Hitachi G15VA Technical Data And Service Manual

Brand: Hitachi

Model: G15VA

Category: Power tools

Type: Technical Data And Service Manual

This manual is also suitable for

These product are high-performance, highly functional electronic disc grinders incorporating a 1500-watt power

input and a slide switch. We aim to expand our market share with these products that can provide added value in

the high-end product markets in Europe and other regions, where there is a growing demand for powerful and

functionally advanced electronic disc grinders.

LIST Nos.

G 12VA : E296

G 13VA : E297

G 13YF: E299

G 15VA : E298

G 15YF: F201

Aug. 2009

PRODUCT NAME

Hitachi Electronic Disc Grinder

Models 115 mm (4”) G 12VA

125 mm (5”) G 13VA, G 13YF

150 mm (6”) G 15VA, G 15YF

• Removal of casting fins and the finishing of various types of steel, bronze, aluminum and various othe

metallic materials

• Grinding of welds or sections cut by a cutting torch

• Grinding of synthetic resins, slate, brick, marble, and other materials

MARKETING OBJECTIVE

APPLICATIONS

SELLING POINTS

[ NEW FEATURES ]

Equipped with four existing electronic controls

+ two most advanced controls

1. Constant speed control

2. Soft-start speed control

3. Variable speed control (G 12VA, G 13VA and G 15VA)

4. Overload protection control

5. Kickback protection control

6. 0-voltage restart protection control

Equipped with most powerful motor in its class

Excellent overload durability (G 13VA)

Sales Division

SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT.

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:

G 12VA

Competitors

Symbols Utilized

Company Name Model Name

C1 MAKITA 9564CV

G 13VA, G 13YF

Competitors

Symbols Utilized

Company Name Model Name

B1 BOSCH GWS14-125CIE, GWS14-125CI

C2 MAKITA 9565CV, 9565C

G 15VA, G 15YF

Competitors

Symbols Utilized

Company Name Model Name

B2 BOSCH GWS14-150CI

C3 MAKITA 9566CV, 9566C

CONTENTS

Page

SELLING POINT DESCRIPTIONS ----------------------------------------------------------------------------------------- 1

SPECIFICATIONS -------------------------------------------------------------------------------------------------------------- 2

COMPARISONS WITH SIMILAR PRODUCTS-------------------------------------------------------------------------- 3

PRECAUTIONS ON SALES PROMOTION ------------------------------------------------------------------------------ 6

1. Safety Instructions ----------------------------------------------------------------------------------------------- 6

2. Control Circuit Functions and Operation ------------------------------------------------------------------- 7

3. Precautions on Usage ------------------------------------------------------------------------------------------ 8

4. Operation Phenomena to Note in Sales Promotion------------------------------------------------------ 9

REPAIR GUIDE---------------------------------------------------------------------------------------------------------------- 11

1. Precautions on Disassembly and Reassembly --------------------------------------------------------- 11

STANDARD REPAIR TIME (UNIT) SCHEDULES-------------------------------------------------------------------- 17

Assembly Diagram for G 12VA

Assembly Diagram for G 13VA

Assembly Diagram for G 13YF

Assembly Diagram for G 15VA

Assembly Diagram for G 15YF

-1-

Equipped with four existing electronic controls + two most

advanced controls

These products are highly functional electronic disc grinders that provide added value and incorporate a

microcomputer with a new original program loaded in place of a conventional general-purpose IC, four fully

updated control features—(1) constant speed control, (2) soft-start speed control, (3) variable speed control

(on Models G 12VA, G 13VA and G 15VA), and (4) overload protection control—and two new additional

control features—(5) kickback protection control and (6) 0-voltage restart protection control.

1. Constant speed control

The constant speed control feature maintains constant rotation speed during operation to ensure highly

efficient work.

2. Soft-start speed control

The soft-start speed control feature reduces the reactive force generated at motor startup so as to lessen

the load on the operator's hands.

3. Variable speed control (G 12VA, G 13VA and G 15VA only)

The variable speed control feature selects an appropriate rotation speed for different applications to

ensure highly efficient work.

4. Overload protection control

The overload protection feature shuts off power to the motor in the event of motor overload or a

conspicuous reduction in rotation speed during operation. This feature thus reduces the risk of motor

burnout and controller failure.

5. Kickback protection control

The kickback protection feature cuts off power to the motor and stops the power tool in the event of a

sudden drop in wheel rotation speed during operation (e.g., wheel locking during cutting operation). This

feature thus lessens the load on the operator's hands.

6. 0-voltage restart protection control

The 0-voltage restart protection feature disables motor startup even with the main switch on when the

power cord is reconnected to the power outlet after being unplugged during operation or when the power

supply is recovered from power failure. This feature thus minimizes accidents due to motor restart.

Equipped with most powerful motor in its class

These products are equipped with a high-performance, powerful motor featuring the highest input and

output in its class to enable highly efficient work.

Maker

HITACHI

Model

G 12VA, G 13VA, G 13YF,

G 15VA and G 15YF

B1, B2 C1, C2, C3

Power input 1500W 1400W 1400W

Max power output 2800W 2100W 2650W

Excellent overload durability (G 13VA)

The Model G 13VA provides the highest overload durability in its class (1.2 times higher than that of B1)

thanks to an improved cooling mechanism and a high-power motor.

116

100

123

0 50 100 150

SELLING POINT DESCRIPTIONS

G 13VA

Practical test data: Com

arison of tor

ue at 200-K rise in stator coil tem

erature

-2-

Model G 12VA G 13VA, G 13YF G 15VA, G 15YF

Dimensions

O.D. 115 mm (4-1/2”)

x thickness 6 mm (1/4”)

x I.D. 22.2 mm (7/8”)

O.D. 125 mm (5”)

x thickness 6 mm (1/4”)

x I.D. 22.2 mm (7/8”)

O.D. 150 mm (6”)

x thickness 6 mm (1/4”)

x I.D. 22.2 mm (7/8”)

Max.

practical

peripheral

speed

4,800 m/min (15,756 ft/min)

Type

27 (A, 36, Q, BF)

Depressed

center

wheels

Spindle

thread

U.S.A., Canada: 5/8-11 UNC Other countries: M14 x 2

Power source

AC single phase 50 or 60Hz

Voltage and power input

No-load speed

G 12VA, G 13VA: 2,800 to 10,500/min

G 13YF: 10,500/min

G 15VA: 2,300 to 9,000/min

G 15YF: 9,000/min

Type of motor

AC single-phase commutator motor

Enclosure

Housing (black)

Tail cover (green)

Gear cover, Packing gland ---------------------------- Aluminum alloy die-casting

Type of switch

Slide switch

Net *

2.0 kg (4.4 lbs.)

Weight

Gross

2.9 kg (6.4 lbs.) 3.0 kg (6.6 lbs.) 3.1 kg (6.8 lbs.)

Type of packing

Corrugated cardboard box, Plastic case

Standard accessories

Depressed center wheel

115 mm (4-1/2”) ----- 1

Side handle ---------- 1

Wrench ---------------- 1

Hex wrench ---------- 1

Depressed center wheel

125 mm (5”) ------------- 1

Side handle ------------- 1

Wrench ------------------- 1

Hex wrench ------------- 1

Depressed center wheel

150 mm (6”) ------------- 1

Side handle -------------- 1

Wrench ------------------- 1

Hex wrench -------------- 1

Optional accessories

Super washer(code No.310338)

* Net weight excludes the cord, side handle, depressed center wheel, wheel nut, wheel washer and wheel

guard.

Voltage (V) Current (A) Power input (W)

110 13.7 1430

120 13.0 1500

127 12.4 1500

230 7.0 1500

240 6.3 1430

SPECIFICATIONS

-----------------------------

Polyamide resin with glass fib

-3-

• Relation between dial settings and rotation speeds of Models G 12VA, G 13VA and G 15VA (Reference)

(Superior specifications:

)

Maker HITACHI

Model name G 12VA

Capacity:

Dia. of depressed center wheel

(mm) 115 (4-1/2”) 115 (4-1/2”)

Power Input

(W) 1,500 1,400

Power output

(W) 850 570

Max power output

(W) 2,800

2,650

No-load speed

(/min) 2,800 to 10,500

2,800 to 11,000

No-load sound pressure level

(dB) 86 84

Service life of carbon brushes

(hrs.) 74 73

0-voltage restart protection Provided None

Kickback protection Provided None

Tool-less wheel guard Provided Provided

Anti-vibration side handle

Provided None

Weight

(Actual weight)

(kg)

2.0 (4.4 lbs.)

2.9 (6.4 lbs.)

1.9 (4.2 lbs.)

2.7 (6.0 lbs.)

L (mm) 297.5 (11-45/64”) 299.0 (11-25/32”)

Dimensions H (mm) 70.0 (2-3/4”) 80.0 (3-9/64”)

P (mm) 220.0 (8-21/32”) 212.0 (8-11/32”)

Depends on the market

Service life of carbon brushes based on

continuous rated load test

Except for (HKU) & (HTM)

Weight without cord, side handle,

depressed-center wheel, wheel nut,

wheel washer and wheel guard

2000

4000

6000

8000

10000

123456

COMPARISONS WITH SIMILAR PRODUCTS

2000

4000

6000

8000

10000

12000

123456

DIAL

Spindle Rotation Speed (/min.)

Model G 15VA

Models G 12VA and G 13VA

-4-

(Superior specifications:

)

Maker HITACHI

Model name

G 13VA

G 13YF

B1 C2

Capacity:

Dia. of depressed center wheel

(mm) 125 (5”) 125 (5”) 125 (5”)

Power Input

(W) 1,500 1,400 1,400

Power output

(W) 850 593 570

Max power output

(W) 2,800

2,100 2,650

No-load speed

(/min)

2,800 to 10,500

10,500

2,800 to 11,000

11,000

2,800 to 11,000

11,000

No-load sound pressure level

(dB) 86 91 84

Service life of carbon brushes

(hrs.) 74 80 73

0-voltage restart protection Provided Provided None

Kickback protection Provided Provided None

Tool-less wheel guard Provided Provided Provided

Anti-vibration side handle

Provided Provided None

Weight

(Actual weight)

(kg)

2.0 (4.4 lbs.)

3.0 (6.6 lbs.)

1.8 (4.0 lbs.)

3.0 (6.6 lbs.)

1.9 (4.2 lbs.)

2.8 (6.2 lbs.)

L (mm) 297.5 (11-45/64”) 298.0 (11-47/64”) 299.0 (11-25/32”)

Dimensions H (mm) 70.0 (2-3/4”) 70.0 (2-3/4”) 80.0

(3-9/64”)

P (mm) 220.0 (8-21/32”) 212.0 (8-21/32”) 212.0 (8-11/32”)

Depends on the market

Service life of carbon brushes based on

continuous rated load test

Except for (HKU) & (HTM)

Weight without cord, side handle,

depressed-center wheel, wheel nut,

wheel washer and wheel guard

-5-

(Superior specifications:

)

Maker HITACHI

Model name

G 15VA

G 15YF

B2 C3

Capacity:

Dia. of depressed center wheel

(mm) 150 (6”) 150 (6”) 150 (6”)

Power Input

(W) 1,500 1,400 1,400

Power output

(W) 850 593 570

Max power output

(W) 2,800

2,100 2,650

No-load speed

(/min)

2,300 to 9,000

9,000

9,300

4,000 to 9,000

9,000

No-load sound pressure level

(dB) 86 91 84

Service life of carbon brushes

(hrs.) 74 80 73

0-voltage restart protection Provided Provided None

Kickback protection Provided Provided None

Tool-less wheel guard Provided Provided Provided

Anti-vibration side handle

Provided Provided None

Weight

(Actual weight)

(kg)

2.0 (4.4 lbs.)

3.1 (6.8 lbs.)

1.8 (4.0 lbs.)

3.1 (6.8 lbs.)

1.9 (4.2 lbs.)

2.9 (6.4 lbs.)

L (mm) 297.5 (11-45/64”) 298.0 (11-47/64”) 299.0 (11-25/32”)

Dimensions H (mm) 70.0 (2-3/4”) 70.0 (2-3/4”) 80.0

(3-9/64”)

P (mm) 220.0 (8-21/32”) 212.0 (8-21/32”) 212.0 (8-11/32”)

Depends on the market

Service life of carbon brushes based on

continuous rated load test

Except for (HKU) & (HTM)

Weight without cord, side handle,

depressed-center wheel, wheel nut,

wheel washer and wheel guard

-6-

1. Safety Instructions

In the interest of promoting the safest and most efficient use of the Models G 12VA, G 13VA, G 13YF,

G 15VA and G 15YF Electronic Disc Grinders by all of our customers, it is very important that when

concluding a sale that the salesperson carefully ensure that the buyer seriously recognizes the importance

of the Handling Instructions, and fully understands 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, the Handling Instructions list general precautions and suggestions on the use of

electric power tools, and specific precautions and suggestions on the use of the disc grinders in order to

enhance the safe, efficient use of the tools by the customer.

Salespersons must be thoroughly familiar with the contents of the Handling Instructions in order to offer

appropriate guidance to customers during sales promotion activities.

(1) Checking the power source voltage

Ensure that the power source voltage complies with the power specifications listed on the Name Plate.

Never operate the Models G 12VA, G 13VA, G 13YF, G 15VA and G 15YF using a direct current (DC)

power source. The control circuit in these tools functions through a phase-control system utilizing a triac,

and will not function under the application of DC power.

Any subsequently uncontrolled increase in motor rotation speed could be extremely hazardous.

Do not operate these tools from an engine generator, booster or any other type of transformer. Doing so

may not only damage the grinder, but may also lead to accidents.

NOTE: When the tool is connected to the power supply, the built-in electronic control circuit shifts

to standby status and the grinder becomes slightly warm, though not a malfunction.

B. Caution on Name Plate

Each tool is provided with a name plate that contains the following basic safety precautions on use of the

tool.

[For Europe]

[For New Zealand and Australia]

CAUTION

Read thoroughly read HANDLING INSTRUCTIONS before use.

PRECAUTIONS ON SALES PROMOTION

-7-

[For the U.S.A. and Canada]

WARNING

To reduce the risk of injury, user must read and understand instruction manual.

Always use guards and wear eye protection.

Use only accessories rated at least * /min.

AVERTISSEMENT

Afin de reduire le risque de blessures, I'utilisateur doit lire et bien comprendre le mode d'emploi.

Utilisez toujours un outil muni d'un protecteur et portez des lunettes on une visiere.

N'utilisez que des accessoires prevus pour au moins * /min.

* G 12VA : 13,300

G 13VA, G 13YF : 12,000

G 15VA, G 15YF : 10,200

2. Control Circuit Functions and Operation

(1) The control circuit generally consists of four components (see Fig. 1). The following describes the

function and operation of each circuit component:

(a) Rotation speed detector

The rotation speed detector generates a signal whose frequency is in proportion to the motor rotation

speed.

A magnetic sensor within the controller assembly detects flux changes due to the magnet built into

the rotor assembly, and generates the frequency signal.

(b) Variable resistor

The variable resistor applies a reference voltage to the microcomputer in order to determine the no-

load speed (reference rotation speed).

A trigger signal from the microcomputer determines the conduction angle of the triac, according to

which voltage is applied to the motor.

(d) Microcomputer

Under program control, the microcomputer generates trigger signals to turn the triac on and off

according to frequency signals from the rotation speed detector, the reference rotation speed

specified by the variable resistor, and the on or off state of the main switch.

The microcomputer performs the following controls based on precise trigger signal control:

• Soft-start speed control: The microcomputer generates trigger signals so that the triac's conduction

angle is gradually increased until motor speed reaches the reference rotation speed.

• Constant speed control: The microcomputer generates trigger signals so that motor speed, even if

varied, approximates the reference rotation speed. In other words, the microcomputer enlarges the

triac's conduction angle to increase voltage applied to the motor when motor load increases,

thereby lowering the rotation speed. In this way, motor speed becomes closer to the reference

rotation speed.

• Overload protection control: For overload protection, the microcomputer issues a command to shut

off power to the motor when the motor is placed under a heavier load during operation or the triac's

conduction angle exceeds a preset limit, thereby significantly lowering the rotation speed below a

preset minimum rotation speed.

• Kickback protection control: For kickback protection, the microcomputer computes the drop in

rotation speed per a specified length of time when the tool attached to the grinder receives a load

large enough to immediately stop the tool's rotation during operation, and issues a command to

shut off power to the motor if this computed drop exceeds a preset drop limit.

• 0-voltage restart protection control: For 0-voltage restart protection, the microcomputer issues a

command to shut off power to the motor to disable motor restarting once power is restored after

being cut off, even if the main switch is on (since it detects the on and off states of the main

switch) .

-8-

G 13V

G 13YF

G 13V

*1 : G 12VA, G 15VA

*2 : G 15YF

(2) Motor characteristics and voltage applied to the motor

Phase control voltage waveform

3. Precautions on Usage

(1) Never press the pushing button while the depressed center wheel is rotating.

Pressing the pushing button during depressed center wheel rotation will immediately stop the spindle. In

such case, the wheel nut may become loose and the depressed center wheel could suddenly fly off,

possibly causing serious injury.

(2) Using this product near a welding machine may cause the motor rotation speed to fluctuate. Since the

control circuit of this product includes a magnetic sensor (to detect flux changes) and a triac (which may

malfunction due to noise), instruct the customer not to use this product near a machine that generates

electromagnetic noise or near an extremely strong magnetic field.

Fig. 2

Fig. 1

-9-

4. Operation Phenomena to Note in Sales Promotion

(1) Constant speed control

The rotation speed during operation may fluctuate somewhat depending on the conditions of use and

power source.

(2) Soft-start speed control

Immediately after startup, the rotation speed may fluctuate somewhat depending on the conditions of

use and power source.

(3) Variable speed control (G 12VA, G 13VA and G 15VA)

For adjusting the number of revolutions, the models above (G 12VA, G 13VA and G 15VA) are

equipped with an electronic infinite-variable-speed drive by which the number of revolutions can be

changed according to specific use. For example, turning and setting the dial scale to 6 increases the

number of revolutions; turning and setting it to 1 decreases the number of revolutions. Before using the

tool, use the dial to set the number of revolutions. Refer to the following table as a rough guide. Be

careful not to turn the dial scale to any setting value below 1 or above 6.

Immediately after shifting gear in the tool, the rotation speed may fluctuate somewhat depending on the

conditions of use and power source.

Dial Use Tools

1 Polishing, finishing

Removal of paint or other coating

Removal of rust

Removal of burrs

Radial grinding disc

Sanding disc

5 Grinding Depressed center wheel

Rough grinding

Cutting

Depressed center wheel

Diamond wheel

(4) Overload protection control

(a) Overload protection control tends to be easily actuated by certain types of work. Applying excessive

pressure on the tool during cutting or similar heavy-duty operation will actuate overload protection

control and automatically stop the motor. This is because overload protection control detects the

increased flow of current caused by excessive pressure on the tool, and automatically turns off the

motor to protect it against possible overload burnout. The customer should be advised that the

Models G 12VA, G 13VA, G 13YF, G 15VA and G 15YF are specifically designed to perform more

efficiently and faster with considerably less pressure applied than that required for conventional disc

grinders, and that skillful use of the tools with minimal applied pressure will avoid actuating overload

protection control. The customer should also be advised, however, that the overload protection

control feature cannot always prevent overload motor burnout under all possible use conditions.

(b) Instruct the customer to immediately turn off the main switch in case overload protection control is

actuated, separate the tool attached to the grinder from the workpiece, turn on the main switch, wait

until the rotation speed increases to normal speed, and then resume work. Also advise the customer

that overload protection control will quickly reactuate even under a slight load if the customer

resumes work before the rotation speed increases to the normal level.

pressing the depressed center wheel or cut-off wheel against the workpiece before the tool reaches

full rotation speed. (This will actuate overload protection control. Therefore, strongly recommend that

the customer never turn the switch on with the depressed center wheel in contact with the workpiece

or press the wheel against the workpiece when beginning operation until normal rotation speed has

been attained.)

-10-

(d) Control circuit failure may result in abnormally high rotation speed. Should the control circuit in the

tool malfunction, the rotation speed may increase excessively, thereby rendering continued use of

the tool extremely hazardous. In such case (of abnormally high rotation speed), the operator will hear

abnormal noise from the motor and/or gears. If such a phenomenon occurs, the customer should

immediately shut off the tool, and then bring it to the nearest Hitachi authorized sales outlet or repair

center for inspection and repair.

(5) Kickback protection control

For kickback protection, the microcomputer computes the drop in rotation speed per a specified length

of time when the tool attached to the grinder is placed under a load large enough to immediately stop

the tool's rotation during operation, and issues a command to shut off power to the motor if this

computed drop exceeds a preset drop limit. Conversely, kickback protection control is not actuated if

the computed drop is less than the preset drop limit. In either case, overload protection control may be

actuated several seconds later to stop the motor. Instruct the customer to immediately turn off the main

switch in case kickback protection control is actuated, separate the tool attached to the grinder from the

workpiece, turn on the main switch, wait until the rotation speed increases to normal speed, and then

resume work. Also advise the customer that overload protection control will quickly reactuate even

under a slight load if the customer resumes work before the rotation speed increases to the normal

level.

(6) 0-voltage restart protection control

Instruct the customer to immediately turn off the main switch in case 0-voltage restart protection control

is actuated, separate the tool attached to the grinder from the workpiece, turn on the main switch, wait

until the rotation speed increases to normal speed, and then resume work. Also instruct the customer to

turn off the main switch and not to use this product near a machine that generates electromagnetic

noise, near an extremely strong magnetic field, or under stormy weather conditions with thunder or

lightning because the microcomputer could malfunction due to noise and 0-voltage restart protection

control may not be actuated correctly. Note that 0-voltage restart protection control may not be actuated

in case of momentarily power failure.

-11-

Before attempting disassembly or reassembly, always remember 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 numbers in the Parts List and exploded

assembly diagrams for the Models G 12VA, G 13VA, G 13YF; the <Bold> numbers correspond to those in

the Parts List and exploded assembly diagrams for the Models G 15VA and G 15YF.

1. Disassembly of the armature

(1) Loosen the Hex. Socket Hd. Bolt (W/Washers) M5 x 20 [31] <32> and remove the Wheel Guard Ass’y [34]

<35>.

(2) Loosen the two Tapping Screws (W/Flange) D4 x 50 (Black) [59] <60> and remove the Tail Cover [57]

<58>.

(3) Remove the two Carbon Brushes [42], [43] <43>, <44> from the Carbon Brush Holders [41] <42>.

(4) Remove the four Tapping Screws D5 x 25 (Black) [2] <1>. The Armature [11] <12> can then be

removed simultaneously with the Gear Cover Ass'y [4] <5>, Packing Gland [25] <26>, and related

parts.

(5) Remove the four Seal Lock Screws (W/Sp. Washer) M5 x 16 [26] <27>. The Packing Gland [25] <26>

can then be removed together with Spindle (A) [28] <29> and the Gear [19] <20>.

(6) After removing the two Seal Lock Screws (W/Sp. Washer) M4 x 10 [1] <3>, the Armature [11] <12>

can be extracted together with the Bearing Cover [10] <11> and related parts.

(7) Carefully wrap the Armature [11] <12> in a soft, clean rag to protect it against damage, and then clamp

it securely in a vise. Then remove the Nut [5] <6> and extract the Pinion [19] <20>.

(8) For the models indicated in Fig. 3, Ball Bearing 629T12DDC3PS2-L [8] <9> can be removed from the

Armature [11]

<12> by utilizing the J-204 Bearing Puller (special repair tool, Code No. 970982) as

illustrated. After removing the ball bearing, you can easily remove the Bearing Cover [10] <11>.

Disassembly

REPAIR GUIDE

Fig. 3

J204 bearing puller (Code No. 970982)

-12-

2. Disassembly of the dust seal

(1) Remove the Magnet [18] <19>. (Note that the magnet features a left-hand thread.)

(2) Insert the hooks of the J-204 Bearing Puller between the commutator and Dust Seal (A) [16] <17> from

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

(3) Place the J-204 Bearing Puller on a supporting jig and push down on the armature shaft with a hand

press to remove Dust Seal (A) [16] <17> together with Ball Bearing 608VVC2PS2L [17] <18>. Replace

Dust Seal (A) [16] <17> with a new one, since it will be damaged by removing Ball Bearing

608VVC2PS2L [17] <18>.

3. Disassembly of the gear

(1) Loosen the four Seal Lock Screws (W/Sp. Washer) M5 x 16 [26] <27>, and then remove the Packing

Gland [25] <26> together with Spindle (A) [28] <29> and the Gear [19] <20> from the Gear Cover Ass'y

[4] <5> as a single body.

(2) When necessary to remove the Gear [19] <20> from Spindle (A) [28] <29>, it is highly recommended to

use the special repair tools described below. As illustrated in Fig. 4 support the angled surface of the

Gear [19] <20> with the J-129-2 Gear Puller (special repair tool, Code No. 970906), rest the J-129-2

Gear Puller on the J-130 Sleeve (special repair tool, Code No. 970907), and then push down on the tip

of Spindle (A) [28] <29> with a hand press to remove the Gear [19] <20>.

Fig. 4

-13-

4. Removal of the controller and the snap switch

(1) Loosen the two Tapping Screws (W/Flange) D4 x 50 (Black) [59] <60> and remove the Tail Cover [57] <58>.

(2) Turn the Controller [53] <54> for the Housing [39] <40> in the arrow "A" direction, and then remove the

Controller [53] <54> from the Housing [39] <40>. (Fig. 5)

(3) While pressing the Switch [49] <50> in the arrow "A" direction, use a small flat-blade screwdriver to

press the latches of the Controller [53] <54> in the arrow "B" direction to remove the snap Switch [49]

<50> from the Controller [53] <54>. (Fig. 6)

5. Disassembly of the stator

(1) After removing the Armature [11] <12>, disconnect the lead wires connected to the carbon Brush

Holders [41] <42>, and then remove the Connector 50091 [52] <53>.

(2) Remove the Fan Guide [12] <13> from the Housing [39] <40>.

(3) Loosen the two Hex. Hd. Tapping Screws D4 x 70 [13] <14>, and then remove the Stator [14] <15> and

Internal Wire [51] <52> from the Housing [39] <40>. If the Stator [14] <15> proves difficult to remove

from the Housing [39] <40>, use an appropriate heating device to heat the Housing [39] <40> to a

temperature of about 60¶C (140¶F) in order to facilitate disassembly.

6. Removal of the slide switch knob

(1) Loosen the two Tapping Screws (W/Flange) D4 x 50 (Black) [59] <60> and remove the Tail Cover [57] <58>.

(2) Hold the Housing [39] <40> and remove the Spring [46] <47>, and then raise the Slide Bar [47] <48>

until the Slide Switch Knob [38] <39> moves to the "ON" position.

(3) Check that the Slide Switch Knob [38] <39> has not moved to the "ON-LOCK" position, and then push

down the Slide Switch Knob [38] <39> until it clicks while keeping the Slide Bar [47] <48> raised.

(4) Raise the Slide Switch Knob [38] <39> straight up and remove it while keeping the Slide Bar [47] <48>

raised.

Fig. 5 Fig. 6

-14-

Perform reassembly by reversing the order of the disassembly procedure. However, special attention

should be given to the following items.

(1) Generously lubricate the teeth of the Gear and Pinion set [19] <20> with grease. Rub grease onto the

teeth with your fingers so that it reaches the bottom of each tooth. Note that insufficient lubrication may

result in faster wear of the Gear and Pinion set [19] <20>.

(2) Be sure to soak the inner diameter of the Felt Packing [24] <25> with machine oil. Otherwise, its dust-

sealing function will fail to work properly, resulting in premature damage to Ball Bearing 6201DDCMP2L

[23] <24>.

(3) When replacing the Armature [11] <12> or Ball Bearing 608VVC2PS2L [17] <18> on the commutator

side, be sure to replace Dust Seal (A) [16] <17> with a new one together. Dust Seal (A) [16] <17> is an

important part to ensure the dust resistance of the ball bearing. Replace Dust Seal (A) [16] <17> with a

new one without fail. Press-fit Ball Bearing 608VVC2PS2L [17] <18> into the position shown in Fig. 7.

(4) Apply Three Bond TB 1406 Screw Locking Agent to the following screws:

• Two Seal Lock Screws (W/Sp. Washer) M4 x 10 [1] <3> that secure the Bearing Cover [10] <11> in

place.

• Three Seal Lock Screws (W/Sp. Washer) M4 x 8 [21] <22> that secure the Bearing Cover (B) [22]

<23> in place.

• Four Seal Lock Screws (W/Sp. Washer) M5 x 16 [26] <27> that secure the Packing Gland [25] <26>

in place.

(5) Check that the end of the spring does not hold the pigtail when mounting the carbon brush. Do not catch

the pigtail in the tail cover when mounting the cover as shown in Fig. 8 below.

(6) When replacing the Gear Cover Ass'y [4] <5>, lubricate the needle bearing with mixed oil.

Mixed oil: Mixture of Hitachi power tool grease No. 2 (Unilube No. 00) and turbine oil

• Mixed ratio ------- 1:1 (weight ratio) • Volume ---------- 0.5 cc

Reassembly

Fig. 7

Press-fitting position:

4.2 to 4.5 mm

Thrust Washer [15] <16>

Dust Seal (A) [16] <17>

Ball Bearing

608VVC2PS2L [17] <18>

rmature shaft

Magnet [18] <19>

Fig. 8

-15-

Fig. 10

Connect the internal wires according to Figs. 9 to 11 below.

Numbers 1 to 4 in the following figures correspond to the internal wires of the stator.

Connection of internal wires and wiring diagrams

Pillar Terminal [48] <49>

Connector 50091

[52]

<53>

Terminal [60] <61>

Carbon Brush Holder

[41] <42> (Side B)

Carbon Brush Holder

[41] <42> (Side A)

Side A

Side B

Connect to the Carbon Brush Holder

[41] <42> (Side A)

Connect to the Carbon Brush Holder

[41] <42> (Side B)

Controller

[53] <54>

Connector 50091

[52] <53>

Pillar Terminal

[48] <49>

Connector 50091

[

]

<53>

Internal Wire

[51] <52>

Gray

Terminal

[

]

<61>

Cord [63] <64>

Switch [49] <50>

Blue or

White

White or

Brown

Black

or Blue

Black

Gray

Red

White

Brown

Fig. 11

Fig. 9

-16-

Pinion chamber of the Gear Cover Ass'y [4] <5> -------COSMO MOLYBDEN No. 2 grease 22 g

Generously rub grease onto the gear and the pinion.

Needle bearing -------------------------------------------------- Mixed oil 0.5 cc

Mixed oil: Mixture of Hitachi power tool grease No. 2

(Unilube No. 00) and turbine oil

Mixed ratio1:1 (weight ratio)

Tapping Screws D4 [13] <14> [55] <56> [59] <60>------- 2.0 r 0.5 N

•m (20 r5 kgf•cm, 1.5 r 0.4 ft-lbs.)

Seal Lock Screws (W/Sp. Washer) M4 x 10 [1] <3> ------ 1.8 r 0.4 N

•m (18 r 4 kgf•cm, 1.3 r 0.3 ft-lbs.)

Tapping Screw D5 x 25 [2] <1>--------------------------------- 2.9 r 0.5 N

•m (30 r 5 kgf•cm, 2.2 r 0.4 ft-lbs.)

Seal Lock Screw (W/Sp. Washer) M4 x 8 [21] <22> ------ 2.9 r 0.5 N

•m (30 r 5 kgf•cm, 2.2 r 0.4 ft-lbs.)

Seal Lock Screw (W/Sp. Washer) M5 x 16 [26] <27>----- 3.4 r 0.7 N

•m (35 r 7 kgf•cm, 2.5 r 0.5 ft-lbs.)

Tapping Screw D3 x 10 [44] <45>------------------------------ 0.74 r 0.15 N

•m (7.5 r 1.5 kgf•cm, 0.5 r 0.1 ft-lbs.)

Magnet [18] <19> (M6 left-hand thread)---------------------- 1.27 r 0.29 N

•m (13 r 3 kgf•cm, 0.9 r 0.2 ft-lbs.)

Nut M8 [5] ----------------------------------------------------------- 13.7 r 2.0 N

•m (140 r 20 kgf•cm, 10.1 r 1.5 ft-lbs.)

Spacial Nut M6 <6> ----------------------------------------------- 5.1 r 1.0 N

•m (50 r 10 kgf•cm, 3.6 r 0.7 ft-lbs.)

Upon completing disassembly and repair, measure the insulation resistance and conduct a dielectric

strength test.

Insulation resistance: 10M: or more using a DC 500 V megohm tester

Dielectric strength test: 4,400 VAC/3 sec., with no abnormalities ------------ More than 150 V of rated voltage

3,000 VAC/3 sec., with no abnormalities ------------ Less than 150 V of rated voltage

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

Voltage (V) 110 120 127 230 240

Current (A) max. 4.9 4.8 4.7 2.4 2.4

Lubrication points and types of lubricant

Tightening torque

Insulation tests

No-load current value

-17-

MODEL

Variable

Fixed

10 20 30 40 50 60 min.

Work Flow

G 12VA

G 13VA

G 13YF

G 15VA

G 15YF

General Assembly

Wheel Guard

Ass’y

Tail Cover

Carbon Brush

x 2

Spring x 2

Controller

Snap Switch

Cord

Cord Armor

Pinion

Ball Bearing

(629T12DD)

Bearing

Cover

Armature

Dust Seal (A)

Ball Bearing

(608VV)

Gear Cover

Ass’y

Pushing

Button

Lock Pin

Gear

Bearing

Cover (B)

Ball Bearing

(6201VV)

Felt Packing

Packing

Gland

Feather Key

Spindle

Housing

Stator

Slide Switch

Knob

Slide Bar

Spring

STANDARD REPAIR TIME (UNIT) SCHEDULES

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Hitachi G15VA Technical Data And Service Manual

Brand: Hitachi

Model: G15VA

Category: Power tools

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