Hitachi PDA-100M Bedienungsanleitung

PRODUCT NAME

Hitachi Disc Grinder

Model PDA-100M

LIST No.

PDA-100M: E270

Sep. 2005

International Sales Division

PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY--------------------------------------------------------- 1

1. Disassembly ----------------------------------------------------------------------------------------------------- 1

2. Reassembly ------------------------------------------------------------------------------------------------------ 2

3. Lubrication Points and Types of Lubricant ---------------------------------------------------------------- 5

4. Tightening Torque ---------------------------------------------------------------------------------------------- 5

5. Wiring Diagram ------------------------------------------------------------------------------------------------- 5

6. Insulation Tests -------------------------------------------------------------------------------------------------- 6

7. No-load Current Value ----------------------------------------------------------------------------------------- 6

STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------- 7

CONTENTS Page

--- 2---

(4) Disassembly of the gear

1) Loosen the four Seal Lock Screws (W/Sp. Washer) M4 x 12 [21] that secure the Packing Gland [20] to the

Gear Cover Ass'y [3] and remove the Packing Gland [20] from the Gear Cover Ass'y [3].

2) Remove the Retaining Ring for D11 Shaft [13] that secures the gear to the Spindle [23].

3) Remove the Wave Washer [14] and the gear from the Spindle [23].

Fig. 1

1-2. Reassembly

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

(1) Ensure that the terminals of the stator are not bent or otherwise damaged.

(2) Generously lubricate the teeth of the gear and the pinion with grease. Rub grease onto the teeth with your

fingers so that the grease reaches each tooth bottom. Note that the gear and the pinion may wear faster than

normal if under-lubricated.

(3) Be sure to soak the inner diameter of the Felt Packing [19] with machine oil. Otherwise, its dust-sealing

function will fail to work properly, resulting in earlier damage of the Ball Bearing 6201VVCMPS2L [18].

(4) When replacing the Armature [7] and the Ball Bearing 608VVC2PS2L [12] on the commutator side, press

inward on the Dust Seal [11] while taking care of its direction until the end face of the Dust Seal [11] contacts

against the end surface of the Armature [7] and make sure that Dust Seal [11] cannot be turned freely by

hand. (See Fig. 1).

The Dust Seal [11] is an important element for improved dust protection of the Ball Bearing 608VVC2PS2L

[12]. Be sure to replace with a new one each time.

Armature shaft

Ball Bearing 608VVC2PS2L [12]

Dust Seal [11]

(5) When connecting the Earth Terminal [41] to the internal wire (the middle wire among three) of the Noise

Suppressor [45], strip the insulation sheath on the internal wire by about 6 mm and press-connect it together

with the Earth Terminal [41] with a clamping tool available on the market.

Fig. 2

Solderless connection

--- 3---

(6) Mount the Cord [54] according to the following

procedure when replacing the standard cord (cord

armor is integrally molded).

1) Remove the standard cord (cord armor is integrally

molded) according to the procedure of 8-1 (3).

2) Strip the coating on the internal wire of the Cord

[54] about 10 mm from the tip and crimp the

Terminal [50] to the brown or black internal wire as

shown in Fig. 3.

3) Insert the Cord [54] into the Cord Armor D8.8 [51].

4) Cut off the rib for holding the cord of Tail Cover (B)

[46] with nippers as shown in Fig. 4.

5) Mount the Cord [54] and the Cord Armor D8.8 [51]

to Tail Cover (A) [35] and secure them with the

Cord Clip [52] and two Tapping Screws (W/Flange)

D4 x 16 [53] as shown in Fig. 5.

6) Mount each internal wire reversing the removal

procedure. Then mount Tail Cover (B) [46] to Tail

Cover (A) [35] and secure them with the Tapping

Screw (W/Flange) D4 x 25 (Black) [47].Fig. 4

Fig. 5

Fig. 3

Terminal [50]

Cord [54]

Caulking

Stripped

length

10 mm

White

or blue

40 mm

85 mm

Black or brown

A --- A

Tail Cover (B) [46]

Approximately

2 mm

(a) For Taiwan (b) For Singapore and Malaysia

: Cut off

--- 4---

Fig. 6

Bottom of the housing

(7) Connect the internal wires of Stator (A) [10] correctly as shown in Fig. 6and Fig. 7.

(8) Connect each internal wire correctly as shown in Fig. 7being careful not to put them between the parts.

Brush Holder [40]

Internal wire from Cord [54]

Machine Screw (W/Washer) M3.5 x 6 [48]

Guide plate

Machine Screw (W/Washer) M3.5 x 6 [48]

Switch (1P Screw Type) [49]

: Tail Cover (A) [35]

Internal wire from Stator (A) [10]

Internal wire from Noise Suppressor [45]

Fig. 7

Internal wire coming from

the Noise Suppressor [45]

Insert the terminal securely then push

and fold the terminal toward the outside

of the housing as much as possible.

(9) When replacing the Gear Cover Ass'y [3], lubricate the needle bearing part with mixed oil.

Mixed oil: A mixture of Hitachi Power Tool Grease No. 2 (Unilube No. 00 Code No. 939302 is recommended)

and turbine oil

Mixture ratio ......... 1:1 (weight ratio) Quantity ........... 0.5 cc

OFF side

ON side

--- 5---

1-3. Lubrication Points and Types of Lubricant

Pinion chamber of Gear Cover Ass'y [3] ..................... Nippeco grease (SEP-3A) 5 g

(Code No. 930035 is recommended.)

Generously rub grease onto the gear and pinion.

Needle bearing ............................................................ Mixed oil 0.5 cc

Mixed oil: Mixture of Hitachi Power Tool Grease No. 2

(Unilube No. 00, Code No. 939302) and

turbine oil

Mixture ratio ................ 1:1 (weight ratio)

1-4. Tightening Torque

Tapping Screws D4 [9] [36] [37] [47] [53] .............................. 2.0 0.5 N•m (20 5 kgf•cm, 1.5 0.4 fb-lbs.)

Seal Lock Screws (W/Sp. Washer) M4 [16] [21] .................... 1.8 0.4 N•m (18 4 kgf•cm, 1.3 0.3 fb-lbs.)

Tapping Screw D5 x 25 (Black) [1] ......................................... 2.9 0.5 N•m (30 5 kgf•cm, 2.2 0.4 fb-lbs.)

Machine Screw (W/Sp. Washer) M5x16 (Black)

[25] ...............

1.6 0.4 N•m (16 4 kgf•cm, 1.2 0.3 fb-lbs.)

Special Nut M7 [4] .................................................................. 6.4 1.0 N•m (65 10 kgf•cm, 4.7 0.7 fb-lbs.)

Brush Cap [38] ........................................................................ 0.6 0.2 N•m (6 2 kgf•cm, 0.4 0.1 fb-lbs.)

1-5. Wiring Diagram

(1) For Taiwan (2) For Singapore

(3) For other countries

Noise

suppressor

Fig. 8

--- 6---

1-6. Insulation Tests

On completion of disassembly and repair, carefully measure the insulation resistance and conduct a dielectric

strength test.

Insulation resistance: 7 M Ωor more with 500 V DC megohm tester

Dielectric strength test: AC 4,000 V/1 minute with no abnormalities .................... 220 V --- 240 V products

AC 3,500 V/1 minute with no abnormalities .................... 110 V --- 127 V products

1-7. No-load Current Value

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

Voltage (V)

Current (A) max.

110

2.6

220

1.2

240

1.2

230

1.2

--- 7---

2. STANDARD REPAIR TIME (UNIT) SCHEDULES

MODEL 10 20 30 40

Fixed

Variable

Work Flow

Gear Cover

Ass'y

Pushing Button

Lock Pin

60 min.

Packing Gland

Ball Bearing

(6201VV)

Spindle

Gear and

Pinion Set

Switch

Tail Cover (A)

Tail Cover (B)

Cord

Cord Armor

Wheel Guard

Ass'y

Armature

Ball Bearing

(628VV)

Bearing Holder

Dust Seal

Ball Bearing

(608VV)

General Assembly

PDA-100M

Housing Ass'y

Stator

ELECTRIC TOOL PARTS LIST

LIST NO. E270

DISC GRINDER

Model PDA-100M

2005

•

(E1)

Hitachi Power Tools

41 42

501 502

* ALTERNATIVE PARTS--- 2 ---

ITEM

NO. CODE NO. DESCRIPTION REMARKS

NO.

USED

PARTS

9 -- 05

PDA-100M

1320-523 TAPPING SCREW D5X25 (BLACK) 4

2301-944 PUSHING BUTTON 1

3316-484 GEAR COVER ASS’Y 1 INCLUD. 2, 15

4301-941 SPECIAL NUT M7 1

5628-VVC BALL BEARING 628VVC2PS2-L 1

6316-480 BEARING HOLDER 1

*7360-744C ARMATURE 110V 1

*7360-744G ARMATURE 220V 1

*7360-744E ARMATURE 230V 1

*7360-744F ARMATURE 240V 1

8319-898 FAN GUIDE 1

9319-358 TAPPING SCREW (W/FLANGE) D4X70 2

*10 340-649C STATOR (A) 110V 1

*10 340-649E STATOR (A) 220V-240V 1

11 315-877 DUST SEAL 1

12 608-VVM BALL BEARING 608VVC2PS2L 1

13 316-487 RETAINING RING FOR D11 SHAFT 1

14 316-486 WAVE WASHER 1

15 301-943 LOCK PIN 1

16 997-263

SEAL LOCK SCREW (W/SP. WASHER) M4X10

17 316-490 BEARING COVER 1

18 620-1VV BALL BEARING 6201VVCMPS2L 1

19 301-946 FELT PACKING 1

20 316-489 PACKING GLAND 1

21 307-127

SEAL LOCK SCREW (W/SP. WASHER) M4X12

22 302-047 WOODRUFF KEY 1

23 316-485 SPINDLE 1

24 301-945 FRINGER 1

25 308-386

MACHINE SCREW (W/SP. WASHER) M5X16 (BLACK)

26 301-949 SET PLATE 1

27 301-948 WHEEL GUARD ASS’Y 1 INCLUD. 25, 26

28 320-497 WHEEL WASHER 1

29 316-820 D. C. WHEELS 100MMX4T A36Q (25 PCS.) 1

30 321-795 WHEEL NUT (C) 1

31 321-450 GEAR AND PINION SET 1

32 HITACHI LABEL 1

33 325-140 HOUSING 1

34 NAME PLATE 1

35 325-143 TAIL COVER (A) 1

36 302-086 TAPPING SCREW (W/FLANGE) D4X20 (BLACK) 1

37 306-664 TAPPING SCREW (W/FLANGE) D4X40 1

38 936-551 BRUSH CAP 2

39 999-021 CARBON BRUSH (1 PAIR) 2

40 313-777 BRUSH HOLDER 2

*41 314-854 EARTH TERMINAL 1 FOR TPE

*42 980-063 TERMINAL 1 FOR NOISE SUPPRESSOR

*43 938-307 PILLAR TERMINAL 1 FOR SIN, IND

*44 959-140 CONNECTOR 50091 (10 PCS.) 1 EXCEPT FOR SIN, IND

*45 994-273 NOISE SUPPRESSOR 1 FOR TPE

*46 325-141 TAIL COVER (B) 1

*46 325-142 TAIL COVER 1 FOR SYR

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