. Washer) D5 x 55 [8] on the Gear Cover [9] and remove the gear cover section from the Inner Cover Ass'y [13]. Remove the Armature [28] together with the Inner Cover Ass'y [13] from the Housing Ass'y [35]. (2) Remove the Armature [28] from the Inner Cover Ass'y [13]. Place the Inner Cover Ass'y [13] on a cylindrical jig and press down on the pinion of the Armature [28] as shown in Fig. 1. (3) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52] on the trigger switch and the Tapping Screw (W/SP. Washer) D5 x 55 [8]. Disconnect the internal wire from the Brush Terminal [32] and the Controller [51]. Tap the end surface of the housing with a wooden or plastic hammer lightly to remove the Stator Ass'y [31].

9-1-3. Drill chuck

Pinion

Press down

Inner cover ass'y

Armature

Fig. 1
The Drill Chuck 13WLR (W/Screw) [3] contacts the Nut [4] fixed on the spindle and is secured with a UN5/8-16 right-handed screw. Put a 17-mm wrench on the Nut [4] and insert the chuck wrench in the wrench hole of the Drill Chuck 13WLR (W/Screw) [3] as shown in Fig. 2. Lightly tap the tip of the chuck wrench with a wooden or plastic hammer so that it turns counterclockwise viewing from the drill chuck side. Turn the loose Drill Chuck 13WLR (W/Screw) [3] and remove it. Wrench Chuck wrench Fig. 2 --- 12 ---

9-1-4. Nut

The Nut [4] is secured to Spindle (B) Ass'y [20] with a UN5/8-16 right-handed screw. Insert a metal bar of 3 mm or less diameter in the air vent and fix it. Put a 21-mm wrench on the Nut [4] and turn it to remove the Nut [4].

Wrench Chuck wrench

9-1-5. Spindle (B) ass'y and others
(1) After removal of the Nut [4], press down on the tip of Spindle (B) Ass'y [20] with a hand press as shown in Fig. 4. Then Spindle (B) Ass'y [20] can be removed from the Gear Cover [9]. (2) Remove the Retaining Ring for D35 Hole [5]. Then the Dust Seal [6] can be removed. Lightly tap the tip of the Gear Cover [9] with a wooden hammer to remove the Ball Bearing 6003VVCMPS2L [7]. (3) Support the Clutch [19] on a cylindrical jig and press down on the end surface of the Spindle (B) Ass'y [20] with a hand press as shown in Fig. 5. Then Sleeve [17] can be removed from Spindle (B) Ass'y [20] together with the Spring [18].

Retaining Ring for D35 Hole [5] Ball Bearing 6003VVCMPS2L [7]
Spindle (B) Ass'y [20] Dust Seal [6] Spindle (B) Ass'y [20] Gear Cover [9]

Sleeve [17]

Clutch [19]

Spring [18]

27 mm or more diameter

Fig. 4

Fig. 5

--- 13 ---

9-2. Reassembly Perform reassembly in the reverse order of disassembly while observing the given precautions and taking care of the following points.
9-2-1. Internal wire arrangement
Arrange the internal wires as shown in Fig. 6. Be careful not to catch the internal wires when mounting the handle. Do not pinch the internal wires under the switch.

Switch

Noise suppressor

Magnet pick up case

Air vent of handle
Put the internal wires under the controller. Controller Volume ass'y

Fig. 6

<CAUTION> Insert the Controller [51] so that its uneven surface faces toward the air vent of the handle. Do not apply excessive force when closing the cover of the handle. Otherwise, the "volume" (variable-speed dial) can be damaged.

--- 14 ---

9-2-2. Reassembly of the gear cover section
Fig. 7 shows the assembly drawing. Reassemble the gear cover section according to the following figure.
Spring (A) High Speed Gear
Washer (A) Second Pinion First Gear

Shift Spring Clutch Disc

Shift Lever
Insert the 4 mm diameter protrusion into the groove of the clutch disc.

Metal (A)

Low Speed Gear Spring (A)

Steel Ball D3.97

Plate Metal (B) Spring Sleeve Ball Bearing 6003VVCMPS2L Dust Seal Nut Spindle (B) Ass'y Clutch

Fig. 7

<CAUTION> Mounting directions of the High Speed Gear [25] and the Low Speed Gear [23] are specified. Mount these parts in the specified direction as shown in the above figure.

--- 15 ---

9-3. Lubrication (1) Apply DOUBREX 251 grease to the following parts. Each gear: tooth portion Spindle (B) Ass'y [20] (including [17], [18] and [19]) Clutch Disc [24]: entirely Shift Lever [15]: 19 mm dia. outer circumference portion and 4 mm dia. convex portion Spindle (A) [21]: claw portion and 10 mm dia. convex portion Second Pinion [11] and first gear: tooth portion Inner Cover Ass'y [13] and Gear Cover [9]: metal portion Inside the Gear Cover [9]: 70 g
<CAUTION> Be sure to use only DOUBREX 251 grease for the gear cover and the components in the gear cover. Use of other grease may cause grease leakage from the tip of the gear cover and the shift lever.
9-4. Tightening Torque (1) Nut [4]

20 -- 30 Nm {200 -- 300 kgfcm} 2.5 -- 3.5 Nm {25 -- 35 kgfcm} 1.5 -- 2.5 Nm {15 -- 25 kgfcm} -

(2) Tapping Screw (W/SP. Washer) D5 x 55 (Black) [8] (3) Tapping Screw (W/Flange) D4 [47] [48]

9-5. Internal Wiring Wiring diagram Stator SW Cord Controller Noise Suppressor

Connector

Stator

--- 16 ---

10-1. Insulation Tests On completion of disassembly and repair, measure the insulation resistance and conduct a dielectric strength test. Insulation resistance: 7 M or more with DC 500V Megohm Tester. Dielectric strength: AC 4000V/1 minute, with no abnormalities
220 V -- 240 V (and 110V for U.K. products)
AC 2500V/1 minute, with no abnormalities
110 V -- 127 V (except U.K. products)
10-2. No-Load Current Value 110 V 230 V 240 V

--- 17 ---

MODEL DC 120VA

Housing Ass'y Stator Ass'y Cord Switch Controller Handle (A) Handle (B)

Variable Fixed

Work Flow

60 min.

Gear Cover Nut Dust Seal Ball Bearing (6003VV) Sleeve Spring Clutch Spindle (B) Ass'y Spindle (A) Spring (A) x 2 Low Speed Gear Clutch Disc High Speed Gear
General Assembly Second Pinion Steel Ball Ball Bearing (608VV)
Inner Cover Ass'y Armature Ball Bearing (609VV) Dust Seal (A) Ball Bearing (608VV)

--- 18 ---

Assembly Diagram for DC 120VA

--- 19 ---

ITEM NO. 27 * * * 30 * * * 47

3 --- 00

DC 120VA DESCRIPTION VINYL BAND CHUCK WRENCH 10G DRILL CHUCK 13WLR (W/SCREW) NUT RETAINING RING FOR D35 HOLE (10 PCS.) DUST SEAL BALL BEARING 6003VVCMPS2L
TAPPING SCREW (W/SP. WASHER) D5X55(BLACK)
CODE NO. 950-288 930-515 950-287 309-125 939-556 981-572 600-3VV 303-281 318-735 959-155 318-728 608-VVM 318-729 984-357 318-726 994-396 309-128 309-167 318-737 318-736 318-722 318-723 318-725 319-115 318-724 318-727 609-VVM 360-523 360-524E 360-524F 318-718 991-007 340-465C 340-465E 340-465F 930-703 956-387 608-VVM 318-739 945-161 999-043 958-900 318-734 938-477
NO. USED 4 INCLUD.32 INCLUD.32 INCLUD.32 INCLUD.17-19

REMARKS

GEAR COVER STEEL BALL D3.97 (10 PCS.) SECOND PINION BALL BEARING 608VVC2PS2L INNER COVER ASS'Y WASHER SHIFT LEVER SHIFT SPRING SLEEVE SPRING CLUTCH SPINDLE (B) ASS'Y SPINDLE (A) SPRING (A) LOW SPEED GEAR CLUTCH DISC HIGH SPEED GEAR WASHER (A) BALL BEARING 609VVC2PS2L ARMATURE 100V-110V ARMATURE 230V ARMATURE 240V FAN GUIDE TAPPING SCREW D5X60 STATOR ASS'Y 110V STATOR ASS'Y 230V STATOR ASS'Y 240V BRUSH TERMINAL DUST SEAL (A) BALL BEARING 608VVC2PS2L HOUSING ASS'Y BRUSH CAP CARBON BRUSH (1 PAIR) BRUSH HOLDER RUBBER PIECE (B) HEX. SOCKET SET SCREW M5X8 NAME PLATE

INCLUD.12,14,27

INCLUD.38-40,44

318-719

HANDLE (A) HITACHI LABEL
318-733 318-721 995-887 984-750
RUBBER PIECE (A) MAGNET MAGNET PICK UP CASE TAPPING SCREW (W/FLANGE) D4X16

: ALTERNATIVE PARTS

--- 20 ---
ITEM NO. 50 * * 56 * * * * * * * * * 59 CODE NO. 301-653 318-720 959-140 318-731 318-738 305-499 318-730 930-039 980-063 937-631 953-327 938-051 980-063 992-810 500-439Z 500-435Z 500-463Z 500-234Z 500-248Z NO. USED TAPPING SCREW (W/FLANGE) D4X20 (BLACK) 5 DESCRIPTION HANDLE (B) CONNECTOR 50091 (10 PCS.) CONTROLLER CONTROLLER MACHINE SCREW (W/WASHER) M3.5X6 SWITCH (1P SCREW TYPE) W/LOCK NOISE SUPPRESSOR TERMINAL CORD CLIP CORD ARMOR D8.8 CORD ARMOR D10.1 TERMINAL TERMINAL CORD CORD CORD CORD CORD FOR CORD FOR CORD (CORD ARMOR D8.8) FOR AUS (CORD ARMOR D8.8) FOR GBR (230V) (CORD ARMOR D8.8) FOR GBR (110V) (CORD ARMOR D8.8) (CORD ARMOR D10.1) FOR SUI FOR GBR (110V) REMARKS
* : ALTERNATIVE PARTS --- 21 ---

STANDARD ACCESSORIES

ITEM NO. 501 CODE NO. 309-122 DESCRIPTION SIDE HANDLE NO. USED 1 REMARKS
Printed in Japan (000315 N)

* : ALTERNATIVE PARTS

--- 22 ---

HUOLTO JA TARKISTUS

1. Tarkasta timanttiter Tylsn tai vahingoittuneen timanttitern jatkuva kytt heikent poraustehoa ja ylikuormittaa moottoria. Vaihda timanttiter uuteen heti, kun se on kulunut. 2. Kiinnitysruuvien tarkistus Tarkista snnllisesti kaikki kiinnitysruuvit ja varmista, ett ne ovat tiukassa. Mikli joku ruuveista on lystynyt, kirist se vlittmsti. Laiminlynti voi aiheuttaa vaaratilanteen. 3. Moottorin huolto Mootorin kmi on shktykalun sydn. Huolehdi siit, ettei kmi vahingoitu ja/tai kastu lijyyn tai veteen. 4. Hiiliharjojen tarkistus (Kuva 3) Koneessa kytettvt hiiliharjat ovat kuluvaia osia. Koska liian kuluneet hiiliharja voivat aiheuttaa moottorille hiriit, on syyt vaihtaa vanhat hiilet uusiin heti, kun ne ovat liian kuluneita tai lhell "kulumisrajaa" (wear-limit). Lisksi hiiliharjat on pidettv aina puhtaina ja varmistettava, ett ne psevt vapaasti liikkumaan harjapitimiss. 5. Hiiliharjan vaihto Irroita hiiliharja ruuvitaltalla. Hiiliharja on sitten helposti irroitettavissa. 6. Huolto-osalista A: Kohtanr. B: Koodinr. C: Kytetty nr. D: Huomautuksia HUOMAUTUS: Hitachi-shktykalujen korjaukset, muutokset ja tarkastukset on teetettv valtuutetussa Hitachihuoltokeskuksessa. Osalista on hydyllinen, kun se annetaan yhdess tykalun kanssa valtuutettuun Hitachihuoltokeskukseen korjausta tai huoltoa pyydettess. Shktykalujen kytss ja huollossa on aina noudatettava kussakin maassa voimassa olevia turvaohjeita ja normeja.
MUUTOKSET: Hitachi-shktykaluja parannetaan ja muutetaan jatkuvasti niin, ett niihin saadaan sisllytetty uusin teknologia. Tst johtuen jotkut osat (esim. koodinumerot ja/tai ulkonk) saattavat muuttua ilman ennakkoilmoitusta. HUOM: HITACHIs jatkuvasta tutkimus-ja kehitysohjemasta johtuen edell estitettyihin voi tulla muutoksia ilman ennakoilmoitusta
Tietoja ilmavlitteisest melusta ja trinst Saavutetut mitta-arvot mriteltiin EN50144-normin mukaan. Tyypillinen A-painotteinen nipainearvo: 84 dB (A) Kyt kuulonsuojaimia. Tyypillinen painollisen juuren keskinelin kiihdytysarvo: 6,0 m/s2

English

17. Avoid unintentional starting. Do not carry a pluggedin tool with a finger on the switch. Ensure switch is off when plugging in. Use outdoor extension leads. When tool is used outdoors, use only extension cords intended for outdoor use. Stay alert. Watch what you are doing. Use common sense. Do not operate tool when you are tired. Check damaged parts. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, free running of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated in this handling instructions. Have defective switches replaced by an authorized service center. Do not use the tool if the switch does not turn it on and off. Warning The use of any accessory or attachment, other than those recommended in this handling instructions, may present a risk of personal injury. Have your tool repaired by a qualified person. This electric tool is in accordance with the relevant safety requirements. Repairs should only be carried out by qualified persons using original spare parts. Otherwise this may result in considerable danger to the user.

GENERAL OPERATIONAL PRECAUTIONS
WARNING! When using electric tools, basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury, including the following. Read all these instructions before operating this product and save these instructions. For safe operations: 1. Keep work area clean. Cluttered areas and benches invite injuries. 2. Consider work area environment. Do not expose power tools to rain. Do not use power tools in damp or wet locations. Keep work area well lit. Do not use power tools where there is risk to cause fire or explosion. 3. Guard against electric shock. Avoid body contact with earthed or grounded surfaces. (e.g. pipes, radiators, ranges, refrigerators). 4. Keep children away. Do not let visitors touch the tool or extension cord. All visitors should be kept away from work area. 5. Store idle tools. When not in use, tools should be stored in a dry, high or locked up place, out of reach of children. 6. Do not force the tool. It will do the job better and safer at the rate for which it was intended. 7. Use the right tool. Do not force small tools or attachments to do the job of a heavy duty tool. Do not use tools for purposes not intended; for example, do not use circular saw to cut tree limbs or logs. 8. Dress properly. Do not wear loose clothing or jewelry, they can be caught in moving parts. Rubber gloves and non-skid footwears are recommended when working outdoors. Wear protecting hair covering to contain long hair. 9. Use eye protection. Also use face or dust mask if the cutting operation is dusty. 10. Connect dust extraction equipment. If devices are provided for the connection of dust extraction and collection facilities ensure these are connected and properly used. 11. Do not abuse the cord. Never carry the tool by the cord or yank it to disconnect it from the receptacle. Keep the cord away from heat, oil and sharp edges. 12. Secure work. Use clamps or a vise to hold the work. It is safer than using your hand and it frees both hands to operate tool. 13. Do not overreach. Keep proper footing and balance at all times. 14. Maintain tools with care. Keep cutting tools sharp and clean for better and safer performance. Follow instructions for lubrication and changing accessories. Inspect tool cords periodically and if damaged, have it repaired by authorized service center. Inspect extension cords periodically and replace, if damaged. Keep handles dry, clean, and free from oil and grease. 15. Disconnect tools. When not in use, before servicing, and when changing accessories such as blades, bits and cutters. 16. Remove adjusting keys and wrenches. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning it on. 22

PRECAUTIONS ON USING DIAMOND CORE DRILL
1. Before drilling into a wall, floor or ceiling, thoroughly confirm that no items such as electric cables or conduits are buried inside. 2. Always hold the body handle and side handle of the power tool firmly. Otherwise the counterforce produced may result in inaccurate and even dangerous operation. 3. This diamond core drill is designed exclusively for use in dry operation. Never use it for any drilling operation using water!

SPECIFICATIONS

Voltage Power Input Gear shift dial(Dial) No-load speed Capacity Brick, Block* Steel Wood Weight (without cord) * When using dry type diamond core bit (Excluding hard brick) 1(AE) min-mm 13 mm 30 mm 4.0 kg 230V 1400 W 2(AE) min-1

STANDARD ACCESSORIES

(1) Chuck wrench... 1 (2) Side handle... 1 Standard accessories are subject to change without notice.
OPTIONAL ACCESSORIES (sold separately)
(1) Diamond Core Bits (Fig. 4-1) Bit Dia. (mm) Length (mm) 300 Bit Dia. (mm) 150 Length (mm) Bit Dia. (mm) (3) Dust Extraction Range Dust Sucker-Large (Fig. 5-1) Dust Sucker-Small (Fig. 5-2) Dust Swivel (Fig. 5-3) Extention Rod for Dust Swivel (Length 230mm) (Fig. 5-4) CAUTION: When using the dust swivel, connect the vacuum cleaner hose before turning on the main unit switch. Used to such chips by connecting a vacuum cleaner. 150 Length (mm)
(2) Adapter Packs and Extension Rods Adapter Pack (Fig. 4-2) Adapter for Dia. mm core Bits (Fig. 4-3) Pilot Spigot (Fig. 4-4) Ejector Drift (Fig. 4-5) Extention Rod (Length 250 mm) (Fig. 4-6)

6 Fig. 4

3 Fig. 5 Optional accessories are subject to change without notice. 23
mounting section of the gear cover and tighten it. Before operation, securely tighten the side handle. (The side handle can be secured in any position over 360.) 5. Clamping Insert the diamond core bit or drill bit as far as it will go into the open chuck. Clamp tightly in normal manner by inserting the toothed end in the chuck wrench into the three key holes.

APPLICATIONS

Drilling various blocks and bricks products Boring holes in metals, wood and plastics.

PRIOR TO OPERATION

1. Power source Ensure that the power source to be utilized conforms to the power requirements specified 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. CAUTION: Damaged cord must be replaced or repaired. 4. Mounting the side handle Mount the side handle in the main body, as shown in Fig. 1. Rotate the handle in clockwise direction to tighten the side handle and rotate it in counterclockwise direction to loosen it. When mounting the side handle, loosen the handle and mount the side handle to the gear cover. Then press it to the proper position in the side handle TABLE 1 Shift lever indication

PRACTICAL HANDLING PROCEDURES
1. Switch operation Switching-on: Push the trigger. Switching-off: Release the trigger. CAUTION Securely hold the handle of the main body and the side handle when switching on as there is danger that your hands may be turned by force of reaction. 2. Relationship between material to be drilled and optimum number of rotation The relationship between the material to be drilled and the optimum number of rotation may slightly differ depending upon the working condition, power supply situation, etc. Use the tool referring to TABLE 1 as a rough guide. For drill positioning, you will find it easier to work if you turn the dial once and set it to the low speed. CAUTION: If you exceed the standard values (optimum numbers of rotation) given in the table or engage in continued work for an extended period of time or perform a drilling job on soft materials, the motor may be

1 [Low speed gear] Dial

2 [High speed gear]
Materials to be drilled Brick, Block
Types of drills Diamond core bit

Drill diameters 65 120

ALC t3.0

Hole saw

Steel SPCC t3.0 Stainless steel t1.6 Wood t50
Steel SPCC t3.0 Wood t50 24

Drill Drill

subjected to an unreasonable load and may result in burnout. Especially, avoid such an abnormal way of use as a case where a drill stops during the drilling work. Adjust the number of rotation so that a smooth drilling job can be done at all times. Make absolutely certain that you never use any tool with more than the maximum capacity as otherwise the service life of the main unit may be extremely shortened. 3. When drilling completely through the material: When the drill bit bores completely through the material, careless handling often results in broken drill bit or damage to the drill body itself due to the sudden movement of the drill. Always be alert and ready to release pushing force when drilling through the material. 4. Diamond Core drilling (1) Place the diamond core bit in the drilling location. (2) When drilling, always hold the tool squarely against the material. (3) Do not force the core bit, but allow the core bit to do the work. This will prolong the life of the core bit and reduce breakage. (4) Ensure that masonry dust/swarf produced during drilling is regularly removed. Allowing dust/swarf to accumulate will result in overheating and excessive clutch/torque limiter wear and loss of segments from the core bit. (5) When entering or leaving a hole, ensure that the core bit is rotating. (6) If the core bit starts to vibrate and when the core bit begins to break through the material, reduce pressure immediately. (7) After use, store the core bit carefully in its box and remember that it is a diamond core bit. cDrilling method by using Pilot Spigotv For easy positioning, carry out the following steps when using a diamond core bit. (1) Make a pilot hole at the center position of the material to be drilled with a 13 mm stone drill bit. (2) Attach a pilot spigot to a diamond core bit. (3) Align the pilot spigot to the pilot hole and begin the drilling operation to make a guide groove. (4) When making the guide groove, temporarily stop the drilling operation and remove the pilot spigot. (5) Align the diamond core bit with the guide groove and start the drilling operation again. CAUTION When drilling with a diamond core bit, there will be a high force of reaction load to your hands. Make sure to hold the handle of the main body and the side handle. Safety-Release Clutch This tool is equipped with a positive type SafetyRelease Clutch. The clutch will slip when a certain torque level is required, causing the motor to disengage from the output shaft. When this happens, the chuck will stop turning. CAUTION Immediately pull away the main body when the Safety-Release Clutch starts its operation. Do not continue to operate the tool for more than two seconds while the clutch is slipping. Do not let the Safety-Release Clutch activate too frequently. 5. Drilling with a conventional drill bit (1) Drilling in wood Use a woodworking drill bit. However, use an metalworking drill bit when drilling a hole which is less than 6.5 mm in diameter. The usable drill bit diameter is maximum 30 mm. (2) Drilling in mild steel or plastics Use a conventional metalworking drill bit. The usable drill bit diameter is minimum 1.2 mm and maximum 13 mm. CAUTIONS Pressure: Drilling will NOT be accelerated by placing heavy pressure on the drill. Such action will only result in a damaged drill bit, decreased drilling efficiency, and/ or shortened service life of the drill. Using a large diameter drill bit: The larger the drill bit diameter, the larger the reactive force on your arm. Be careful not to lose control of the drill because of this reactive force. To maintain firm control, establish a good foot-hold, hold the drill tightly with both hands, and ensure that the drill is vertical to the material being drilled. When drilling completely through the material: When the drill bit bores completely through the material, careless handling often results in broken drill bit or damage to the drill body itself due to the sudden movement of the drill. Always be alert and ready to release pushing force when drilling through the material.

MAINTENANCE AND INSPECTION
1. Inspecting the diamond core bit Continued use of a dull or damaged diamond core bit results in reduced drilling efficiency and may cause overloading of the motor. Replace the diamond core bit with a new one as soon as excessive 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 hazard. 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. 3) The motor employs carbon brushes which are consumable parts. Since an excessively worn carbon brush can result in motor trouble, replace the carbon brushes with new ones which have the same carbon brush No. shown in the figure when they become worn to or near the wear limit. In addition, always keep carbon brushes clean and ensure that they slide freely within the brush holders. 5. Replacing carbon brushes Disassemble the brush caps with a slotted-head screwdriver the carbon brushes can the be easily removed.
6. Service parts list A: Item No. B: Code No. C: No. Used D: Remarks CAUTION Repair, modification and inspection of Hitachi Power Tools must be carried out by an Hitachi Authorized Service Center. This Parts List will be helpful it presented with the tool to the Hitachi Authorized Serivde 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: Hitachi Power Tools are constantly being improved and modified to incorporate the latest technological advancements. Acccordingly, some parts (i.e. code numbers and/or design) may be changed without prior notice. NOTE Due to HITACHIs continuing program of research and development, the specifications herein are subject to change without prior notice.
Information concerning airborne noise and vibration The measured values were determined according to EN50144. The typical A-weighted sound pressure level: 84 dB (A) Wear ear protection. The typical weighted root mean square acceleration value: 6.0 m/s2

Hitachi Power Tools Europe GmbH Siemensring 34, 47877 Willich, F. R. Germany Hitachi Koki Co., Ltd. Shinagawa Intercity Tower A, 15-1, Konan 2-chome, Minato-ku, Tokyo, Japan

Y. Hirano

103 Code No. C99101781 Printed in Japan