Hitachi 180 mm Disc Grinder

Transcription

1 LIST Nos. G 18SS: E293 G 23SS: E294 Jun PRODUCT NAME Hitachi 180 mm Disc Grinder Model G 18SS Hitachi 230 mm Disc Grinder Model G 23SS MARKETING OBJECTIVE The Models G 18SS and G 23SS have been developed to meet the market demand for low-end class products like the Models G 10SS and G 12SS in order to expand the sales of Hitachi Disc Grinders. The main features of the Models G 18SS and G 23SS are as follows. (1) Excellent overload durability: 26% higher than B (2) Protected armature coil (3) Dust-proof ball bearing thanks to the labyrinth construction G APPLICATIONS Deburring diecast products and finishing iron, bronze, aluminum and diecast products Finishing welds and torch-cut surfaces Cutting soft steel materials Grooving and cutting concrete and other stone materials SELLING POINTS [ NEW FEATURES ] Excellent overload durability Protected armature coil Dust-proof ball bearing thanks to the labyrinth construction SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT. International Sales Division

2 REMARK: For more information about HANDLING INSTRUCTIONS, visit our website at: 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: Symbols Utilized Company Name Competitors Model Name B MAKITA 9067/9069

3 CONTENTS Page SELLING POINT DESCRIPTIONS SPECIFICATIONS COMPARISONS WITH SIMILAR PRODUCTS PRECAUTIONS IN SALES PROMOTION REPAIR GUIDE Precautions in disassembly and reassembly STANDARD REPAIR TIME (UNIT) SCHEDULES Assembly diagram for G 18SS Assembly diagram for G 23SS

4 SELLING POINT DESCRIPTIONS Excellent overload durability The Models G 18SS and G 23SS provide excellent overload durability in common with the current models. The graph below shows the comparison of overload durability when the stator coil temperature rise is 200 K using the Model G 23SS as the reference. As is evident from this, the Models G 18SS and G 23SS are superior to B in overload durability. Protected armature coil Both ends of the armature coil are protected with long wedges in addition to the varnish treatment to minimize damage to the coil caused by dust. Protected with long wedges -1-

5 Dust-proof ball bearing thanks to the labyrinth construction The ball bearing retainers at both sides of the armature have a labyrinth construction to make the ball bearings dust-proof. Labyrinth Ball bearing (6301VVCM) Commutator Labyrinth Ball bearing (6000VVCM) Armature shaft Dust seal Housing Bearing cover Fan -2-

6 1. Specifications Model G 18SS G 23SS O.D.180 mm (7 ) Dimensions x Thickness 6 mm (1/4 ) x I.D mm (7/8 ) -3- Depressedcenter wheels peripheral speed Max. practical 80 m/s (15,800 ft/min) Type A, 24, R, B Spindle thread M14 x 2 * 1 Power source AC single phase 50 or 60 Hz Voltage and power input * 2 O.D.230 mm (9 ) x Thickness 6 mm (1/4 ) x I.D mm (7/8 ) Voltage (V) Current (A) Power input (W) , , , , , ,900 No-load speed 8,500/min * 3 6,600/min * 3 Type of motor AC single phase commutator motor Housing (green) Enclosure Handle (black) Polyamide resin with glassfiber Gear cover, packing gland Aluminum alloy diecasting Type of switch Trigger switch New weight * 4 (Main body) Gross weight Type of packing Standard accessories SPECIFICATIONS Side handle (Code No ) Wrench (Code No ) Hex. bar wrench 6 mm (Code No ) kg (9.5 lbs.) 7.3 kg (16.1 lbs.) Corrugated cardboard box Side handle (Code No ) Wrench (Code No ) Wheel nut (B) (Code No Z) * 5 Hex. bar wrench 6 mm (Code No ) * 1 : For the U.S.A and Mexico: 5/8-11 UNC * 2 : Be sure to check the nameplate on the product as it is subject to change by areas. * 3 : For the U.S.A and Mexico: 6,000/min. * 4 : Net weight excludes cord, side handle, depressed-center wheel, wheel nut, wheel washer and wheel guard. * 5 : Standard accessories may vary depending on market areas.

7 COMPARISONS WITH SIMILAR PRODUCTS 1. Specification comparisons (Superior specifications: ) Maker HITACHI Model name G 18SS B Capacity Depressed-center wheel dia. (mm) 180 (7 ) 180 (7 ) Power input * 1 (W) 1,900 2,000 Power output * 1 (W) 1,200 1,160 Max. power output * 1 (W) 3,150 2,900 No-load speed (/min) 8,500 8,500 No-load sound pressure level (db/a) Service life of carbon brushes * 2 (hr) Weight * 3 (kg) 4.3 (9.48 lbs.) 4.2 (9.26 lbs.) (Actual weight) (kg) 4.5 (9.92 lbs.) 4.4 (9.70 lbs.) Dimensions L mm (inch) 463 (18-7/32) 458 (18-1/32) H mm (inch) 83 (3-9/32) 92 (3-20/32) Maker HITACHI Model name G 23SS B Capacity Depressed-center wheel dia. (mm) 230 (9 ) 230 (9 ) Power input * 1 (W) 1,900 2,000 Power output * 1 (W) 1,200 1,160 Max. power output * 1 (W) 3,150 2,900 No-load speed (/min) 6,600 6,600 No-load sound pressure level (db/a) Service life of carbon brushes * 2 (hr) Weight * 3 (kg) 4.3 (9.48 lbs.) 4.2 (9.26 lbs.) (Actual weight) (kg) 4.5 (9.92 lbs.) 4.4 (9.70 lbs.) Dimensions L mm (inch) 463 (18-7/32) 458 (18-1/32) H mm (inch) 83 (3-9/32) 92 (3-20/32) * 1 : Depends on market. * 2 : Service life of carbon brushes in the continuous rated load test * 3 : Weight without cord, side handle, depressed-center wheel, wheel nut, wheel washer and wheel guard -4-

8 1. Safety instructions In the interest of promoting the safest and most efficient use of the Models G 18SS and G 23SS Disc Grinders 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 Name Plate or Caution Plate attached to each tool. A. 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 disc grinders are listed in the Handling Instructions to enhance the safe and efficient use of the tool by the customer. Salespersons must be thoroughly familiar with the contents of the Handling Instructions to be able to offer appropriate guidance to the customer during sales promotion. B. Caution on the name plate PRECAUTIONS IN SALES PROMOTION Each tool is provided with a name plate which contains the following basic safety precautions in the use of the tool. (1) For U.K., Germany, Belgium, France, Netherlands, Austria, Russia, Switzerland, Spain, Portugal, Canary Islands, Italy, Finland, Denmark, Sweden and Norway (2) For Australia CAUTION Read thoroughly HANDLING INSTRUCTIONS before use. C. Precautions on usage Never press the pushing button while the depressed-center wheel is rotating. If the pushing button is pressed while the depressed-center wheel is rotating, the spindle will stop immediately. In such a case, there is a danger that the wheel nut may be loosened and the depressedcenter wheel may fly off unexpectedly, resulting in possible serious injury. -5-

9 1. Precautions in disassembly and reassembly The [Bold] numbers in the descriptions below correspond to the numbers in the Parts List and the exploded assembly diagram for the Models G 18SS and G 23SS. 1. Removal of the armature REPAIR GUIDE Disassembly (a) Loosen the Hex. Socket Hd. Bolt M8 x 25 [28] and remove the Wheel Guard Ass'y [29]. (b) Remove the Brush Caps [34] and take out the Carbon Brushes (1 Pair) [35]. (c) Remove the four Tapping Screws (W/Flange) D5 x 35 (Black) [17]. The Armature [10] can then be taken out together with the Gear Cover Ass'y [5], Packing Gland [26] and related parts. (d) Remove the four Hex. Socket Hd. Bolts (W/Flange) M5 x 16 [27]. (e) After removing the two Seal Lock Screws (W/Sp. Washer) M5 x 14 (Black) [1], the Armature [10] can be extracted together with the Bearing Cover [9] and the related parts. (f) Carefully wrap the Armature [10] with a soft, clean rag to protect it from being damaged, and clamp it securely in a vise. Then, remove the Special Nut M10 [6] and extract the Gear and Pinion Set [33]. (g) As illustrated in Fig. 1, the Ball Bearing 6301VVCMPS2L [7] can be removed from the Armature [10] by utilizing a J-204 bearing puller (special repair tool, Code No ). After removal of the ball bearing, the Bearing Cover [9] can be easily taken off. Fig. 1 Push Bearing puller (Code No ) -6-

10 2. Removal of the dust seal (a) Insert the hooks of the J-204 bearing puller between the commutator and the Dust Seal [14] from both sides, and fix the hooks with the wing bolts. (b) Place the J-204 bearing puller on a supporting jig and push down on the armature shaft with a hand press to remove the Dust Seal [14] together with the Ball Bearing 6000VVCMPS2L [15]. Replace the Dust Seal [14] with new one because it is damaged by the removal of the Ball Bearing 6000VVCMPS2L [15]. 3. Removal of the stator ass'y (a) After removing the Armature [10], disconnect the internal wires connected to the Brush Holders [36] and the Switch [48]. (b) Loosen the two Hex. Hd. Tapping Screws D5 x 60 [12] and remove the Stator Ass'y [13] from the Housing Ass'y [38]. If the Stator Ass'y [13] cannot be easily removed from the Housing Ass'y [38], disassembly can be facilitated by heating the Housing Ass'y [38] to a temperature of approximately 60 C (140 F) with an appropriate heating device. 4. Removal of the gear and pinion set (a) Loosen the four Hex. Socket Hd. Bolts (W/Flange) M5 x 16 [27] and remove the Packing Gland [26] together with the Spindle [24] and the Gear and Pinion Set [33] from the Gear Cover Ass'y [5] in a single body. (b) Remove the Retaining Ring for D12 Shaft [19] from the Spindle [24]. (c) When it is necessary to remove the Gear and Pinion Set [33] from the Spindle [24], it is highly recommended that the special repair tools described below are utilized. Fig. 2 Push Spindle [24] Gear and Pinion Set [33] Place the assembly on a sleeve that matches the dimension of the Packing Gland [26] and push down on the top of the Spindle [24] with a hand press to remove the Gear and Pinion Set [33] as shown in Fig. 2. Packing Gland [26] Sleeve -7-

11 Reassembly Put the parts together in the reverse order of disassembly, with the precautions given below. (1) Apply machine oil to Felt Packing (B) [23] then mount it to the Packing Gland [26] to increase the dust resistance. (2) Generously lubricate the teeth of the Gear and Pinion Set [33] with grease. Rub grease onto the teeth with your fingers so that the grease reaches each tooth bottom. Note that under-lubricated Gear and Pinion Set [33] may wear at a faster rate. (3) When replacing the Armature [10] and the Ball Bearing 6000VVCMPS2L [15] on the commutator side, press inward on the Dust Seal [14] while taking care of its direction until the end face of the Dust Seal [14] hits against the butting surface of the Armature [10] and make sure that the Dust Seal [14] cannot turn freely. (See Fig. 3.) The Dust Seal [14] is an important element for improved dust protection of the Ball Bearing 6000VVCMPS2L [15]. Be sure to use a new one at every disassembly work of the Ball Bearing 6000VVCMPS2L [15]. Fig. 3 Armature [10] Dust Seal [14] Ball Bearing 6000VVCMPS2L [15] (4) Apply Three Bond TB 1406 Screw Locking Agent to the following screws. Two Seal Lock Screws (W/Sp. Washer) M5 x 14 (Black) [1] which fix the Bearing Cover [9] in place. Four Hex. Socket Hd. Bolts (W/Flange) M5 x 16 [27] which fix the Packing Gland [26] in place. -8-

12 (5) Arrange the internal wires as shown in Figs. 4 and 5 being careful not to connect in wrong direction or position and not to get the internal wires caught in parts. Fig. 4 Pass the internal wire of the cord through this area. Fit the internal wire in the groove securely. Fig. 5 Pass the internal wire with a tube of the stator through this groove. -9-

13 (6) Mount the cord clip as shown in Fig. 6 being careful of the direction. Fig. 6 Cord dia.: Over 8.5 mm Cord dia.: Max. 8.5 mm Cord clip mounting diagram Lubrication points and type of lubricant Pinion chamber of the Gear Cover Ass'y [5] COSMO MOLYBDEN NO g Generously rub grease onto the gear, pinion and inner circumference of the metal. Tightening torque Tapping Screws (W/Flange) D4 x 16 [45] [46] ± 0.5 N m (20 ±5 kgf cm, 1.5 ± 0.4 ft-lbs.) Seal Lock Screws (W/Sp. Washer) M5 x 14 (Black) [1] ± 1.0 N m (50 ± 10 kgf cm, 3.6 ± 0.8 ft-lbs.) Tapping Screw (W/Flange) D5 x 35 (Black) [17] ± 0.7 N m (35 ± 7 kgf cm, 2.5 ± 0.5 ft-lbs.) Hex. Socket Hd. Bolt (W/Flange) M5 x 16 [27] ± 1.5 N m (80 ± 15 kgf cm, 5.8 ± 1.1 ft-lbs.) Special Nut M10 [6] ± 3.1 N m (200 ± 30 kgf cm, 14.4 ± 2.2 ft-lbs.) Machine Screw M5 x 10 [20] ± 1.5 N m (60 ± 15 kgf cm, 4.3 ± 1.1 ft-lbs.) -10-

14 Wiring diagram Wiring diagram Insulation tests On completion of disassembly and repair, measure the insulation resistance, and conduct the dielectric strength test. Insulation resistance: After the switch is turned on, more than 10 MΩ by 500 V DC megohm meter between live parts and accessible metal parts. Dielectric strength: After the switch is turned on, there must be no trouble when the voltage indicated below is provided between live parts and accessible metal parts. Less than 150 V of the rated voltage: 3,000 V x 3 sec. More than 150 V of the rated voltage: 4,400 V x 3 sec. No-load current value After no-load operation for 30 minutes, the no-load current value should be as follows. Voltage (V) Current (A) max

15 STANDARD REPAIR TIME (UNIT) SCHEDULES MODEL Fixed Variable min. Work Flow G 18SS G 23SS Wheel Guard Ass y Housing Ass y Stator General Assembly Gear Cover Ass y Pinion Ball Bearing (6301VV) Rubber Ring Bearing Cover Armature Dust Seal Ball Bearing (6000VV) Handle (B) Seal Plate Handle (A) Switch Cord Gear Bearing Cover (B) Ball Bearing (6302VV) Felt Packing (B) Packing Gland Spindle -12-

16 LIST NO. E293 DISC GRINDER Model G 18SS (E1)

17 PARTS G 18SS ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS SEAL LOCK SCREW (W/SP. WASHER) M5X14 (BLACK) PUSHING BUTTON SPRING FELT WASHER GEAR COVER ASS'Y 1 INCLUD. 2-4, SPECIAL NUT M VV BALL BEARING 6301VVCMPS2L RUBBER RING BEARING COVER 1 * C ARMATURE 110V 1 * U ARMATURE ASS'Y 120V-127V 1 INCLUD. 7, 14, 15 * E ARMATURE 220V-240V FAN GUIDE HEX. HD. TAPPING SCREW D5X60 2 * C STATOR ASS'Y 110V 1 INCLUD. 16 * D STATOR ASS'Y 120V 1 INCLUD. 16 * G STATOR ASS'Y 127V 1 INCLUD. 16 * E STATOR ASS'Y 220V-230V 1 INCLUD. 16 * F STATOR ASS'Y 240V 1 INCLUD DUST SEAL VV BALL BEARING 6000VVCMPS2L BRUSH TERMINAL TAPPING SCREW (W/FLANGE) D5X35 (BLACK) SIDE HANDLE FOR M RETAINING RING FOR D12 SHAFT (10 PCS.) MACHINE SCREW M5X10 (10 PCS.) BEARING COVER (B) VV BALL BEARING 6302VVCMPS2L FELT PACKING (B) 1 * SPINDLE 1 * SPINDLE 1 FOR USA, CAN, MEX SEAL PLATE PACKING GLAND HEX. SOCKET HD. BOLT (W/FLANGE) M5X HEX. SOCKET HD. BOLT M8X25 (10 PCS.) 1 * WHEEL GUARD ASS'Y 1 INCLUD. 28 * WHEEL GUARD ASS'Y 1 INCLUD. 28 FOR USA, CAN, MEX * Z WHEEL WASHER (A) 1 * P WHEEL WASHER (B) FOR D5/8" HOLE 1 FOR USA, CAN, MEX * Z WHEEL NUT M14X2 1 * P WHEEL NUT 5/8"-11UNC 1 FOR USA, CAN, MEX LOCK PIN 1 * GEAR AND PINION SET 1 * GEAR AND PINION SET 1 FOR USA, CAN, MEX BRUSH CAP CARBON BRUSH (1 PAIR) BRUSH HOLDER 2 37 HITACHI LABEL HOUSING ASS'Y 1 INCLUD. 36, NAME PLATE *ALTERNATIVE PARTS 6-08

18 PARTS ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS HEX. SOCKET SET SCREW M5X HANDLE (A) 1 * TERMINAL M4.0 (10 PCS.) 2 FOR USA, CAN * TUBE (D) 2 FOR CORD CORD CLIP TAPPING SCREW (W/FLANGE) D4X TAPPING SCREW (W/FLANGE) D4X16 (BLACK) HANDLE (B) 1 * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 W/LOCK * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 OFF/LOCK * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 INCLUD. 49 FOR USA, CAN * SWITCH COVER 1 FOR USA, CAN * CORD ARMOR D * CORD ARMOR D8.2 1 * Z CORD 1 (CORD ARMOR D10.7) * Z CORD 1 (CORD ARMOR D8.2) FOR THA, INA, SIN, HKG * Z CORD 1 (CORD ARMOR D10.7) FOR VEN * Z CORD 1 (CORD ARMOR D10.7) FOR KUW * Z CORD 1 (CORD ARMOR D10.7) FOR USA, CAN, MEX * Z CORD 1 (CORD ARMOR D8.2) FOR CHN G 18SS *ALTERNATIVE PARTS

19 STANDARD ACCESSORIES ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS WRENCH HEX. BAR WRENCH 6MM 1 G 18SS OPTIONAL ACCESSORIES ITEM NO. CODE NO. DESCRIPTION USED REMARKS D. C. WHEELS 180MM A24R (25 PCS.) SUPER WASHER PIPE HANDLE SET 1 INCLUD BOLT M14 2 FOR PIPE HANDLE NO *ALTERNATIVE PARTS Printed in Japan 6-08 (080618N)

20 LIST NO. E294 DISC GRINDER Model G 23SS (E1)

21 PARTS G 23SS ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS SEAL LOCK SCREW (W/SP. WASHER) M5X14 (BLACK) PUSHING BUTTON SPRING FELT WASHER GEAR COVER ASS'Y 1 INCLUD. 2-4, SPECIAL NUT M VV BALL BEARING 6301VVCMPS2L RUBBER RING BEARING COVER 1 * C ARMATURE 110V 1 * U ARMATURE ASS'Y 120V-127V 1 INCLUD. 7, 14, 15 * E ARMATURE 220V-240V FAN GUIDE HEX. HD. TAPPING SCREW D5X60 2 * C STATOR ASS'Y 110V 1 INCLUD. 16 * D STATOR ASS'Y 120V 1 INCLUD. 16 * G STATOR ASS'Y 127V 1 INCLUD. 16 * E STATOR ASS'Y 220V-230V 1 INCLUD. 16 * F STATOR ASS'Y 240V 1 INCLUD DUST SEAL VV BALL BEARING 6000VVCMPS2L BRUSH TERMINAL TAPPING SCREW (W/FLANGE) D5X35 (BLACK) SIDE HANDLE FOR M RETAINING RING FOR D12 SHAFT (10 PCS.) MACHINE SCREW M5X10 (10 PCS.) BEARING COVER (B) VV BALL BEARING 6302VVCMPS2L FELT PACKING (B) 1 * SPINDLE 1 * SPINDLE 1 FOR USA, CAN, MEX SEAL PLATE PACKING GLAND HEX. SOCKET HD. BOLT (W/FLANGE) M5X HEX. SOCKET HD. BOLT M8X25 (10 PCS.) 1 * WHEEL GUARD ASS'Y 1 INCLUD. 28 * WHEEL GUARD ASS'Y 1 INCLUD. 28 FOR USA, CAN, MEX * Z WHEEL WASHER (A) 1 * Z WHEEL WASHER (B) 1 FOR AUS * P WHEEL WASHER (B) FOR D5/8" HOLE 1 FOR USA, CAN, MEX * Z WHEEL NUT M14X2 1 * Z WHEEL NUT (B) 1 FOR AUS * P WHEEL NUT 5/8"-11UNC 1 FOR USA, CAN, MEX LOCK PIN GEAR AND PINION SET BRUSH CAP CARBON BRUSH (1 PAIR) BRUSH HOLDER 2 37 HITACHI LABEL HOUSING ASS'Y 1 INCLUD. 36, *ALTERNATIVE PARTS 6-08

22 PARTS ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS 39 NAME PLATE HEX. SOCKET SET SCREW M5X HANDLE (A) 1 * TERMINAL M4.0 (10 PCS.) 2 FOR USA, CAN * TUBE (D) 2 * TUBE (D) 2 FOR GBR (110V) CORD CLIP TAPPING SCREW (W/FLANGE) D4X TAPPING SCREW (W/FLANGE) D4X16 (BLACK) HANDLE (B) 1 * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 W/LOCK * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 OFF/LOCK * SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 INCLUD. 49 FOR USA, CAN * SWITCH COVER 1 FOR USA, CAN * CORD ARMOR D * CORD ARMOR D8.2 1 * Z CORD 1 (CORD ARMOR D10.7) * Z CORD 1 (CORD ARMOR D8.2) FOR THA, INA, SIN, HKG * Z CORD 1 (CORD ARMOR D10.7) FOR VEN G 23SS * Z CORD 1 (CORD ARMOR D10.7) FOR KUW, GBR (230V) * Z CORD 1 (CORD ARMOR D10.7) FOR GBR (110V) * Z CORD 1 (CORD ARMOR D8.2) FOR NZL, AUS * Z CORD 1 (CORD ARMOR D10.7) FOR USA, CAN, MEX * Z CORD 1 (CORD ARMOR D8.2) FOR CHN *ALTERNATIVE PARTS

23 STANDARD ACCESSORIES ITEM NO. CODE NO. DESCRIPTION NO. USED REMARKS WRENCH HEX. BAR WRENCH 6MM 1 G 23SS OPTIONAL ACCESSORIES ITEM NO. CODE NO. DESCRIPTION USED REMARKS D. C. WHEELS 230MM A24R (25 PCS.) SUPER WASHER PIPE HANDLE SET 1 INCLUD BOLT M14 2 FOR PIPE HANDLE NO *ALTERNATIVE PARTS Printed in Japan 6-08 (080618N)