Hitachi G 10SD2 Manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
DISC GRINDERS
G 10SD2, G 12S2, G 13SD
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST Nos. G 10SD2: E234
G 12S2: E235
G 13SD: E236
Sep. 2001
G
MODEL
G 10SD2, G 12S2,
G 13SD
REVISED

REMARK:
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:
Symbols Utilized
Competitors
Company Name Model Name
BOSCH GWS7-115
B
G 12S2
Symbol Utilized
Competitor
Company Name Model Name
MAKITA 9526NB
C
G 10SD1
Symbol Utilized
Competitor
Company Name Model Name
MAKITA 9528NB
C
G 13SD
MAKITA 9527NB
C

Page
CONTENTS
[ Business Section ]
1. PRODUCT NAME •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
2. MARKETING OBJECTIVE •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
3. APPLICATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
4. SELLING POINTS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
5. SPECIFICATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3
6. COMPARISONS WITH SIMILAR PRODUCTS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
6-1. Specification Comparisons ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
6-2. Comparisons in Torque vs. Rotation Speed and Stator Coil Temperature Rise ••••••••••••••••••••••••••• 7
7. PRECAUTIONS IN SALES PROMOTION ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
7-1. Handling Instructions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
7-2. Caution on Name Plate •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
7-3. Precautions on Usage ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10
8. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
8-1. Disassembly ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
8-2. Reassembly •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
8-3. Lubrication Points and Types of Lubricant ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14
8-4. Tightening Torque •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 14
8-5. Wiring Diagrams •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 15
8-6. Insulation Tests •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
8-7. No-Load Current Value •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
9. STANDARD REPAIR TIME (UNIT) SCHEDULES •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 17
Assembly Diagram for G 10SD2 •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 18
Assembly Diagram for G 12S2 •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 22
Assembly Diagram for G 13SD ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 26

--- 1 ---
1. PRODUCT NAME
Hitachi Disc Grinders, Models G 10SD2 [100 mm (4")]
G 12S2 [115 mm (4-1/2")]
G 13SD [125 mm (5")]
2. MARKETING OBJECTIVE
We sell Models G 10SD1 and G 12S1 in the international market, where they have been favorably accepted.
However, to maintain leadership in the marketplace and promote greater sales, more powerful models with
superior dust-proof construction are demanded. To address this need, the Models G 10SD2 and G 12S2
incorporate many significant upgrades over current Models G 10SD1 and G 12S1.
In addition to these models, the Model G 13SD [125 mm (5 ")] is introduced with outstanding working efficiency
and wear resistance.
These Models are extensions of the HITACHI compact-body disc grinder series and are intended to boost sales,
and draw attention to the whole line.
3. APPLICATIONS
•Removal of casting fin and finishing of various types of steel, bronze, aluminum and various other metallic
materials
•Grinding of welds, or sections cut by means of a cutting torch
•Grinding of synthetic resins, slate, brick, marble etc.
4. SELLING POINTS
250 mm (9-7/8")
Compact body: 250 mm (9-7/8")
High power
(with maximum output of 1,000 W)
Maker B's model: 887 W
Maker C's model: 915 W
Maker B's model: 286 (11-9/32")
Maker C's model: 257 (10-1/8")
Wear resistance of armature coil:
3.3 times higher compared to maker B's model
2.5 times higher compared to maker C's model
Excellent overload durability:
1.25 times higher compared to maker B's model
1.43 times higher compared to maker C's model

--- 2 ---
106 G 10SD2/
G 12S2 G 13SD
G 10SD1/
G 12S1
B
C
100 50 0 100500
C
60
80
70
100
70
100 G 10SD2/
G 12S2 G 13SD
G 10SD1/
G 12S1
B
C
100 50 0 100500
C
100
30
40
100
40
•Excellent overload durability
The Models G 10SD2, G 12S2 and G 13SD provide excellent overload durability thanks an improved cooling
mechanism and a high-power motor.
Comparison of wear resistance of armature coils when dust and fine gravel are sucked into the machines
Practical test data: Comparison of torque when the stator coil temperature rise is 200 ˚K
•Wear resistance of armature coil
Both ends of the armature coil are sealed with heat-resistant adhesive in addition to varnish treatment to
minimize wear of the armature coil caused by dust.
Coating of heat-resistant adhesive.

--- 3 ---
5. SPECIFICATIONS
Item
Model G 10SD2
O.D. 100 mm (4")
x Thickness 4 mm (5/32")
x I.D. 16 mm (5/8")
4,300 m/min
(14,100 ft/min, 72 m/s)
A, 36, Q, BF
Depressed
center
wheel
Dimensions
Max. prectical
peripheral speed
Type
AC single phase 50 or 60 Hz
Power source
Voltage (V)
Voltage, current and
power input
110
*1230
240
Current (A)
7.3
3.7
3.4
Power input (W)
800
G 12S2
O.D. 115 mm (4-1/2")
x Thickness 6 mm (1/4")
x I.D. 22 mm (7/8")
4,800 m/min
(15,756 ft/min, 80 m/s)
G 13SD
O.D. 125 mm (5")
x Thickness 6 mm (1/4")
x I.D. 22 mm (7/8")
11,000 /minNo-load speed
AC single phase commutator motorType of motor
Slide switchType of switch
Material: Housing
Tail cover
Gear cover, Packing gland ••••• Aluminum alloy die casting
Painting: Gear cover, Packing gland ••••• Metallic silver
Enclosure
1.6 kg (3.5 lbs)
Net*2
2.6 kg (5.7 lbs)
Gross
Corrugated cardboard box
Packaging
••••• Glassfiber reinforced polyamide resin (green)
Depressed center wheel
100 mm (4") ••••••••••••• 1
Side handle ••••••••••••••••• 1
Wrench ••••••••••••••••••••••• 1
Standard accessories
2.8 kg (6.2 lbs)
Depressed center wheel
115 mm (4-1/2") •••••••• 1
Side handle ••••••••••••••••• 1
Wrench ••••••••••••••••••••••• 1
2.9 kg (6.4 lbs)
Depressed center wheel
125 mm (5") ••••••••••••• 1
Side handle ••••••••••••••••• 1
Wrench ••••••••••••••••••••••• 1
10,000 /min
*1For some destinations: 230 (V), 3.5 (A), 760 (W)
*2Net weight excludes cord, side handle, depressed center wheel, wheel nut, wheel washer and wheel guard.
Weight
220 3.8
115 7.0 760
760

--- 4 ---
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons
Maker HITACHI
Model G 10SD2
Wheel diameter 100 (4")
mm
Power input*1800
Output*1530
Max. output*11,000
No-load speed 11,000
Grip diameter
63 dia. (2-1/2")
Grip perimeter 207 (8-9/64")
Dimensions
250 (9-7/8")
H63 (2-1/2")
W72 (2-53/64")
Weight*21.6 (3.5 lbs.)
(Actual weight) (1.65) (3.6 lbs.)
W
W
W
/min
mm
mm
mm
mm
mm
62 dia.
(2-7/16")
kg
L
G 10SD1
550
360
800
11,000
63 dia.
(2-1/2")
207 (8-9/64")
261 (10-1/4")
60 (2-3/8")
67 (2-5/8")
1.6 (3.5 lbs.)
(1.6) (3.5 lbs.)
62 dia.
(2-7/16")
C
750
435
915
11,000
56 dia. (2-7/32")
195 (7-43/64")
257 (10-1/8")
70 (2-3/4")
81 (3-3/16")
1.5 (3.3 lbs.)
(1.5) (3.3 lbs.)
65 dia.
(2-9/16")
WL
H
Grip diameter
Grip perimeter
*1Depends on market.
*2Weight excludes cord, side handle, depressed center wheel, wheel nut, wheel washer and wheel guard.
100 (4") 100 (4")

--- 5 ---
Maker HITACHI
Model G 12S2
Wheel diameter 115 (4-1/2")
mm
Power input*1800
Output*1530
Max. output*11,000
No-load speed 11,000
Grip diameter
63 dia. (2-1/2")
Grip perimeter 207 (8-9/64")
Dimensions
250 (9-7/8")
H63 (2-1/2")
W72 (2-53/64")
Weight*21.6 (3.5 lbs.)
(Actual weight) (1.65) (3.6 lbs.)
W
W
W
/min
mm
mm
mm
mm
mm
62 dia.
(2-7/16")
kg
L
G 12S1
63 dia.
(2-1/2")
62 dia.
(2-7/16")
C
56 dia.
(2-7/32")
65 dia.
(2-9/16")
W
H
Grip diameter
Grip perimeter
207 (8-9/64")
261 (10-1/4")
60 (2-3/8")
67 (2-5/8")
1.6 (3.5 lbs.)
(1.6) (3.5 lbs.)
206 (8-1/8")
286 (11-9/32")
73 (2-7/8")
76 (3")
1.55 (3.4 lbs.)
(1.55) (3.4 lbs.)
195 (7-43/64")
257 (10-1/8")
70 (2-3/4")
81 (3-3/16")
1.5 (3.3 lbs.)
(1.5) (3.3 lbs.)
115 (4-1/2")
550
360
800
11,000
115 (4-1/2")
750
455
887
11,000
115 (4-1/2")
750
435
915
11,000
B
59 dia.
(2-5/16")
66 dia.
(2-19/32")
L
*1Depends on market.
*2Weight excludes cord, side handle, depressed center wheel, wheel nut, wheel washer and wheel guard.

--- 6 ---
Maker HITACHI
Model G 13SD
Wheel diameter 125 (5")
mm
Power input*1800
Output*1530
Max. output*11,000
No-load speed 10,000
Grip diameter
63 dia. (2-1/2")
Grip perimeter 207 (8-9/64")
Dimensions
250 (9-7/8")
H63 (2-1/2")
W72 (2-53/64")
Weight*21.6 (3.5 lbs.)
(Actual weight) (1.67) (3.7 lbs.)
W
W
W
/min
mm
mm
mm
mm
mm
62 dia.
(2-7/16")
kg
L
56 dia.
(2-7/32")
65 dia.
(2-9/16")
WL
H
Grip diameter
Grip perimeter
C
125 (5")
750
435
915
11,000
195 (7-43/64")
257 (10-1/8")
70 (2-3/4")
81 (3-3/16")
1.5 (3.3 lbs.)
(1.5) (3.3 lbs.)
*1Depends on market.
*2Weight excludes cord, side handle, depressed center wheel, wheel nut, wheel washer and wheel guard.

--- 7 ---
6-2. Comparisons in Torque vs. Rotation Speed and Stator Coil Temperature Rise
Fig. 1 and Fig. 2 show comparisons of the rotation speed and the stator coil temperature rise between some
competitive models with respect to torque. Torque represents the magnitude of load, i.e., the amount of pressing
force, cutting depth and forward force in actual cutting jobs. This shows that a powerful motor is less likely to burn
out because it has both a minimum drop of rotation speed even with a higher torque and a lower stator coil
temperature rise at the same torque.
2,000 200
400
0
0
4,000
6,000
8,000
10,000
12,000
Rotation speed of spindle
HITACHI
C
C
Load
B
B
G 10SD2
G 12S2
HITACHI G 10SD2
G 12S2
HITACHI G 10SD1 G 12S1
HITACHI
Rotation speed of spindle (/min)
G 10SD1
G 12S1
Stator coil temp.rise
: Burn-out point
Stator coil temp. rise (K)
Fig. 1 Comparison in torque vs. rotation speed and stator coil temperature rise (G 10SD2 and G 12S2)
Fig. 1 indicates:
(1) The Models G 10SD2 and G 12S2 are equipped with high-power motors and improved cooling mechanisms,
and are superior to the Models G 10SD1, G 12S1, B and C in the rotation speed and the stator coil
temperature rise at the same torque.
(2) The motor speed of the Models G 10SD2 and G 12S2 is about 10 % higher than that of B and C at the same
torque. This means that the working efficiency of the Models G 10SD2 and G 12S2 is superior to the other
maker's models.
(3) The stator coil temperature rise of the Models G 10SD2 and G 12S2 is lower than that of B and C at the same
torque, and the torque when the motor is burnt out is about 1.3 times higher compared to B and C. This
means that the overload durability of the Models G 10SD2 and G 12S2 is superior to the other maker's
models.

--- 8 ---
2,000 200
400
0
0
4,000
6,000
8,000
10,000
Rotation speed of spindle
C
Load
C
HITACHI G 13SD
HITACHI G 13SD
Rotation speed of spindle (/min)
Stator coil temp. rise
: Burn-out point
Stator coil temp. rise (K)
Fig. 2 Comparison in torque vs. rotation speed and stator coil temperature rise (G 13SD)
Fig. 2 indicates:
(1) The Model G 13SD is equipped with a high-power motor and improved cooling mechanism. As a result, it is
superior to C in both rotation speed and stator coil temperature rise at the same torque.
(2) The Model G 13SD has a tenacious motor with less rotation speed drop than C at the same torque. This
means that the working efficiency of the Model G 13SD is superior to C in heavy-duty work.
(3) The stator coil temperature rise of the Model G 13SD is lower than that of C at the same torque, and the
torque when the motor burns out is about 1.4 times higher compared to C. This means that the overload
durability of the Model G 13SD is superior to C.

--- 9 ---
*G 12S2: 13,300
7. PRECAUTIONS IN SALES PROMOTION
In the interest of promoting the safest and most efficient use of the Models G 10SD2, G 12S2 and G 13SD 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 constants of the Handling Instructions, and fully understands
the meaning of the precautions listed on the Name Plate or Caution Plate attached to each tool.
7-1. 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 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.
7-2. Caution on 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.
(1) For Australia, New Zealand and China
(2) For U.S.A. and Canada
*
*

--- 10 ---
7-3. Precautions on Usage
(1) The wheel guard must be aligned in relation to the side handle mounting position.
As illustrated in Figs. 3 and 4, the customer should be instructed that the wheel guard mounting angle must be
aligned and fixed in accordance with the side handle mounting position so that the operator's hand will not
contact the depressed center wheel.
Fig. 3 Fig. 4
(2) 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 so that the depressed center wheel flies
off unexpectedly to cause possible serious injury.

--- 11 ---
8. 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 G 10SD2 and G 12S2, and the <Bold> numbers to those in the Parts List and the exploded
assembly diagram for G 13SD.
8-1. Disassembly
(1) Disassembly of the Armature
1) Loosen the Tapping Screw D4 x 16 [51] <52> to pull out the Tail Cover [50] <51>.
2) Remove the two Carbon Brushes [39] <40> from the Brush Holders [40] <41>.
3) Loosen the four Tapping Screws D5 x 25 [1] <1> which fix the Gear Cover Ass'y [4] <4> to remove the
Armature [9] <9> from the Housing [35] <36> together with the Bearing Holder [8] <8>.
4) Loosen the Special Nut M7 [5] <5> which fixes the Pinion [6] <6> to remove the Pinion [6] <6>.
5) Insert the hooks of the J-204 bearing puller between the Ball Bearing [7] <7> and the Bearing Holder [8]
<8> from both sides and fix the hooks with the wing bolts.
6) Place the J204 bearing puller on a supporting jig and push down on the tip of the armature shaft with a
hand press to remove the Ball Bearing [7] <7>. Then remove the Bearing Holder [8] <8>.
(2) Disassembly of the Dust Seal
1) Insert the hooks of the J-204 bearing puller between the commutator and the Dust Seal [13] <13> from
both sides, and fix the hooks with the wing bolts.
2) Place the J204 bearing puller on a supporting jig and push down on the armature shaft with a hand press to
remove the Dust Seal [13] <13> together with the Ball Bearing [14] <14>. Replace the Dust Seal [13] <13>
with new one because it is damaged by the removal of the Ball Bearing [14] <14>.
(3) Disassembly of the Stator Ass'y
1) Remove the Armature [9] <9> and then pull out the two Brush Holders [40] <41> from the Housing [35]
<36>.
2) Disconnect the internal wires of the Stator (A) [12] <12> from the Brush Holders [40] <41>.
3) Loosen the set screw of the Slide Switch [44] <45> and disconnect the two internal wires coming from the
Stator (A) [12] <12>.
4) Remove the Fan Guide [10] <10> from the Housing [35] <35>.
5) Loosen the two Hex. Hd. Tapping Screws D4 x 70 [11] <11> to remove the Stator (A) [12] <12> from the
Housing [35] <35>. If the Stator (A) [12] <12> cannot be removed easily, heat the Housing [35] <35> to
about 60 ˚C. Then the Stator (A) [12] <12> can be removed.
(4) Disassembly of the Slide Knob
1) Loosen the Tapping Screw D4 x 16 [51] <52> to pull out the Tail Cover [50] <51>.
2) Hold the Housing [35] <35> and raise the Slide Bar [42] <43> until the Slide Knob [34] <35> moves to the
"ON" position.
3) Check that the Slide Knob [34] <35> has not moved to the "ON-LOCK" position, and push down the Slide
Knob [34] <35> until it clicks while keeping the Slide Bar [42] <43> raised.
4) Raise the Slide Knob [34] <35> straight up and remove it keeping the Slide Bar [42] <43> raised.

--- 12 ---
(5) Disassembly of the gear (Fig. 5)
1 Loosen the four Seal Lock Screws M4 x 12 [23] <23> fixing the Packing Gland [22] <22>, and remove the
Packing Gland [22] <22> from the Gear Cover Ass'y [4] <4>.
2 Support the bottom of the Packing Gland [22] <22> with a jig, and push down on the upper portion of the
Spindle [25] <25> with a hand press until the end surface of the Woodruff Key [24] <24> contacts the Ball
Bearing [20] <20> and the Spindle [25] <25> cannot be pushed down any more. Be careful not to deform
the Finger [26] <26>.
3 Turn the Packing Gland [22] <22> upside down and fix it, then push down the Spindle [25] <25>.
4 Insert the J-128 gear puller (use of a steel plate is permitted as a substitute) between the Gear [17] <17>
and the Packing Gland [22] <22>, and push down the Spindle [25] <25> with a hand press to remove it.
Replace the Ball Bearing [20] <20> with new one every time should the gear be disassembled
because the stress while pulling out the gear is applied to the Ball Bearing [20] <20>.
[24] <24> [25] <25>
[20] <20>
[22] <22>
[26] <26>
[24] <24>
[25] <25>
[20] <20> [22] <22>
Push [25] <25>
[20] <20>
[22] <22>
[17] <17>
Push
Push
Gear puller J-128
(Steel plate)
Step 4
Step 3
Step 2
Fig. 5
8-2. Reassembly
Push the parts together in the reverse order of disassembly, with the precautions given below.
(1) Generously lubricate the teeth of Gear [17] <17> and Pinion [6] <6> with grease. Rub grease onto the teeth
with your fingers so that the grease reaches each tooth bottom. Note that the Gear [17] <17> and Pinion [6]
<6> if under-lubricated may wear at an faster rate.
(2) Be sure to soak the inner diameter of the Felt Packing [21] <21> with machine oil. Otherwise, its dust-sealing
function will fail to work properly, resulting in an earlier damage of the Ball Bearing [20] <20>.
(3) When replacing the Armature [9] <9> and the Ball Bearing [14]
<14> on the commutator side, press inward on the Dust Seal
[13] <13> while taking care of its direction until the end face of
the Dust Seal [13] <13> hits against the butting surface of the
Armature [9] <9> and make sure that Dust Seal [13] <13>
cannot turn freely. (See Fig. 6)
The Dust Seal [13] <13> is an important element for improved
dust protection of the Ball Bearing [14] <14>. Be sure to use a
new one at every disassembly work of the Ball Bearing [14] <14>.
Armature shaft
Ball Bearing [14] <14>
Dust Seal [13] <13>
Fig. 6
[24]
<24>

--- 13 ---
Fig. 7
(4) Connect the four internal wires of Stator (A) [12] <12> with the parts indicated in Fig. 7.
Connect the internal wires correctly as shown in Fig. 8.
Connect to the Brush
Holder [40] <41> (Side B)
Connect both the internal wire of the Noise
Suppressor [47] <48> and this wire to Tube
(D) [48] <49> with a solderless connection
and connect it to the Slide Switch [44] <45>.
(If the Noise Suppressor [47] <48> is not
used, connect this internal wire to the Slide
Switch [44] <45> after clamping Tube (D) [48]
<49> with the solderless connection.)
Side A
Side B
Connect to the Brush
Holder [40] <41> (Side A)
a. Noise suppressor provided b. Noise suppressor not provided
Fig. 8

--- 14 ---
(5) When connecting the Earth Terminal [46] <47> to the internal wire (the middle wire among three) of the Noise
Suppressor [47] <48>, strip the insulation sheath on the internal wire by about 6 mm and press connect it
together with the Earth Terminal [46] <47> with a clamping tool available on the market.
Solderless connection
Fig. 9
(6) Check that the spring end does not hold the pigtail when mounting the carbon brush. Do not catch the pigtail
in the tail cover when mounting the tail cover.
Fig. 10
(7) When replacing the Gear Cover Ass'y [4] <4>, lubricate the metal part with mixed oil.
Mixed oil: Mixture of Hitachi power tool grease No. 2 (Unilube No. 00) and tubine oil
•Mixture ratio...1:1 (weight ratio) •Volume... 0.5 cc
8-3. Lubrication Points and Types of Lubricant
•Pinion chamber of Gear Cover Ass'y [4] <4> ••••••••••
Nippeko grease (SEP-3A) 5g
Generously rub grease onto the gear and pinion.
•Metal •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Mixed oil 0.5 cc
Mixed oil: Mixture of Hitachi power tool grease No.2
(Unilube No. 00) and turbine oil
Mixture ratio 1:1 (weight ratio)
8-4. Tightening Torque
D4 Tapping Screws [11] <11> [45] <46> [51] <52> ••••••••••••••• 2.0 0.5 N •m (20 5 kgf •cm, 1.5 0.4 ft-lbs)
M4 Seal Lock Screws (W/SP. Washer) [18] <18> [23] <23> ••• 1.8 0.5 N •m (18 4 kgf •cm, 1.3 0.3 ft-lbs)
D5 Tapping Screw [1] <1> ••••••••••••••••••••••••••••••••••••••••••••••••••• 2.9 0.5 N •m (30 5 kgf •cm, 2.2 0.4 ft-lbs)
M5 Machine Screw (W/SP. Washer) [27] <27> •••••••••••••••••••••• 1.6 0.4 N •m (16 4 kgf •cm, 1.2 0.3 ft-lbs)
Special Nut M7 [5] ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6.4 1.0 N •m (65 10 kgf •cm, 4.7 0.7 ft-lbs)
Pigtail
Spring end

--- 15 ---
8-5. Wiring Diagrams
(1) For European countries, Australia, New Zealand, South Africa and China
Stator
Black
Black Stator
Black
Black
Noise
suppressor
Brown
or
Black
Blue
or
White
Cord
21
43
(2) For other countries
Stator
Black
Black
Stator
Black
Black
Brown
or
Black
Blue
or
White
Cord
21
43
A
A
Switch
Switch

--- 16 ---
8-6. Insulation Tests
On completion of disassembly and repair, measure the insulation resistance, and conduct the dielectric strength
test.
Insulation resistance: 7 M or more with DC 500V Megohm Tester
Dielectric strength test: AC 4,000 V/1 minute, with no abnormalities •••••••••••••• 220 V --- 240 V products
AC 2,500 V/1 minute, with no abnormalities •••••••••••••• 110 V ---127 V products
8-7. No-Load Current Value
After no-load operation for 30 minutes, the no-load current value should be as follows.
Voltage (V)
Current (A) max.
220 230 240
1.7 1.7 1.6
110
3.2
115
3.0

--- 17 ---
9. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL 10 20 30 40 50 60 min.
Fixed
Variable
G 10SD2 Work Flow
Slide Switch
Cord
Tail Cover
Carbon Brush
x 2
Housing
Startor (A)
Slide Bar
Pinion
Ball Bearing
(628 VV)
Bearing Holder
Armature
Ball Bearing
(608 VV)
Bearing Cover
Ball Bearing
(6201 DD)
Felt Packing
Packing Gland
Spindle
Fringer
General Assembly
Pushing Button
Gear Cover
Ass'y
Lock Pin
Gear
Needle Bearing
Wheel Guard
Ass'y
G 12S2
G 13SD