Hitachi G18ST Bedienungsanleitung

REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------1

1. Precautions on disassembly and reassembly -----------------------------------------------------------1

STANDARD REPAIR TIME (UNIT) SCHEDULES --------------------------------------------------------------------8

LIST Nos.

G 18ST: F227

G 18SW2: F228

G 23ST: F229

G 23SW2: F230

Dec. 2014

PRODUCT NAME

Hitachi 180 mm Disc Grinder

Models G 18ST, G 18SW2

Hitachi 230 mm Disc Grinder

Models G 23ST, G 23SW2

International Sales Division

CONTENTS

G 23ST

-1-

Fig. 1

WARNING: Before attempting disassembly or reassembly, be sure to turn off the power switch and

disconnect the plug from the power source outlet.

1. Precautions on 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 18ST, G 18SW2, G 23ST, and G 23SW2.

1. Removal of the armature

(1) Loosen the Wheel Nut [27] and remove the wheel and Wheel Washer (C) [26].

(2) Loosen the Bolt M8 x 25 [24] and remove the Wheel Guard Ass’y [25].

Disassembly

REPAIR GUIDE

Wheel

[24]

[25]

[26]

[27]

-2-

Fig. 3

Fig. 2

(3) Loosen the Tapping Screws D4 x 16 [38] and remove the Brush Cover [37]. Then take out the Carbon

Brushes (1 Pair) [36].

(4) Remove the four Tapping Screws D5 x 35 [1]. The Armature [12] can then be taken out together with

the Gear Cover Ass'y [4], Packing Gland [22] and related parts as shown in Fig. 3.

(5) Loosen the four Bolts M5 x 16 [23]. Remove the Packing Gland [22] and related parts.

(6) Remove the Special Nut M10 [6] and extract the pinion of the Gear and Pinion Set [29].

(7) Carefully extract the Armature [12] from the Gear Cover Ass'y [4].

[12]

[1]

[4]

[22]

[23]

[6]

Pinion

[29]

[31]

[7]

[8]

[9]

[10]

[11]

[32]

[38]

[37]

[38]

[36]

-3-

Fig. 4

2. Removal of the dust seal

(1) Insert the hooks of the J-204 bearing puller between the commutator and the Dust Seal [31] from

both sides, and fix the hooks with the wing bolts.

(2) 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 [31] together with the Ball Bearing 6000VV [32]. Replace the Dust

Seal [31] with new one because it is damaged by the removal of the Ball Bearing 6000VV [32].

3. Removal of the stator ass'y

(1) After removing the Armature [12], disconnect the internal wires connected to the Brush Holders [34]

and the Switch [40].

(2) Remove the Stator [30] from the Housing [33]. If the Stator [30] cannot be easily removed from the

Housing [33], disassembly can be facilitated by heating the Housing [33] to a temperature of

approximately 60°C (140°F) with an appropriate heating device.

4. Removal of the gear and pinion set

(1) Loosen the four Bolts M5 x 16 [23] and remove the Packing Gland [22] together with the Spindle

[20] and the gear of the Gear and Pinion Set [29] from the Gear Cover Ass'y [4] in a single body.

(2) Remove the Retaining Ring [15] from the Spindle [20].

(3) When it is necessary to remove the gear of the Gear and Pinion Set [29] from the Spindle [20], it is

highly recommended that the special repair tools described below are utilized.

NOTE: Place the assembly on a sleeve that

matches the dimension of the Packing

Gland [22] and push down on the top

of the Spindle [20] with a hand press

to remove the gear of the Gear and

Pinion Set [29] as shown in Fig. 4.

Push.

[15]

[20]

[22]

Sleeve

Gear of the

Gear and Pinion Set [29]

-4-

Fig. 5 Fig. 6

Put the parts together in the reverse order of disassembly, with the precautions given below.

(1) Apply machine oil to Felt Packing (B) [19] then mount it to the Packing Gland [22] to increase the dust

resistance.

(2) Generously lubricate the teeth of the Gear and Pinion Set [29] 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 [29] may wear at a faster rate.

(3) When replacing the Armature [12] and the Ball Bearing 6000VV [32] on the commutator side, press

inward on the Dust Seal [31] while taking care of its direction until the end face of the Dust Seal [31]

hits against the butting surface of the Armature [12] and make sure that the Dust Seal [31] cannot turn

freely as shown in Fig. 6. The Dust Seal [31] is an important element for improved dust protection of

the Ball Bearing 6000VV [32]. Be sure to use a new one at every disassembly work of the Ball Bearing

6000VV [32].

(4) Apply Three Bond TB 1406 screw locking agent to the following screws. (See Fig. 5.)

• Two Machine Screws M5 x 10 [16] which fix Bearing Cover (B) [17] in place

• Four Bolts M5 x 16 [23] which fix the Packing Gland [22] in place

Reassembly

[29]

[16]

[23]

[22]

[17]

Pinion

Gear

[12]

[32]

[31]

[18]

[19]

[20]

[21]

-5-

Fig. 7

Fig. 8

(5) Arrange the internal wires as shown in Fig. 7 and Fig. 8 being careful not to connect in wrong direction

or position and not to get the internal wires caught in parts.

Pass the internal wire covered with the

tube of the stator through this groove.

Pass the internal wire of

the cord through this area.

Fit the internal wire in the groove securely.

-6-

Fig. 9 • Cord clip mounting diagram

(6) Mount the cord clip as shown in Fig. 9 being careful of the direction.

Pinion chamber of the Gear Cover Ass'y [4] --------50 g of COSMO DYNAMAX EP No. 1

Generously rub grease onto the gear, pinion and

inner circumference of the metal.

Tapping Screws D4 x 16 [35] [38] ----------------------------2.0 ± 0.5 N•m (20 ± 5 kgf•cm, 1.5 ± 0.4 ft-lbs.)

Tapping Screw D5 x 35 [1] -------------------------------------3.4 ± 0.7 N•m (35 ± 7 kgf•cm, 2.5 ± 0.5 ft-lbs.)

Bolt M5 x 16 [23] --------------------------------------------------7.8 ± 1.5 N•m (80 ± 15 kgf•cm, 5.8 ± 1.1 ft-lbs.)

Special Nut M10 [6] ----------------------------------------------20.4± 3.1N•m (200± 30 kgf•cm,14.4± 2.2ft-lbs.)

Machine Screw M5 x 10 [16] -----------------------------------5.9 ± 1.5 N•m (60 ± 15 kgf•cm, 4.3 ± 1.1 ft-lbs.)

Lubrication points and type of lubricant

Tightening torque

Cord dia.: Over 8.4 mm Cord dia.: Max. 8.4 mm

-7-

Fig. 10 • Wiring diagram

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 M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.

After no-load operation for 30 minutes, the no-load current value should be as follows.

Voltage 110 V 120 V 127 V 220 V 230 V 240 V

Current max. 7.2 A 5.7 A 6.0 A 3.7 A 3.9 A 3.2 A

Wiring diagram

Insulation tests

No-load current value

Field coil

Switch

Power source Condensor ass'y

(0.22 ȝF)

-8-

MODEL Variable

Fixed 10 20 30 40 50 60 min.

G 18ST

G 18SW2

G 23ST

G 23SW2

General Assembly

Gear Cover

Ass’y

Seal Plate

Handle (A)

Switch

Cord

Ball Bearing

(6301VV)

Rubber Ring

Armature

Dust Seal

Ball Bearing

(6000VV)

Gear and

Pinion Set

Housing

Stator

Bearing

Cover (B)

Ball Bearing

(6302VV)

Felt

Packing (B)

Packing

Gland

Spindle

Work Flow

Wheel Guard

Ass’y

Handle (B)

STANDARD REPAIR TIME (UNIT) SCHEDULES

Model G 18ST

DISC GRINDER

LIST NO. F227

2014·12·11

(E1)

1 2

31 32

34 35 36

37 38

41 42

501 502 503

602

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