HIKOKI G 10ST User manual

Read through carefully and understand these instructions before use.
Disc Grinder
G 10ST
HANDLING INSTRUCTIONS
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Wrench
Wheel nut
Depressed center wheels
Wheel washer
Spindle
Notched part
Wheel guard
Tighten
Convex side
Lock pin
Washer nut
Sanding disc
Rubber pad
Washer
Wear limit
No. of carbon brush
Symbols
WARNING
The following show symbols
used for the machine. Be sure
that you understand their
meaning before use.
To reduce the risk of injury,
user must read instruction
manual.
Always wear eye protection.
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䡬
䡬
䡬
˚ ˚
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HiKOKI
HiKOKI
HiKOKI
HiKOKI

9
GENERAL POWER TOOL SAFETY WARNINGS
WARNING
Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result
in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your
mains-operated (corded) power tool or battery-operated
(cordless) power tool.
1) Work area safety
a) Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust.
Power tools create sparks which may ignite the
dust or fumes.
c) Keep children and bystanders away while
operating a power tool.
Distractions can cause you to lose control.
2) Electrical safety
a) Power tool plugs must match the outlet.
Never modify the plug in any way.
Do not use any adapter plugs with earthed
(grounded) power tools.
Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with earthed or grounded
surfaces, such as pipes, radiators, ranges and
refrigerators.
There is an increased risk of electric shock if
your body is earthed or grounded.
c) Do not expose power tools to rain or wet
conditions.
Water entering a power tool will increase the
risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts.
Damaged or entangled cords increase the risk
of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces
the risk of electric shock.
f) If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply.
Use of an RCD reduces the risk of electric shock.
3) Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool.
Do not use a power tool while you are tired or
under the influence of drugs, alcohol or medication.
A moment of inattention while operating power
tools may result in serious personal injury.
b) Use personal protective equipment. Always wear
eye protection.
Protective equipment such as dust mask, non-
skid safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce
personal injuries.
c) Prevent unintentional starting. Ensure the switch
is in the off-position before connecting to power
source and/or battery pack, picking up or
carrying the tool.
Carrying power tools with your finger on the
switch or energising power tools that have the
switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on.
A wrench or a key left attached to a rotating part
of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and
balance at all times.
This enables better control of the power tool in
unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts.
Loose clothes, jewellery or long hair can be
caught in moving parts.
g) If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used.
Use of dust collection can reduce dust related
hazards.
4) Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application.
The correct power tool will do the job better and
safer at the rate for which it was designed.
b) Do not use the power tool if the switch does
not turn it on and off.
Any power tool that cannot be controlled with
the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools.
Such preventive safety measures reduce the risk
of starting the power tool accidentally.
d) Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the
power tool or these instructions to operate the
power tool.
Power tools are dangerous in the hands of
untrained users.
e) Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts
and any other condition that may affect the
power tool's operation.
If damaged, have the power tool repaired before
use.
Many accidents are caused by poorly maintained
power tools.
f) Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are
easier to control.
g) Use the power tool, accessories and tool bits
etc. in accordance with these instructions, taking
into account the working conditions and the
work to be performed.
Use of the power tool for operations different from
those intended could result in a hazardous situation.
5) Service
a) Have your power tool serviced by a qualified
repair person using only identical replacement
parts.
This will ensure that the safety of the power tool
is maintained.
PRECAUTION
Keep children and infirm persons away.
When not in use, tools should be stored out of reach of
children and infirm persons.
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SAFETY WARNINGS COMMON FOR
GRINDING AND SANDING OPERATIONS
a) This power tool is intended to function as a grinder,
sander. Read all safety warnings, instructions,
illustrations and specifications provided with this
power tool.
Failure to follow all instructions listed below may
result in electric shock, fire and/or serious injury.
b) Operations such as polishing, wire brushing or
abrasive cutting-off are not recommended to be
performed with this power tool.
Operations for which the power tool was not designed
may create a hazard and cause personal injury.
c) Do not use accessories which are not specifically
designed and recommended by the tool
manufacturer.
Just because the accessory can be attached to
your power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least
equal to the maximum speed marked on the power
tool.
Accessories running faster than their rated speed
can break and fly apart.
e) The outside diameter and the thickness of your
accessory must be within the capacity rating of
your power tool.
Incorrectly sized accessories cannot be adequately
guarded or controlled.
f) The arbour size of wheels, flanges, backing pads
or any other accessory must properly fit the spindle
of the power tool.
Accessories with arbour holes that do not match
the mounting hardware of the power tool will run
out of balance, vibrate excessively and may cause
loss of control.
g) Do not use a damaged accessory. Before each use
inspect the accessory such as abrasive wheels for
chips and cracks, backing pad for cracks, tear or
excess wear, wire brush for loose or cracked wires.
If power tool or accessory is dropped, inspect for
damage or install an undamaged accessory. After
inspecting and installing an accessory, position
yourself and bystanders away from the plane of
the rotating accessory and run the power tool at
maximum no-load speed for one minute.
Damaged accessories will normally break apart
during this test time.
h) Wear personal protective equipment. Depending on
application, use face shield, safety goggles or safety
glasses. As appropriate, wear dust mask, hearing
protectors, gloves and workshop apron capable of
stopping small abrasive or workpiece fragments.
The eye protection must be capable of stopping
flying debris generated by various operations. The
dust mask or respirator must be capable of filtrating
particles generated by your operation. Prolonged
exposure to high intensity noise may cause hearing
loss.
i) Keep bystanders a safe distance away from work
area. Anyone entering the work area must wear
personal protective equipment.
Fragments of workpiece or of a broken accessory
may fly away and cause injury beyond immediate
area of operation.
j) Hold power tool by insulated gripping surfaces
only, when performing an operation where the
cutting accessory may contact hidden wiring or its
own cord.
Cutting accessory contacting a”live” wire may make
exposed metal parts of the power tool “live” and
shock the operator.
k) Position the cord clear of the spinning accessory.
If you lose control, the cord may be cut or snagged
and your hand or arm may be pulled into the
spinning accessory.
l) Never lay the power tool down until the accessory
has come to a complete stop.
The spinning accessory may grab the surface and
pull the power tool out of your control.
m) Do not run the power tool while carrying it at your
side.
Accidental contact with the spinning accessory
could snag your clothing, pulling the accessory
into your body.
n) Regularly clean the power tool’s air vents.
The motor’s fan will draw the dust inside the
housing and excessive accumulation of powdered
metal may cause electrical hazards.
o) Do not operate the power tool near flammable
materials.
Sparks could ignite these materials.
p) Do not use accessories that require liquid coolants.
Using water or other liquid coolants may result
in electrocution or shock.
KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged
rotatingwheel,backingpad,brushoranyotheraccessory.
Pinching or snagging causes rapid stalling of the rotating
accessory which in turn causes the uncontrolled power
tooltobeforcedinthedirectionoppositeoftheaccessory’s
rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched
by the workpiece, the edge of the wheel that is entering
into the pinch point can dig into the surface of the material
causing the wheel to climb out or kick out. The wheel may
either jump toward or away from the operator, depending
on direction of the wheel’s movement at the point of
pinching. Abrasive wheels may also break under these
conditions.
Kickbackis theresultofpower tool misuseand/orincorrect
operating procedures or conditions and can be avoided
by taking proper precautions as given below.
a) Maintain a firm grip on the power tool and position
your body and arm to allow you to resist kickback
forces. Always use auxiliary handle, if provided, for
maximum control over kickback or torque reaction
during start-up.
The operator can control torque reactions or
kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory.
Accessory may kickback over your hand.
c) Do not position your body in the area where power
tool will move if kickback occurs.
Kickback will propel the tool in direction opposite
to the wheel’s movement at the point of snagging.
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d) Use special care when working corners, sharp edges
etc. Avoid bouncing and snagging the accessory.
Corners, sharp edges or bouncing have a tendency
to snag the rotating accessory and cause loss of
control or kickback.
e) Do not attach a saw chain woodcarving blade or
toothed saw blade.
Such blades create frequent kickback and loss of
control.
SAFETY WARNINGS SPECIFIC FOR
GRINDING OPERATION
a) Use only wheel types that are recommended for
your power tool and the specific guard designed
for the selected wheel.
Wheels for which the power tool was not designed
cannot be adequately guarded and are unsafe.
b) The guard must be securely attached to the power
tool and positioned for maximum safety, so the
least amount of wheel is exposed towards the
operator.
The guard helps to protect operator from broken
wheel fragments and accidental contact with wheel.
c) Wheels must be used only for recommended
applications. For example: do not grind with the
side of cut-off wheel.
Abrasive cut-off wheels are intended for peripheral
grinding, side forces applied to these wheels may
cause them to shatter.
d) Always use undamaged wheel flanges that are of
correct size and shape for your selected wheel.
Proper wheel flanges support the wheel thus
reducing the possibility of wheel breakage. Flanges
for cut-off wheels may be different from grinding
wheel flanges.
e) Do not use worn down wheels from larger power
tools.
Wheel intended for larger power tool is not suitable
for the higher speed of a smaller tool and may
burst.
SAFETY WARNINGS SPECIFIC FOR SANDING
OPERATIONS
a) Do not use excessively oversized sanding disc paper.
Follow manufacturers recommendations, when
selecting sanding paper.
Larger sanding paper extending beyond the sanding
pad presents laceration hazard and may cause
snagging, tearing of the disc or kickback.
PRECAUTIONS ON USING DISC GRINDER
1. Never operate these power tools without Wheel
Guards.
2. Use only a depressed center wheel of permissible
peripheral speed 72 m/s (4300 m/min) or more.
3. Correct use for safe operation.
4. Mounting the standard depressed center wheel.
5. Have a trial run before grinding commence.
6. Keep away from a revolving depressed center
wheel.
7. Pay strict attention to sparks.
8. Do not leave the revolving Grinder unattended on
the floor.
9. Follow the procedures of these Handling Instructions
on depressed center wheel replacement.
10. Avoid overload operation.
11. Do not push in the lock pin while the spindle is
running.
12. Be careful those around one while operating.
SPECIFICATIONS
Model
Voltage (by areas)*1
Power Input*1
Rated Speed
Wheel size
external dia.
thickness
hole dia.
Weight*2
G10ST
(110V, 220V, 230V, 240V) 50/60 Hz
720 W
12,000/min
Max. Peripheral Speed: 72 m/s (4300 m/min)
100 mm
4 mm, 6 mm
16 mm
1.5 kg
*1Be sure to check the nameplate on product as it is subject to change by areas.
*2Only main body.
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STANDARD ACCESSORIES
(1) Depressed center wheel ............................................1
(Resinoid Wheel)
external dia. 100 mm
thickness 4 mm
hole dia. 16 mm
(2) Wrench ........................................................................1
Standardaccessoriesaresubject tochangewithoutnotice.
OPTIONAL ACCESSORIES ...... sold separately
CAUTION:
Always operate the grinder with the wheel guard
attached.
1. 100mm Sanding Disc Set
In case when only a relatively small metal surface
area is to be polished and it is desired to give it
a particularly fine finish, this is used for preliminary
polishing of the metal surface before applying point,
for removing rust, and for removing point when a
new test is to be applied.
There are eleven different kinds of sanding discs,
having grains of #16, #20, #24, #30, #36, #40, #50,
#60, #80, #100, #120. When placing your order,
please specify the grain of the disc desired.
APPLICATIONS
䡬Removal of casting fin and finishing of various
types of steel, bronze and aluminum materials and
castings.
䡬Grinding of welded sections or sections cut by
means of a cutting torch.
䡬Grinding of brick, marble, etc.
PRIOR TO OPERATION
1. Power source
Ensure that the power source to be utilized con-
forms to the power requirements specified on the
product nameplate.
CAUTION:
Do not operate from a direct current power source.
Doing so may not only cause damage to the grinder,
but may lead to accidents.
2. Power switch
Ensure that the power switch is in the OFF position.
If the plug is connected to a receptacle while the
power switch is in the ON position, the power tool
will start operating immediately, which could cause
a serious accident.
Switch position is indicated as I-mark on Tail Cover
stands for ON position and O-mark stands for OFF
position respectively.
3. Extension cord
When the work area is removed from the power
source, use an extension cord of sufficient thickness
and rated capacity. The extension cord should be
kept as short as practicable.
4. Confirming condition of the environment
Confirm that the work site is placed under appro-
priate conditions conforming to prescribed
precautions.
When grinding a thin steel plate, depending upon
the state of the workbench, a loud noise will be
created due to resounding noise from the steel
plate being ground. To eliminate nuwanted noise
in this instance, place a rubber mat beneath the
material to be ground.
5. Mounting the wheel guard
Be sure to mount the wheel guard at an angle that
will protect the operator’s body from injury by a
broken wheel piece.
6. Confirm the lock pin
Confirm that the lock pin is disengaged by pushing
lock pin two or three times before switching the
power tool on.
7. Confirming and mounting the depressed center
wheel.
Throughly check that a specified depressed center
wheel is free of cracks and splits is mounted.
Confirm that the depressed center wheel is mounted
under the specified condition and is firmly clamped.
For details, refer to the item “Assembling and Dis-
assembling the depressed center wheel.”
8. Apply a trial run
To start grinding work without checking for possible
cracks and splits in the depressed center wheel is
very dangerous. Prior to start of grinding, direct the
grinder in a direction where no one is present, and
apply a trial run without fail to confirm that the
grinder displays no abnormalities.
Duration of the trial run is as follows:
When depressed center wheels is replaced
................................................ 3 minutes or more
When starting daily work...... 1 minute or more
PRACTICAL GRINDER APPLICATIONS
1. Since grinding by utilizing only the grinder’s own
weight is feasible, the grinder should never be
pressed forcibly against the plane to be ground
Hold the grinder lightly so that it only slightly
contacts the plane to be ground.
Heavy pressure will reduce the revolving speed and
such deteriorate the finished surface, and phenom-
ena as overload will lead to burning out of the
motor.
2. Do not utilize the grinder entire surface when grinding.
Use only its peripheral surface by tilting the wheel
at an angle of 15~30°, as shown in Fig. 1.
3. When a grinder equipped with a new depressed
center wheel is pushed forward (direction A), the
wheel edge may occasionally cut into the material
to be ground. Always pull it backward (direction B)
in this instance.
However, once the depressed center wheel angle
has been adequately abraded, both forward and
backward operations are permissible.
Washer Nut
Sanding DiscRubber Pad
Washer
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4. The provided depressed center wheel (resinoid
wheel) is rated as Class A grain and #36 grain size.
Accordingly, its range of applications cover a wide
variety, proving to be most suitable for heavy
grinding of general steel materials. Since the wheel
grain size is rather coarse, creating a fine-surfaced
finish is very difficult.
In this instance, hold the grinder lightly as through
trying to lift it, and apply grinding slowly at a
constant low speed. Whereby a fine finish similar
to that accomplished with a fine-grain depressed
center wheel is obtainable.
5. Switching on the grinder
The switch can be turned ON by turning its lever
-mark side, or turn OFF by turning its lever to the
O-mark side.
6. Precaution after use
Do not lay the grinder down immediately after use
in a place where there are many shavings and much
dirt and dust until it has completely stopped
revolving.
CAUTIONS:
䡬Shock to the main body can be the cause of cracks
or splits in the depressed center wheel. Be espe-
cially careful to avoid sudden shocks when using
the equipment.
If the main unit is accidentally bumped or dropped,
make a careful check for cracks or splits on the
depressed center wheel before further use.
䡬Do not press the lock pin when the equipment is
turning. Also, do not turn on the switch when the
lock pin is pressed down.
ASSEMBLING AND DISASSEMBLING
THE DEPRESSED CENTER WHEEL (Fig. 2)
CAUTION:
Be sure to switch power OFF and disconnect the
attachment plug from the power receptacle to avoid
serious trouble.
(1) Turn the equipment upsidedown so that the spindle
will be facing up.
(2) Mount the wheel washer onto the spindle.
(3) Mount the protuberance of the depressed center
wheel onto the wheel washer.
(4) Mount the convex side of the wheel nut onto the
depressed center wheel, and screw the wheel nut
onto the spindle.
(5) As shown in Fig. 2 push in the lock pin to prevent
rotation of the spindle. Then, secure the depressed
center wheel by tightening the wheel nut with the
wrench.
CAUTION: Confirm that the depressed center wheel
is mounted firmly.
Confirm that the lock pin is disengaged by
pushing lock pin two or three times before
switching the power tool on.
䡬Disassembling of the depressed center wheel is the
reverse of assembling.
HOW TO INSTALL THE OPTIONAL
ACCESSORIES
CAUTIONS:
䡬Be sure to switch power OFF and disconnect the
plug from the power receptacle to avoid serious
trouble. When utilizing the optional accessories,
keep the wheel guard attached and wear protective
glasses.
䡬Do not use the optional accessories which exceed
the designated external diameter designated in the
paragraph.
1. Mounting the 100mm Sanding Disc. (see Fig. 3)
NOTE:
Do not use the wheel washer and wheel nut of the
depressed center wheel.
(1) Mount the washer, rubber pad and sanding disc
onto the spindle.
(2) Screw from the washer nut onto the spindle.
(3) As shown in Fig. 3, push in the lock pin to prevent
rotation of the spindle. Then, secure the sanding
disc by tightening the wheel nut with the wrench.
MAINTENANCE AND INSPECTION
1. Inspecting the depressed center wheel
Ensure that the depressed center wheel is free of
cracks and surface defects.
Replace the depressed center wheel when it has
been worn out to about 60mm in external diameter.
2. Inspecting the mounting screws:
Regularly inspect all mounting screws and ensure
that they are properly tightened. Should any of the
screws be loose, retighten them immediately. Fail-
ure to do so could result in serious hazard.
3. Maintenance of the motor
The motor unit winding is the very “heart” of the
power tool. Exercise due care to ensure the winding
does not become damaged and/or wet with oil or
water.
4. Inspecting the carbon brushes (Fig. 4)
The motor employs carbon brushes which are
consumable parts. Since an excessively worn car-
bon brush can result in motor trouble, replace the
carbon brush with a new one having the same
carbon brush No. shown in the figure when it
becomes worn to or near the “wear limit”. In
addition, always keep carbon brushes clean and
ensure that they slide freely within the brush holders.
5. Replacing carbon brushes:
Disassemble the brush caps with a slotted-head
screwdriver. The carbon brushes can then be easily
removed.
6. If the supply cord of this tool damaged, it must be
replaced by a specially prepared cord available
through the service organization.
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7. Service parts list
CAUTION
Repair, modification and inspection of HiKOKI Power
Tools must be carried out by a HiKOKI Authorized
Service Center.
This Parts List will be helpful if presented with the
tool to the HiKOKI Authorized Service Center when
requesting repair or other maintenance.
In the operation and maintenance of power tools,
the safety regulations and standards prescribed in
each country must be observed.
MODIFICATIONS
HiKOKI Power Tools are constantly being improved
and modified to incorporate the latest technological
advancements.
Accordingly, some parts may be changed without
prior notice.
NOTE
Due to HiKOKI’s continuing program of research and
development, the specifications herein are subject to
change without prior notice.
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Item
No. Part Name Q'TY
1TAPPING SCREW D5 ×25 4
2GEAR COVER ASS'Y 1
3
RETAINING RING FOR D11 SHAFT
1
4WAVE WASHER 1
5LOCK PIN 1
6SLOTTED HD. SCREW
(SEAL LOCK) M4 ×8 2
7BALL BEARING 6201VVCMPS2L 1
8FELT PACKING 1
9PACKING GLAND 1
10 SEAL LOCK SCREW
(W/SP. WASHER) M4 ×12 4
11 WOODRUFF KEY 1
12 SPINDLE 1
13 FRINGER 1
14 MACHINE SCREW
(W/SP. WASHER) M5 ×16 2
15 SET PLATE 1
16 WHEEL GUARD ASS'Y 1
17 WHEEL WASHER 1
18 D. C. WHEELS 100MM 1
19 WHEEL NUT(C) 1
20 PUSHING BUTTON 1
21 SPECIAL NUT M7 1
22 GEAR AND PINION SET 1
23 BALL BEARING 608VVC2PS2L 1
24 BEARING HOLDER 1
25 ARMATURE 1
26 FAN GUIDE 1
27 TAPPING SCREW D4 ×70 2
28 STATOR 1
29 DUST SEAL 1
30 BALL BEARING 626VVC2PS2L 1
31 RUBBER BUSHING 1
32 HOUSING ASS'Y 1
33 NAME PLATE 1
34 TAIL COVER (A) 1
35 TAPPING SCREW
(W/FLANGE) D4 ×45 1
36 TAPPING SCREW
(W/FLANGE) D4 ×20 1
37 BRUSH CAP 2
38 CARBON BRUSH 2
39 BRUSH HOLDER 2
40 PILLAR TERMINAL 1
Item
No. Part Name Q'TY
41 CONNECTOR 50091 1
42 TERMINAL 1
43 EARTH TERMINAL 1
44 TERMINAL 1
45 NOISE SUPPRESSOR 1
46 TAIL COVER(B) 1
47 TAPPING SCREW
(W/FLANGE) D4 ×25 1
48 MACHINE SCREW
(W/WASHER) M3.5 ×6 2
49 SWITCH 1
50 CORD 1
501 WRENCH 1
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Hitachi Koki Co.,Ltd.
服务中心
工机商业 (中国) 有限公司
上海市闵行区浦江工业园区三鲁路3585号7幢3楼
制造商
高壹工机（马来西亚）有限公司
马来西亚柔佛州士乃第二工业区
806
Code No. C99195025 M
Printed in Malaysia
03BackG10STChS.indd34 2017/04/1710:05:01