Hitachi G 18SS User manual

Hitachi
Brand
Hitachi
Model
G 18SS
Category
Power tools
Type
User manual

This manual is also suitable for

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
LIST Nos.
G 18SS: E293
G 23SS: E294
Jun. 2008
PRODUCT NAME
Hitachi 180 mm Disc Grinder
Model G 18SS
Hitachi 230 mm Disc Grinder
Model G 23SS
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
MARKETING OBJECTIVE
APPLICATIONS
SELLING POINTS
[ NEW FEATURES ]
Excellent overload durability
Protected armature coil
Dust-proof ball bearing thanks to the labyrinth
construction
International Sales Division
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT.
G
REMARK:
For more information about HANDLING INSTRUCTIONS, visit our website at:
http://www.hitachi-koki.com/manual_view_export/
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:
Competitors
Symbols Utilized
Company Name Model Name
B MAKITA 9067/9069
CONTENTS
Page
SELLING POINT DESCRIPTIONS-----------------------------------------------------------------------------------------1
SPECIFICATIONS --------------------------------------------------------------------------------------------------------------3
COMPARISONS WITH SIMILAR PRODUCTS--------------------------------------------------------------------------4
PRECAUTIONS IN SALES PROMOTION--------------------------------------------------------------------------------5
REPAIR GUIDE------------------------------------------------------------------------------------------------------------------6
1. Precautions in disassembly and reassembly--------------------------------------------------------------6
STANDARD REPAIR TIME (UNIT) SCHEDULES-------------------------------------------------------------------- 12
Assembly diagram for G 18SS
Assembly diagram for G 23SS
-1-
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.
SELLING POINT DESCRIPTIONS
Protected with “long wedges”
-2-
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.
Fan
Labyrinth
Ball bearing (6301VVCM)
Commutator
A
rmature shaft
Housing
Dust seal
Bearing cover
Labyrinth
Ball bearing (6000VVCM)
-3-
Voltage (V) Current (A) Power input (W)
110 18.2 1,900
120 15.0 1,700
127 14.0 1,700
220 9.1 1,900
230 8.7 1,900
240 8.3 1,900
1. Specifications
Model G 18SS G 23SS
Dimensions
O.D.180 mm (7”)
x Thickness 6 mm (1/4”)
x I.D. 22.2 mm (7/8”)
O.D.230 mm (9”)
x Thickness 6 mm (1/4”)
x I.D. 22.2 mm (7/8”)
Max. practical
peripheral speed
80 m/s (15,800 ft/min)
Type A, 24, R, B
Depressed-
center wheels
Spindle thread M14 x 2 *
1
Power source AC single phase 50 or 60 Hz
Voltage and power input *
2
No-load speed 8,500/min *
3
6,600/min *
3
Type of motor AC single phase commutator motor
Housing (green)
Handle (black)
Polyamide resin with glassfiber
Enclosure
Gear cover, packing gland Aluminum alloy diecasting
Type of switch Trigger switch
New weight *
4
(Main body)
Gross weight
4.3 kg (9.5 lbs.)
7.3 kg (16.1 lbs.)
Type of packing Corrugated cardboard box
Standard accessories
Side handle (Code No. 937981) ---1
Wrench (Code No. 325491)--------1
Hex. bar wrench 6 mm
(Code No. 872422)-------------------1
Side handle
(Code No. 937981)----------------1
Wrench (Code No. 325491)-----1
Wheel nut (B)
(Code No. 937917Z)--------------1*
5
Hex. bar wrench 6 mm
(Code No. 872422)----------------1
*
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.
SPECIFICATIONS
-4-
(Superior specifications:
)
1. Specification comparisons
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) 90 91
Service life of carbon brushes *
2
(hr) 100 160
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) 90 91
Service life of carbon brushes *
2
(hr) 100 160
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
COMPARISONS WITH SIMILAR PRODUCTS
-5-
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
Each tool is provided with a name plate which contains the following basic safety precautions in the use of
the tool.
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 depressed-
center wheel may fly off unexpectedly, resulting in possible serious injury.
(1) For U.K., Germany, Belgium, France, Netherlands, Austria, Russia, Switzerland,
S
p
ain, Portu
g
al, Canar
y
Islands, Ital
y
, Finland, Denmark, Sweden and Norwa
y
(
2
)
For Australia
PRECAUTIONS IN SALES PROMOTION
-6-
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
(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. 970982). After removal of the ball
bearing, the Bearing Cover [9] can be easily taken off.
Disassembl
y
REPAIR GUIDE
Push
Bearing puller (Code No. 970982)
Fig. 1
-7-
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.
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.
Push
Fig. 2
Spindle [24]
Packing Gland [26]
Sleeve
Gear and Pinion Set [33]
-8-
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].
(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.
Reassembl
y
A
rmature [10]
Ball Bearing 6000VVCMPS2L [15]
Fig. 3
Dust Seal [14]
-9-
(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.
Pass the internal wire of the
cord through this area.
Fit the internal wire in the groove securely.
Fig. 4
Pass the internal wire with a tube of the stator through this groove.
Fig. 5
-10-
(6) Mount the cord clip as shown in Fig. 6 being careful of the direction.
Pinion chamber of the Gear Cover Ass'y [5] ---------COSMO MOLYBDEN NO. 2 60 g
Generously rub grease onto the gear, pinion and
inner circumference of the metal.
Tapping Screws (W/Flange) D4 x 16 [45] [46] -------------2.0 ± 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] --4.9 ± 1.0 N
•m (50 ± 10 kgf•cm, 3.6 ± 0.8 ft-lbs.)
Tapping Screw (W/Flange) D5 x 35 (Black) [17] ----------3.4 ± 0.7 N
•m (35 ± 7 kgf•cm, 2.5 ± 0.5 ft-lbs.)
Hex. Socket Hd. Bolt (W/Flange) M5 x 16 [27] -------------7.8 ± 1.5 N
•m (80 ± 15 kgf•cm, 5.8 ± 1.1 ft-lbs.)
Special Nut M10 [6] -----------------------------------------------20.4 ± 3.1 N
•m (200 ± 30 kgf•cm, 14.4 ± 2.2 ft-lbs.)
Machine Screw M5 x 10 [20] -----------------------------------5.9 ± 1.5 N
•m (60 ± 15 kgf•cm, 4.3 ± 1.1 ft-lbs.)
Fig. 6
Cord dia.: Max. 8.5 mm
Cord clip mounting diagram
Cord dia.: Over 8.5 mm
Lubrication points and t
y
pe of lubricant
Ti
g
htenin
g
torque
-11-
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.
After no-load operation for 30 minutes, the no-load current value should be as follows.
Voltage (V) 110 120 127 220 230 240
Current (A) max. 6.3 5.2 4.8 3.0 3.2 3.4
Wirin
dia
ram
Insulation tests
• Wiring diagram
No-load current value
-12-
MODEL
Variable
Fixed
10 20 30 40 50 60 min.
Work Flow
G 18SS
G 23SS
General Assembly
Wheel Guard
Ass’y
Handle (B)
Gear Cover
Ass’y
Seal Plate
Handle (A)
Switch
Cord
Pinion
Ball Bearing
(6301VV)
Rubber Ring
Bearing Cover
Armature
Dust Seal
Ball Bearing
(6000VV)
Gear
Housing Ass’y
Stator
Bearing
Cover (B)
Ball Bearing
(6302VV)
Felt
Packing (B)
Packing Gland
Spindle
STANDARD REPAIR TIME (UNIT) SCHEDULES
Model G 18SS
DISC GRINDER
LIST NO. E293
(E1)
1
17
18
2
3
4
6
7
8
9
10
11
12
13
14
15
19
20
21
22
23
24
25
26
27
29
30
601
31
28
5
38
37
36
35
34
39
40
46
47
48
45
44
50
41
51
501
502
16
42
43
49
32
33
PART
S
G 18SS
DESCRIPTION REMARKS
1 315-636 SEAL LOCK SCREW (W/SP. WASHER) M5X14 (BLACK) 2
2 306-888 PUSHING BUTTON 1
3 320-219 SPRING 1
4 937-033 FELT WASHER 1
5 330-080 GEAR COVER ASS'Y 1 INCLUD. 2-4, 32
6 320-226 SPECIAL NUT M10 1
7 630-1VV BALL BEARING 6301VVCMPS2L 1
8 330-031 RUBBER RING 1
9 330-030 BEARING COVER 1
* 10 360-852C ARMATURE 110V 1
* 10 360-852U ARMATURE ASS'Y 120V-127V 1 INCLUD. 7, 14, 15
* 10 360-852E ARMATURE 220V-240V 1
11 330-081 FAN GUIDE 1
12 961-501 HEX. HD. TAPPING SCREW D5X60 2
* 13 340-737C STATOR ASS'Y 110V 1 INCLUD. 16
* 13 340-737D STATOR ASS'Y 120V 1 INCLUD. 16
* 13 340-737G STATOR ASS'Y 127V 1 INCLUD. 16
* 13 340-737E STATOR ASS'Y 220V-230V 1 INCLUD. 16
* 13 340-737F STATOR ASS'Y 240V 1 INCLUD. 16
14 330-029 DUST SEAL 1
15 600-0VV BALL BEARING 6000VVCMPS2L 1
16 937-623 BRUSH TERMINAL 2
17 323-209
TAPPING SCREW (W/FLANGE) D5X35 (BLACK) 4
18 937-981 SIDE HANDLE FOR M14 1
19 939-542 RETAINING RING FOR D12 SHAFT (10 PCS.) 1
20 949-236 MACHINE SCREW M5X10 (10 PCS.) 2
21 320-229 BEARING COVER (B) 1
22 630-2VV BALL BEARING 6302VVCMPS2L 1
23 990-852 FELT PACKING (B) 1
* 24 320-234 SPINDLE 1
* 24 321-541 SPINDLE 1 FOR USA, CAN, MEX
25 320-228 SEAL PLATE 1
26 320-227 PACKING GLAND 1
27 994-192
HEX. SOCKET HD. BOLT (W/FLANGE) M5X16 4
28 949-760 HEX. SOCKET HD. BOLT M8X25 (10 PCS.) 1
* 29 330-038 WHEEL GUARD ASS'Y 1 INCLUD. 28
* 29 330-039 WHEEL GUARD ASS'Y 1 INCLUD. 28 FOR USA, CAN, MEX
* 30 937-907Z WHEEL WASHER (A) 1
* 30 937-922P WHEEL WASHER (B) FOR D5/8" HOLE 1 FOR USA, CAN, MEX
* 31 937-909Z WHEEL NUT M14X2 1
* 31 937-923P WHEEL NUT 5/8"-11UNC 1 FOR USA, CAN, MEX
32 306-890 LOCK PIN 1
* 33 330-040 GEAR AND PINION SET 1
* 33 330-032 GEAR AND PINION SET 1 FOR USA, CAN, MEX
34 945-161 BRUSH CAP 2
35 999-038 CARBON BRUSH (1 PAIR) 2
36 938-241 BRUSH HOLDER 2
37 HITACHI LABEL 1
38 330-028 HOUSING ASS'Y 1 INCLUD. 36, 40
39 NAME PLATE 1
- 2 - 6 - 08
*ALTERNATIVE PARTS
ITEM
NO.
NO.
USED
CODE NO.
PART
S
G 18SS
DESCRIPTION REMARKS
40 938-477 HEX. SOCKET SET SCREW M5X8 2
41 330-033 HANDLE (A) 1
* 42 930-804 TERMINAL M4.0 (10 PCS.) 2 FOR USA, CAN
* 43 981-373 TUBE (D) 2 FOR CORD
44 960-266 CORD CLIP 1
45 984-750 TAPPING SCREW (W/FLANGE) D4X16 2
46 305-812
TAPPING SCREW (W/FLANGE) D4X16 (BLACK) 4
47 330-034 HANDLE (B) 1
* 48 320-239
SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 W/LOCK
* 48 320-238
SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 OFF/LOCK
* 48 330-035
SWITCH (2P PILLAR TYPE) W/SAFETY LOCK 1 INCLUD. 49 FOR USA, CAN
* 49 322-549 SWITCH COVER 1 FOR USA, CAN
* 50 940-778 CORD ARMOR D10.7 1
* 50 958-049 CORD ARMOR D8.2 1
* 51 500-247Z CORD 1 (CORD ARMOR D10.7)
* 51 500-234Z CORD 1
(CORD ARMOR D8.2) FOR THA, INA, SIN, HKG
* 51 500-474Z CORD 1 (CORD ARMOR D10.7) FOR VEN
* 51 500-450Z CORD 1 (CORD ARMOR D10.7) FOR KUW
* 51 500-453Z CORD 1
(CORD ARMOR D10.7) FOR USA, CAN, MEX
* 51 500-456Z CORD 1 (CORD ARMOR D8.2) FOR CHN
6 - 08 - 3 -
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.
STANDARD ACCESSORIE
S
G 18SS
DESCRIPTION REMARKS
501 325-491 WRENCH 1
502 872-422 HEX. BAR WRENCH 6MM 1
OPTIONAL ACCESSORIE
S
DESCRIPTION REMARKS
601 316-824 D. C. WHEELS 180MM A24R (25 PCS.) 1
602 310-337 SUPER WASHER 1
603 323-993 PIPE HANDLE SET 1 INCLUD. 604
604 985-597 BOLT M14 2 FOR PIPE HANDLE
- 4 - Printed in Japan 6 - 08
(080618N)
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.
NO.
USED
CODE NO.
ITEM
NO.
Model G 23SS
DISC GRINDER
LIST NO. E294
(E1)
1
17
18
2
3
4
6
7
8
9
10
11
12
13
14
15
19
33
20
21
22
23
24
25
26
27
29
30
601
31
28
5
16
34
35
36
37
38
39
40
44
45
41
42
43
46
47
48
49
50
51
501
502
32
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Hitachi G 18SS User manual

Hitachi
Brand
Hitachi
Model
G 18SS
Category
Power tools
Type
User manual
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