Hitachi DC 120VA Manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
DIAMOND CORE DRILL
DC 120VA
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. 0192 Jun. 2000
D
MODEL
DC 120VA

Page
CONTENTS
[ Business Section ]
1. PRODUCT NAME ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
2. MARKETING OBJECTIVE ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
1
3. APPLICATIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
1
4. SELLING POINTS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
2
4-1. Selling Point Descriptions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3
5. SPECIFICATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
6
5-1. Main Specifications ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
5-2. Optional Accessories ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
6. COMPARISONS WITH SIMILAR PRODUCTS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
8
6-1. Specification Comparisons •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8
7. PRECAUTIONS IN SALES PROMOTION ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
9
7-1. Safety Precautions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
8. PRECAUTIONS IN USAGE ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10
8-1. Drilling with Diamond Core Bits ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10
[ Service Section ]
9. PRECAUTIONS IN DISASSEMBLYAND REASSEMBLY••••••••••••••••••••••••••••••••••••••••••••••••••••••••12
9-1. Disassembly •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12
9-2. Reassembly ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14
9-3. Lubrication ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
9-4. Tightening Torque ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
9-5. Internal Wiring •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
10. CONFIRMATION AFTER REASSEMBLY•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••17
10-1. Insulation Tests •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••17
10-2. No-Load Current Value ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••17
11. STANDARD REPAIR TIME (UNIT) SCHEDULES ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
18
[ Appendix ]
Assembly Diagram for DC 120VA••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 19
Notice for use
Specifications and parts are subject to change for improvement.
Refer to Hitachi Power Tool Technical News for further information.

--- 1 ---
1. PRODUCT NAME
Hitachi Diamond Core Drill (with slip clutch function), Model DC 120VA
2. MARKETING OBJECTIVE
The diamond core drill market is showing growth due to increase of demands for reform applications and
comfortable operation (low noise and vibration). Especially, a core drill capable of drilling various types of
materials efficiently is demanded.
To meet such demand, the Model DC 120VA was developed as an advanced version of the current dry-type
Model DC 120V in efficiency and operability. The key features are as follows:
(1) 1400 W high-power motor for fast drilling (110 V product: 1250 W)
(2) Various drilling applications thanks to the speed control system with 2-speed transmission, dial-type stepless
variable speed control and constant speed control
(3) High slip torque mechanism for powerful drilling
(4) Synchronized gear shift mechanism for easy speed switching
(5) Easy-to-use rotary type side handle
(6) Vibration-isolating handle for reduced operator fatigue
3. APPLICATIONS
The Model DC 120VA can drill various workpieces using the appropriate bit or accessory tool.
Diamond core bit
(Hitachi)
Tool Capacity
Hole saw for metal
(Commercial)
Hole saw for wood
(Commercial)
Drill bit for steel
(Hitachi)
Drill bit for wood
(Hitachi)
27 mm to 120 mm
(available in 10 sizes)
Up to 60 mm
Up to 120 mm
Up to 13 mm
Up to 30 mm
Workpiece
Reinforced concrete
Brick
Mortar
Slate
Autoclaved lightweight concrete External wall material
Gypsum board
Wood
Chloroethylene material
Fiber reinforced plastic
Steel
Stainless
<Typical applications>
Air conditioning •••••••••••••••••••••• Installation of air conditioners and water coolers
Piping and wiring ••••••••••••••••••• Electric, gas and water supply work
Electrical fixtures ••••••••••••••••••• Installation of electrical fixtures
Reinforcing •••••••••••••••••••••••••••• Anchoring
Residencial facilities ••••••••••••••• Construction of terrace, garage, etc.

--- 2 ---
4. SELLING POINTS
Various drilling applications, thanks to the speed control
system with 2-speed transmission and variable 5-speed dial
Fast drilling with 1400 W high-power motor
(110 V product: 1250 W)
* Shown with an optional core bit.
Vibration-isolating handle
reduces operator fatigue
Synchronized gear shift mechanism
for easy speed switching
Stable gripping and
powerful drilling
thanks to
long side handle
and high slip torque
mechanism

--- 3 ---
4-1. Selling Point Descriptions
4-1-1. Powerful motor with a power input of 1400 W
Although the motor has the same dimensions as the Model DC 120V, the motor of the Model DC 120VA is more
powerful thanks to the larger-diameter motor coil.
4-1-2. Faster drilling speed
The Model DC 120VA can drill holes in various materials using diamond core bits of up to 120 mm in diameter
which are generally used for hand-held drills, or tools (hole saws) corresponding to specific materials, thanks to
the optimum design. The drilling speed is about 30 % faster than the Model DC 120V and equivalent to C.
Drilling speed comparison of dry-type drills
60
50
40
30
20
10
027 65 120
(Test conditions)
•Power requirements: 230 V, 50 Hz
•Concrete compression strength: 2.5 x 10
5
MPa
•Test material: Concrete reinforced with 10-mm diameter bars (drilling depth 150 mm)
•Orientation: Horizontal drilling
(Hitachi) DC 120VA
(Hitachi) DC 120V
C
Drilling speed (mm/min.)
Core bit diameter (mm)
* Drilling performance varies depending on the operating conditions such as strength of concrete, diameter and
number of reinforcing bars. The test results shown above should be used as a reference only.

--- 4 ---
4-1-3. High slip torque mechanism for powerful drilling
The table below shows the factory test results on slip-mechanism life cycles. The Model DC 120VA is superior to
the Model DC 120V and C.
Test conditions: Repeated cycle of 2 seconds slip and 13 seconds rest.
40
30
20
10
001000 2000 3000 4000 5000 6000
(34 N
•
m)
(27 N
•
m)
(18 N
•
m)
(22 N
•
m)
(16 N
•
m)
(Test conditions)
•
Repeated cycle of 2 seconds slip and 13 seconds rest.
(Hitachi) DC 120VA
(Hitachi) DC 120V
C
Slip torque (N
•
m)
Slip life (cycles)
<Slip clutch mechanism>
DC 120VA: A claw clutch, which is the same as that of the Model DC 120V, is provided to increase the
service life.
C: A friction-plate clutch with a belleville spring, which is the same as that of 6300T, is provided.
4-1-4. Synchronized gear shift mechanism for easy speed switching
A synchronized gear shift mechanism is provided to permit automatic shifting between the low- and high-speed
ranges just by turning the shift lever. This eliminates the need to turn the drill chuck by hand while making the
changeover.
Model
Hitachi DC 120VA
Hitachi DC 120V
C
Slip torque after testing
2.2 kgf-m after 5000 cycles
1.6 kgf-m after 5000 cycles
0.8 kgf-m after 500 cycles
Influence on operation
No problem
No problem but slipped frequently
Drilling impossible
Model
Hitachi DC 120VA
Hitachi DC 120V
C
Synchronized gear shift mechanism
Provided
2-speed transmission is not provided
Not provided

--- 5 ---
4-1-5. Constant speed electronic control with stepless variable speed for stable drilling efficiency
The Model DC 120VA contains an electronic control circuit which allows the number of revolutions to be steplessly
adjustable on the dial. The number of revolutions in the low-speed range is from 400 min-1 to 1,000 min-1, and the
high-speed range from 800 min-1 to 2,000 min-1. The constant speed control minimizes the change in the number
of revolutions even if the load fluctuates, thus providing ease of use and increased service life of drill bits. The
graph below shows the relationship between load and speed.
2000
1500
1000
0068101214
Dial No. E
Dial No. D
Dial No. C
Dial No. B
Dial No. A
Load current (A)
Number of revolutions
of high-speed gear (min-1)
4-1-6. Easy-to-use rotary type side handle
For ease of operation, the side handle can be secured in any position over 360˚in increments of 45˚to suit the
operating position.
4-1-7. Vibration-isolating handle reduces operator fatigue
For safety, the handle and the housing are rubber-isolated to reduce vibrations transmitted to the operator's hand.
4-1-8. Unique body design
The ergonomically designed, unique styling ensures excellent operability.

--- 6 ---
5. SPECIFICATIONS
5-1. Main Specifications
* Drilling may not be possible with some very hard brick and block materials.
Capacity (with dry-type
diamond core bit)
Type of motor
Brick, block *
Single-phase series commutator motor
Mild steel
Wood
152 mm (5 --- 63/64")
13 mm (1/2")
30 mm (1 --- 1/8")
Drill chuck Capacity 1.2 mm (0.047") --- 13 mm (1/2")
100 V ••••••• 12 A
230 V ••••••• 6.4 A
240 V ••••••• 6.2 A
Power source
Enclosure Housing, handle ••••••••••••••••• Nylon resin
Inner cover, gear cover ••••••• Aluminum alloy die casting
Type of switch Trigger switch with stopper
Type of handle D-type handle
Full-load current 100 V ••••••• 12 A
230 V ••••••• 6.4 A
240 V ••••••• 6.2 A
Power consumption 100 V ••••••• 1250 W
230 V ••••••• 1400 W
240 V ••••••• 1400 W
Rotation speed No-load: Low speed gear 400 --- 1000 /min.
No-load: High speed gear 800 --- 2000 /min.
Full-load: Low speed gear 400 --- 860 /min.
Full-load: High speed gear 800 --- 1920 /min.
Full-load output 380 W
Weight 4.0 kg (without cord and side handle) (8.8 lbs.)
Packaging Corrugated cardboard box
Weight after packaging 5.2 kg (11.4 lbs.)
Cord Type: 2-core cabtire cord
Nominal sectional area: 0.75 mm2
Length: 2.5 m (8.3 ft.)
Standard accessories Chuck wrench ••••••• 1
Side handle •••••••••• 1

--- 7 ---
5-2. Optional Accessories
(1) Diamond core bits
Dia. bit
22 mm (7/8")
28 mm (1-7/64")
38 mm (1-1/2")
48 mm (1-57/64")
52 mm (2-3/64")
65 mm (2-9/16")
78 mm (2-1/16")
91 mm (3-37/64")
107 mm (4-7/32")
117 mm (4-39/64")
127 mm (5")
152 mm (64/64")
300 mm (11 --- 11/16")
Length
150 mm (5 --- 29/32")
(2) Adapter packs & extension rods
•Adapter pack Adapter for dia. 38 --- 152 mm (1-1/2 " --- 6 ")
core bits
Pilot spigot
Ejector drift
•Extension rod (length 250 mm (9-27/32 "))
(3) Dust extraction range
•Dust sucker - Large
•Dust sucker - Small

--- 8 ---
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons
Brick, block
Mild steel
Wood
Diameter
Diameter
Diameter
mm
mm
mm
V
A
W
min-1
kg
min-1
A
min-1
kg-m
W
kg-m
kg-m
dB
Voltage
Current
Power consumption
No-load rotation speed
Weight (without cord)
Characteristics
of motor
(measured
values)
No-load rotation
speed
Full-load current
Full-load rotation
speed
Full-load torque
Maximum output
Locked torque
Slip torque
Insulation structure
Full-load noise level
Standard accessories
Values listed on catalogs
Item Maker, Model HITACHI
DC 120VA C HITACHI DC 120
152 (5-63/64")
13 (1/2")
30 (1-1/2")
230/50 Hz
6.4
1400
Low-speed) 400 --- 1000
High-speed) 800 --- 2000
Low-speed) 400 --- 1020
High-speed) 760 --- 1920
Low-speed) 450 --- 1050
High-speed) 850 --- 2000
6.4
4.0 (8.8 lbs.)
(Low-speed) 4
(High-speed) 2
1560
(Low-speed) 70
(High-speed) 35
34
Double insulation
86
Chuck wrench
•••••••1
Side handle
•••••••1
152 (5-63/64")
13 (1/2")
30 (1-1/2")
230/50 Hz
6.4
1400
Low-speed) 900 --- 2000
High-speed) 1800 --- 4000
4.2 (9.2 lbs.)
Low-speed) 900 --- 2000
High-speed) 1800 --- 4000
Low-speed) 900 --- 1600
High-speed) 1700 --- 3200
(Low-speed) 3
(High-speed) 1.5
1560
(Low-speed) 46
(High-speed) 23
18
Double insulation
88
Chuck wrench •••••1
Side handle •••••••1
Rubber gloves
•••••••1 pair
152 (5-63/64")
13 (1/2")
30 (1-1/2")
230/50 Hz
4.0
900
600 --- 1400
3.1 (6.8 lbs.)
580 --- 1410
4.0
890
5.3
1090
60
27
Double insulation
88
Chuck wrench •••••1
Side handle ••••••••1
Plastic case ••••••••1
Capacity

--- 9 ---
7. PRECAUTIONS IN SALES PROMOTION
7-1. Safety Precautions
In the interest of promoting the safest and most efficient use of the Models DC 120VA Diamond Core Drill 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 caution plate attached to each tool.
(1) 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 Diamond Core Drill are listed in the Handling Instructions to enhance the
safe, efficient use of the tool by the customer. Salespersons should ensure that the customer thoroughly
reads and understands these precautions, with particular attention to the following.
1 Check the power source voltage:
Ensure that the power source voltage conforms with the power specifications listed on the nameplate.
(2) Cautions on nameplate:
1 Each tool is provided with a nameplate which lists the following basic safety precautions in the use of the
tool.
For Europe
For France
TRES IMPORTANT: Lire avec attention la notice
d'utilisation.
ACHTUNG
Bedienungsanleitung vor Inbetriebnahme lesen.
CAUTION
Read thoroughly HANDLING INSTRUCTIONS before use.
For Germany

--- 10 ---
8. PRECAUTIONS IN USAGE
8-1. Drilling with Diamond Core Bits
(1) Ensure that the Side Handle is firmly secured before
attempting to operate the tool. The side handle is
separated from the main body of the tool when it is shipped
from the factory. Carefully instruct the customer to loosen
the grip portion of the side handle by turning it as shown in
the right figure, install it on the gear cover portion, and fix it
securely in the desired position before operating the tool.
(2) Diamond core bits:
Diamond core bits applicable to the Model DC 120VA and DC 120V are dry-type diamond core bits for drilling
brick, concrete block and similar materials. Instruct the customer not to apply water during the drilling
operation. In addition, the customer should be advised that drilling may not be possible in bricks and blocks
which are particularly high in hardness and density.
(3) Rotation speed during drilling:
If you exceed the standard values (optimum speed of rotation) given in Table 1 in the Handling Instructions or
engage in continued work for an extended period of time or perform a drilling job on soft materials, the motor
may be subjected to an unreasonable load and may result in burnout. Especially, avoid any abnormal use
where the drill stops during the drilling work. Adjust the number of rotations so that a smooth drilling job can
be done at all times. Make absolutely certain that you never use any tool or bit beyond its maximum capacity
as otherwise the service life of the main unit may be extremely shortened.
Table 1
Side handle
Grip
Gear cover
Dial
1
[Low speed gear] 2 [High speed gear]
ABCDEABCDE
450 600 770 940 1050 850 1100 1400 1700 2000
No load
speed
(min-1)
Drill diameters
Shift lever indication
Materials to be drilled Types of drills
Brick, block
Autoclaved lightweight
concrete t3.0
Steel
SPCC t3.0
Stainless steel
t1.6
Wood
t50
Steel SPCC t3.0
Wood t50
Diamond
core bit
Hole saw
Hole saw
Hole saw
Hole saw
Drill
Drill
27
65
152
27
65
120
15
55
15
55
27
65
120
13
30
: Standard values (optimum speed of rotation)

--- 11 ---
(4) Pressure:
Drilling will NOT be accelerated by placing heavy pressure on the drill. Such action will only result in a
damaged drill bit, decreased drilling efficiency, and/or shortened service life of the drill.
(5) When drilling completely through the material:
When the drill bit bores completely through the material, careless handling often results in broken drill bit or
damage to the drill body itself due to the sudden movement of the drill.
Always be alert and ready to release pushing force when drilling through the material.

--- 12 ---
9. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY
The [Bold] numbers in the descriptions below correspond to the item numbers in the Parts List and exploded
assembly diagram.
9-1. Disassembly
9-1-1. Handle cover section and carbon brush
(1) Loosen the Tapping Screw (W/Flange) D4 x 20 [48] and remove Handle (B) [49].
(2) Remove the Tapping Screw (W/Flange) D4 x 20 [48] from the Cord Clip [56] and remove the Cord [59]
together with the Cord Armor [57].
(3) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52] on the Switch [53] and remove the Noise Suppressor
[54].
(4) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52] on the Switch [53] and remove the internal wire with
terminal. Remove the Switch [53].
(5) Remove the Carbon Caps [36] with a flat-blade screwdriver to remove the Carbon Brushes [37].
9-1-2. Armature and stator ass'y
(1) Loosen the Tapping Screw (W/SP. Washer) D5 x 55 [8] on the Gear Cover [9] and remove the gear cover
section from the Inner Cover Ass'y [13]. Remove the Armature [28] together with the Inner Cover Ass'y [13]
from the Housing Ass'y [35].
(2) Remove the Armature [28] from the Inner Cover Ass'y
[13]. Place the Inner Cover Ass'y [13] on a cylindrical
jig and press down on the pinion of the Armature [28]
as shown in Fig. 1.
(3) Loosen the Machine Screw (W/Washer) M3.5 x 6 [52]
on the trigger switch and the Tapping Screw (W/SP.
Washer) D5 x 55 [8]. Disconnect the internal wire from
the Brush Terminal [32] and the Controller [51]. Tap the
end surface of the housing with a wooden or plastic
hammer lightly to remove the Stator Ass'y [31].
9-1-3. Drill chuck
The Drill Chuck 13WLR (W/Screw) [3] contacts the Nut
[4] fixed on the spindle and is secured with a UN5/8-16
right-handed screw. Put a 17-mm wrench on the Nut
[4] and insert the chuck wrench in the wrench hole of
the Drill Chuck 13WLR (W/Screw) [3] as shown in Fig.
2. Lightly tap the tip of the chuck wrench with a wooden
or plastic hammer so that it turns counterclockwise
viewing from the drill chuck side. Turn the loose Drill
Chuck 13WLR (W/Screw) [3] and remove it.
Fig. 1
Fig. 2
Pinion Press
down Inner cover ass'y
Armature
Chuck wrench
Wrench

--- 13 ---
9-1-4. Nut
The Nut [4] is secured to Spindle (B) Ass'y [20] with a
UN5/8-16 right-handed screw. Insert a metal bar of 3 mm
or less diameter in the air vent and fix it. Put a 21-mm
wrench on the Nut [4] and turn it to remove the Nut [4].
9-1-5. Spindle (B) ass'y and others
(1) After removal of the Nut [4], press down on the tip of Spindle (B) Ass'y [20] with a hand press as shown in
Fig. 4. Then Spindle (B) Ass'y [20] can be removed from the Gear Cover [9].
(2) Remove the Retaining Ring for D35 Hole [5]. Then the Dust Seal [6] can be removed. Lightly tap the tip of
the Gear Cover [9] with a wooden hammer to remove the Ball Bearing 6003VVCMPS2L [7].
(3) Support the Clutch [19] on a cylindrical jig and press down on the end surface of the Spindle (B) Ass'y [20]
with a hand press as shown in Fig. 5. Then Sleeve [17] can be removed from Spindle (B)Ass'y [20] together
with the Spring [18].
Wrench Chuck wrench
Fig. 4 Fig. 5
Retaining Ring
for D35 Hole [5]
Ball Bearing
6003VVCMPS2L [7]
Press
down
Spindle (B) Ass'y [20]
Dust Seal [6]
Gear Cover [9]
Spindle (B)
Ass'y [20]
Press
down
Clutch [19]
Sleeve [17]
Spring [18]
27 mm or more
diameter

--- 14 ---
9-2. Reassembly
Perform reassembly in the reverse order of disassembly while observing the given precautions and taking care of
the following points.
9-2-1. Internal wire arrangement
Arrange the internal wires as shown in Fig. 6. Be careful not to catch the internal wires when mounting the
handle.
Do not pinch the internal wires under the switch.
Switch
Noise suppressor
Magnet pick
up case
Air vent of handle
Put the internal wires under the controller.
Controller
Volume ass'y
Fig. 6
<CAUTION>
•Insert the Controller [51] so that its uneven surface faces toward the air vent of the handle.
•Do not apply excessive force when closing the cover of the handle. Otherwise, the "volume" (variable-speed
dial) can be damaged.

--- 15 ---
9-2-2. Reassembly of the gear cover section
Fig. 7 shows the assembly drawing. Reassemble the gear cover section according to the following figure.
Spring (A)
High Speed Gear
Shift Spring
Washer (A)
Second Pinion
First Gear
Metal (A)
Steel Ball D3.97
Plate
Clutch
Ball Bearing 6003VVCMPS2L
Clutch Disc
Shift Lever
I nsert the 4 mm diameter protrusion
into the groove of the clutch disc.
Low Speed Gear
Spring (A)
Metal (B)
Spring
Sleeve
Dust Seal
Nut Spindle (B) Ass'y
Fig. 7
<CAUTION>
Mounting directions of the High Speed Gear [25] and the Low Speed Gear [23] are specified. Mount these parts
in the specified direction as shown in the above figure.

--- 16 ---
9-3. Lubrication
(1) Apply DOUBREX 251 grease to the following parts.
•Each gear: tooth portion
•Spindle (B) Ass'y [20] (including [17], [18] and [19])
•Clutch Disc [24]: entirely
•Shift Lever [15]: 19 mm dia. outer circumference portion and 4 mm dia. convex portion
•Spindle (A) [21]: claw portion and 10 mm dia. convex portion
•Second Pinion [11] and first gear: tooth portion
•Inner Cover Ass'y [13] and Gear Cover [9]: metal portion
•Inside the Gear Cover [9]: 70 g
<CAUTION>
Be sure to use only DOUBREX 251 grease for the gear cover and the components in the gear cover. Use of
other grease may cause grease leakage from the tip of the gear cover and the shift lever.
9-4. Tightening Torque
(1) Nut [4] ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 20 --- 30 N•m {200 --- 300 kgf•cm}
(2) Tapping Screw (W/SP. Washer) D5 x 55 (Black) [8] •••••• 2.5 --- 3.5 N•m {25 --- 35 kgf•cm}
(3) Tapping Screw (W/Flange) D4 [47] [48] ••••••••••••••••••••••• 1.5 --- 2.5 N•m {15 --- 25 kgf•cm}
9-5. Internal Wiring
•Wiring diagram
Stator
Stator
Connector
Controller
Noise
Suppressor
SW
Cord
3 4
1 2

--- 17 ---
10. CONFIRMATION AFTER REASSEMBLY
10-1. Insulation Tests
On completion of disassembly and repair, measure the insulation resistance and conduct a dielectric strength test.
Insulation resistance: 7 MΩor more with DC 500V Megohm Tester.
Dielectric strength: AC 4000V/1 minute,
with no abnormalities •••••••••••••••••• 220 V --- 240 V
(and 110V for U.K. products)
AC 2500V/1 minute,
with no abnormalities •••••••••••••••••• 110 V --- 127 V
(except U.K. products)
10-2. No-Load Current Value
110 V ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 A
230 V ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6.4 A
240 V ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6.2 A

--- 18 ---
11. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL 10 20 30 40
Fixed Variable
DC 120VA Work Flow
60 min.
50
Cord
Switch
Controller
Handle (A)
Handle (B)
Housing Ass'y
Stator Ass'y
Gear Cover
Nut
Dust Seal
Ball Bearing
(6003VV)
Sleeve
Spring
Clutch
Spindle (B)
Ass'y
Spindle (A)
Spring (A) x 2
Low Speed
Gear
Clutch Disc
High Speed
Gear
General Assembly Second Pinion
Steel Ball
Ball Bearing
(608VV)
Inner Cover
Ass'y
Armature
Ball Bearing
(609VV)
Dust Seal (A)
Ball Bearing
(608VV)