Hitachi GP 2S2 User manual

[SAME FEATURES AS THE CONVENTIONAL MODELS]
Powerful motor with high grinding speed
Compact, slim housing that is easy to grip
LIST No.
GP 2S2: F202
Apr. 2010
The new Model GP 2S2 was developed to replace the existing Model GP 2. The GP 2S2 has the same
specifications and performance as the GP 2, and is assembled at our production facility in Malaysia.
International Sales Division
MARKETING OBJECTIVE
PRODUCT NAME
Hitachi Portable Grinder
Model 25 mm (1”) GP 2S2
• Finishing of dies for press working, die casting, and molding
• Finishing of thread-cutting dies, tools, and other small parts
• Internal grinding of tools and machine parts
APPLICATIONS
SELLING POINTS
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT .
G

REMARK:
• For more information about HANDLING INSTRUCTIONS, visit our website at:
http://www.hitachi-koki.com/manual_view_export/
• Throughout this TECHNICAL DATA AND SERVICE MANUAL, a symbol(s) is(are) used in the place of
company name(s) and model name(s) of our competitor(s). The symbol(s) utilized here is(are) as follows:
Competitors
Symbols Utilized
Company Name Model Name
BBOSCH
GGS27L
(1215 for USA)
C MAKITA GD0601

CONTENTS
Page
SELLING POINTS -------------------------------------------------------------------------------------------------------------- 1
SPECIFICATIONS -------------------------------------------------------------------------------------------------------------- 2
1. Specifications --------------------------------------------------------------------------------------------------------------------------------- 2
2. Optional Accessories --------------------------------------------------------------------------------------------------------------------- 3
COMPARISON WITH SIMILAR PRODUCTS---------------------------------------------------------------------------- 4
1. Comparison of Specifications-------------------------------------------------------------------------------------------------------- 4
PRECAUTIONS ON SALES PROMOTION ------------------------------------------------------------------------------ 5
1. Safety Instructions ------------------------------------------------------------------------------------------------------------------------- 5
2. Precautions Requiring Particular Attention during Sales Promotion ------------------------------------------ 6
REPAIR GUIDE------------------------------------------------------------------------------------------------------------------ 7
1. Precautions on Disassembly and Reassembly ---------------------------------------------------------- 7
STANDARD REPAIR TIME (UNIT) SCHEDULES-------------------------------------------------------------------- 12
Assembly Diagram for GP 2S2

-1-
Powerful motor with high grinding speed
Model GP 2S2 B C
Power input 520 W 500 W 400 W
Compact, slim housing that is easy to grip
SELLING POINTS
359 mm (14-1/8”)

-2-
1. Specifications
Model
Item GP 2S2
Max. wheel diameter 25 mm (1”)
Chuck grip diameter
ø3 mm, ø6 mm, ø8 mm
ø1/8”, ø1/4”
(Collet chuck supplied with main unit: ø6 or ø1/4”)
Type of wheel Vitrified
Power source AC single phase 50 or 60 Hz
Voltage, current and
power input
No-load speed 29,000 min-1
Type of motor AC single phase commutator motor
Type of switch Slide switch
Enclosure
• Material: Housing --------- Glassfiber-reinforced polyamide resin (green)
Tail cover ------- Glassfiber-reinforced polyamide resin (black)
Nose bracket, Inner cover-------- Aluminum alloy die casting
• Paint color: Nose bracket, Inner cover ---- Metallic silver
Net 1.7 kg (3.8 lbs.) (without cord and wheel)
Weight Gross 2.5 kg (5.5 lbs.)
Packaging Corrugated cardboard box
Standard accessories • Side handle*1----------------------------------------------------------------------- 1
• Wrench (17 mm, 12 mm) --------------------------------------------------------- 2
*1: Depends on the market.
SPECIFICATIONS
Voltage (V) Current (A) Power input (W)
110 4.9
120 4.7 520
127 4.0 480
220 2.5
230 2.4
240 2.3
520

-3-
2. Optional Accessories
(1) For 6-mm shaft diameter (Grit WA 60 PV) --- 10 pcs. per package
Type Code No. Type Code No.
KA-2 939101 KA-8 939107
KA-3 939102 KA-9 939108
KA-4 939103 KA-11 949023
KA-5 939104 KA-12 949021
KA-7 939106 KA-13 949022
(2) For 3-mm shaft diameter (Grit WA80P)------- 20 pcs. per package
Type Code No. Type Code No.
KA-20 939110 KC-20 939115
KA-21 939111 KC-21 939116
KA-22 939112 KC-22 939117
KA-23 939113 KC-23 939118
KA-24 939114 KC-24 939119
(3) Collet Chuck
Capacity Code No.
3 mm 932624
6 mm 932627
8 mm 985135
1/8” 985136
1/4” 932666Z
(4) Dresser
Code No.
939120

-4-
1. Comparison of Specifications
HITACHI
Maker
Model
Item GP 2S2 GP 2 B C
Wheel diameter mm 25 (1”) 25 (1”) 25 (1”) 38 (1-1/2”)
Power input*1W 520 520 500 400
Max. output*1W 610 610 - -
No-load speed min-1 29,000 25,000 27,000 25,000
Grip perimeter mm 200 (7-7/8”) 205 (8-5/64”) 220 (8-43/64”) 200 (7-7/8”)
Weight*2kg 1.7 (3.8 lbs.) 1.75 (3.9 lbs.) 1.6 (3.5 lbs.) 1.6 (3.5 lbs.)
L mm 359 (14-1/8”) 365 (14-3/8”) 332 (13-5/64”) 359 (14-1/8”)
a mm 100 (3-15/16”) 100 (3-15/16”) 78 (3-1/16”) 95 (3-47/64”)
øD mm 35 (1-3/8”) 35 (1-3/8”) 38 (1-1/2”) 43 (1-11/16”)
Dimensions
b mm 184 (7-1/4”) 184 (7-1/4”) 170 (6-11/16”) 180 (7-5/64”)
*1: Depends on the market.
*2: Without cord and wheel.
COMPARISON WITH SIMILAR PRODUCTS
L (Overall length)
(Housing length)
b
øD Mount
diameter
a

-5-
1. Safety Instructions
In the interest of promoting the safest and most efficient use of the Model GP 2S2 Portable Grinder by all of
our customers, it is very important 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, general precautions and suggestions on the use of electric power tools, and specific
precautions and suggestions on the use of the portable 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 Handling Instructions in order to offer appropriate guidance to the customer during sales promotion
activities.
B. Caution on Name Plate
Each tool is provided with a Name Plate that contains the following basic safety precautions on the use of
the tool.
[For New Zealand and Australia]
CAUTION
Read thoroughly read HANDLING INSTRUCTIONS before use.
[For the USA and Canada]
WARNING
To reduce the risk of injury, user must read and understand instruction manual.
Always use proper guards when grinding and wear eye protection.
Use only accessories rated at least 31,900 /min.
AVERTISSEMENT
Afin de réduire les resques de blessures, I'utilisateur doit lire et bien comprendre le mode d'emploi.
Utilisez toujours un outil muni d'un protecteur adéquat et portez des lunettes on une visiére.
N'utilisez que des accessoires prévus pour au moins 31,900 /min.
[For China]
PRECAUTIONS ON SALES PROMOTION

-6-
[For Mexico]
ADVERTENCIA
Lea las instruciones de manejo antes de usar.
[For Taiwan]
2. Precautions Requiring Particular Attention during Sales Promotion
A. Precautions on usage
(1) Trial run before operation
Operating the grinder with a damaged or cracked whetstone is very dangerous.
Please be sure to instruct the user to make a trial run by facing the whetstone away from any nearby
person, and confirm that there is no abnormality before operating the grinder.
The trial run time is as follows:
• After replacing a whetstone -------------- At least 3 minutes
• Before starting operation------------------ At least 1 minute

-7-
Screw driver
Coupling [10]
Tap lightly
A
rmature
A
ss'y [17]
Pry Pry
Screw driver
Fig. 2
Push down
Shaft
Inner Cover [15]
ø63 to ø72
A
rmature
A
ss'y [17]
Fig. 1
1. Precautions on Disassembly and Reassembly
[Bold] numbers in the descriptions below correspond to numbers in the Parts List and exploded assembly
diagram.
1. Disassembly of the Armature Ass’y
(1) Loosen the Tapping Screw (W/Flange) D4 x
16 [41] to pull out the Tail Cover [40].
(2) Remove the two Carbon Brush [29] from the
Brush Holder [30].
(3) Loosen the four Tapping Screw (W/Sp.
Washer) D5 x 30 [6] and remove the Nose
Bracket [8]. Use a screwdriver to separate the
Inner Cover [15] from the Housing [26], and
then remove the Inner Cover [15] together
with the Armature Ass'y [17].
(4) As illustrated in Fig, 1, support the Inner Cover
[15] with a tubular jig having an inner diameter
large enough (63 mm) to accommodate the
Armature Ass'y [17], and then push down the
end of the Armature Ass'y [17] shaft with a
hand press to remove the Armature Ass'y [17].
2. Disassembly of Coupling
The Coupling [10] may be difficult to remove from
the Armature Ass'y [17] due to rust. if it cannot be
removed by pulling by hand, follow the procedure
below.
(1) As illustrated in Fig. 2, use a screwdriver or
similar tool to slightly lift the Coupling [10] and
partially remove it.
(2) Tap the Coupling [10] lightly with a wooden
hammer to push it again.
(3) Repeat steps (1) and (2) several times until
freeing enough rust to allow complete
removal of the Coupling [10] .
3. Disassembly of the Dust Seal
(1) Insert the hooks of the J204 bearing puller between the commutator and Dust Seal [21] from both
sides, and then fix the hooks with the wing bolts.
(2) Place the J204 bearing puller on a supporting jig, and then push down on the armature shaft with a
hand press to remove the Dust Seal [21] together with the Ball Bearing 608VVC2PS2L [22]. Replace
the Dust Seal [21] damaged by removing the Ball Bearing 608VVC2PS2L [22] with a new one.
REPAIR GUIDE
Disassembly

-8-
Fig. 3
A
rmature shaft
Ball Bearing 608VVC2PS2L [22]
Dust Seal [21]
4. Disassembly of the Stator (A)
(1) Remove the Armature Ass’y [17], and then pull out both Brush Holder [30] from the Housing [26].
(2) Disconnect the internal wires of the Stator (A) [20] from the Brush Holder [30].
(3) Loosen the set screw on the Slide Switch [35] and disconnect the two internal wires protruding from
the Stator (A) [20].
(4) Remove the Fan Guide [18] from the Housing [26].
(5) Loosen the two Hex. Hd. Tapping Screw D4 x 70 [19] and remove the Stator (A) [20] from the
Housing [26]. If the Stator (A) [20] cannot be easily removed, heat the Housing [26] to about 60°C.
The Stator (A) [20] can then be easily removed.
5. Disassembly of the Slide Knob
(1) Loosen the Tapping Screw (W/Flange) D4 x 16 [41] to pull out the Tail Cover [40].
(2) Hold the Housing [26] and raise the Slide Bar [32] until the Slide Knob [24] moves to the "ON"
position.
(3) Confirm that the Slide Knob [24] has not moved to the "ON-LOCK" position, and then push down on
the Slide Knob [24] until it clicks, while keeping the Slide Bar [32] raised.
(4) Raise the Slide Knob [24] straight up and remove it, while keeping the Slide Bar [32] raised.
6. Disassembly of the Spindle
Loosen the Hex. Socket Set Screw M4 x 4 [16], and remove Bearing Lid (B) [2].
The Spindle [3] can then be taken out.
Reassemble the parts by reversing the disassembly procedure, and note the precautions given below.
(1) To replace the Armature Ass’y [17] and Ball
Bearing 608VVC2PS2L [22] on the
commutator side, press in the Dust Seal [21]
while carefully noting its direction until the end
face of the Dust Seal [21] strikes the butting
surface of the Armature Ass’y [17]. Make sure
that the Dust Seal [21] cannot turn freely.
(See Fig. 3.)
The Dust Seal [21] is an important component
for improved dust protection of the Ball
Bearing 608VVC2PS2L [22]. Be sure to use a
new one every time you disassemble the Ball
Bearing 608VVC2PS2L [22].
Reassembly

-9-
Fig. 5
Fig. 4 Connect to the
Brush Holder [30] (Side A)
Connect to the
Brush Holder [30] (Side B)
Side B
Side A
Connect both the internal wire of the Noise
Suppressor [38] and this wire to Tube (D) [39]
with a solderless connection and connect it to the
Slide Switch [35].
(If the Noise Suppressor [38] is not used,
connect this internal wire to the Slide Switch [35]
after clamping Tube (D) [39] with the solderless
connection.)
(2) Connect the four internal wires of Stator (A) [20] with the parts indicated in Fig. 4.
Connect the internal wires correctly as shown in Fig. 5.
a. Choke coil and Noise Suppressor provided b. Noise Suppressor not provided

-10-
Fig. 6
Solderless connection
Tightening Torque
Adhesive Agent
Insulation Tests
No-Load Current Value
(3) When connecting the Earth Terminal [37] to
the internal wire (middle wire among three) of
the Noise Suppressor [38], strip off about 6
mm of the insulation sheath on the internal
wire, and then press-connect it together with
the Earth Terminal [37] with a clamping tool
available on the market.
(4) Confirm 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.
• Hex. Socket Set Screw M4 x 4 [16]-------------------------- TB1406 (Synthetic rubber base)
• Tapping Screw D4 [19][36][41] ------------------------------- 2.0 ± 0.5 N•m (20 ± 5 kgf•cm, 1.5 ± 0.4 ft-lbs)
• Seal Lock Screw (W/Sp. Washer) M4 x 10 [11] ----------- 1.8 ± 0.5 N•m (18 ± 4 kgf•cm, 1.3 ± 0.3 ft-lbs)
• Tapping Screw (W/Sp. Washer) D5 x 30 [6] --------------- 2.9 ± 0.5 N•m (30 ± 5 kgf•cm, 2.2 ± 0.4 ft-lbs)
• Hex. Socket Set Screw M4 x 4 [16]--------------------------- 0.5N
•m 5 kgf•cm, 0.4 ft-lbs
00 0
• Bearing Lid (B) [2]------------------------------------------------ 6.9 ± 0.5 N•m (70 ± 5 kgf•cm, 5.0 ± 0.4 ft-lbs)
Upon the completion of disassembly and repair, measure the insulation resistance and conduct a dielectric
strength test.
Insulation resistance: 10 MΩor more with DC 500 V megohm tester
Dielectric strength test: AC 4,400 V for 3 seconds, with no abnormalities ----------- 220 to 240 V products
AC 3,000 V for 3 seconds, with no abnormalities ----------- 110 to 127 V products
After no-load operation for 30 minutes, the no-load current value should be as follows:
Voltage (V) 110 120 127 220 230 240
Current (A) max. 4.9 4.7 4.0 2.5 2.4 2.3
Pigtail
Spring end
Fig. 7
0.5 + 5 + 0.4 +

-11-
A
Choke coil
Brown
or
Black
Blue
or
White
Cord [46]
Black or White
Black or White
Noise
Suppressor [38]
Stator Ass'y (A) [20]
Stator Ass'y (A) [20]
Choke coil
Black
or
White
Black
or
White
Slide Switch [35]
21
43
• Wiring Diagrams
• Wiring Diagrams
Wiring Diagrams
(1) For European countries, Australia, New Zealand, South Africa, and China
(2) For other countries
A
Brown
or
Black
Blue
or
White
Cord [46]
Black or White
Black or White
Stator (A) [20]
Stator (A) [20]
Black
or
White
Black
or
White
Slide Switch [35]
21
43

-12-
MODEL Variable
Fixed 10 20 30 40 50 60 min.
Work Flow
GP 2S2
General Assembly
Slide Switch
Cord
Tail Cover
Carbon Brush
x 2
Spindle
Ball Bearing
6001VVCMPS2L
Ball Bearing
6000VVCMPS2L
Armature
Ball Bearing
608VVC2PS2L
Inner Cover
Ball Bearing
608VVC2PS2L
Bearing Cover
Housing
Stator (A)
Slide Bar
Nose Bracket
Bearing Lid (B)
STANDARD REPAIR TIME (UNIT) SCHEDULES

Model GP 2S2
HAND GRINDER
LIST NO. F202
(E1)
2010 4 22
26
22
2
4
6
3
5
7
9
16
11
12
13
14
501 502
1
8
503 504
505
17
18
19
20
21
23
24
25
27
28
29
30
31
32
33
34
35
37
38
39
40
41
42
43
44
45
46
15
10
36
36
••

PART
S
GP 2S2
DESCRIPTION REMARKS
*1 331-421 COLLET CHUCK 6MM 1
*1 331-422 COLLET CHUCK 1/4" 1 FOR USA, CAN, MEX, PAN (120V), AUS
2 332-452 BEARING LID (B) 1
3 332-453 SPINDLE 1
4 600-1VV BALL BEARING 6001VVCMPS2L 1
5 932-617 RING 1
6 986-011 TAPPING SCREW (W/SP. WASHER) D5 X 30 4
7 317-807 GUARD PLATE 1
8 331-474 NOSE BRACKET 1
9 600-0VV BALL BEARING 6000VVCMPS2L 1
10 985-140 COUPLING 1
11 987-201 SEAL LOCK SCREW (W/SP. WASHER) M4 X 10 2
12 949-453 SPRING WASHER M4 (10 PCS.) 2
13 937-876 BEARING COVER 1
14 608-VVM BALL BEARING 608VVC2PS2L 1
15 331-475 INNER COVER 1
16 981-478 HEX. SOCKET SET SCREW M4 X 4 1
*17 360-879U ARMATURE ASS'Y 110V-120V 1 INCLUD. 14, 21, 22
*17 360-879E ARMATURE 220V-230V 1
*17 360-879F ARMATURE 240V 1
18 319-898 FAN GUIDE 1
19 982-021 HEX. HD. TAPPING SCREW D4 X 70 2
*20 340-758C STATOR (A) 110V-120V 1
*20 340-758G STATOR ASS'Y (A) 110V 1 FOR GBR (110V)
*20 340-758M STATOR (A) 110V 1 FOR TPE
*20 340-758E STATOR (A) 220V-230V 1
*20 340-758H STATOR (A) 230V 1 FOR NZL
*20 340-758F STATOR (A) 240V 1
*20 340-758L STATOR (A) 240V 1 FOR AUS
21 315-877 DUST SEAL 1
22 608-VVM BALL BEARING 608VVC2PS2L 1
23 332-804 WASHER M14 1
24 314-428 SLIDE KNOB 1
25 CAUTION PLATE 1
26 317-802 HOUSING 1
27 NAME PLATE 1
28 HITACHI LABEL 1
29 999-088 CARBON BRUSH (1 PAIR) 2
30 317-810 BRUSH HOLDER 2
31 308-536 SPRING 2
32 317-806 SLIDE BAR 1
33 314-429 SPRING 1
34 995-662 RUBBER RING 1
*35 332-805 SLIDE SWITCH (2P PILLAR TYPE) 1
*35 321-208 SLIDE SWITCH (2P PILLAR TYPE) 1 FOR USA, CAN
36 984-750 TAPPING SCREW (W/FLANGE) D4 X 16 3
37 314-854 EARTH TERMINAL 1
38 325-566 NOISE SUPPRESSOR 1
39 981-373 TUBE (D) 2
40 317-808 TAIL COVER 1
- 2 - 4 - 10
*ALTERNATIVE PARTS
ITEM
NO. NO. USED
CODE NO.

PART
S
GP 2S2
DESCRIPTION REMARKS
41 984-750 TAPPING SCREW (W/FLANGE) D4 X 16 1
42 317-811 SWITCH HOLDER 1
43 937-631 CORD CLIP 1
44 981-373 TUBE (D) 2
* 45 953-327 CORD ARMOR D8.8 1
* 45 938-051 CORD ARMOR D10.1 1
* 46 500-409Z CORD 1 (CORD ARMOR D8.8)
* 46 500-247Z CORD 1 (CORD ARMOR D8.8) FOR FIN, DEN, SWE, NOR
* 46 500-461Z CORD 1 (CORD ARMOR D8.8) FOR GBR (110V)
* 46 500-435Z CORD 1 (CORD ARMOR D8.8) FOR GBR (230V), HKG
* 46 323-974 CORD 1 (CORD ARMOR D10.1) FOR UAE, TPE
* 46 500-240Z CORD 1 (CORD ARMOR D8.8) FOR USA, CAN, PAN (120V)
* 46 500-237Z CORD 1 (CORD ARMOR D8.8) FOR CHI
* 46 500-484Z CORD 1 (CORD ARMOR D8.8) FOR ARG
* 46 500-439Z CORD 1 (CORD ARMOR D8.8) FOR AUS, NZL
* 46 500-455Z CORD 1 (CORD ARMOR D8.8) FOR CHN, PHI
* 46 500-423Z CORD 1 (CORD ARMOR D8.8) FOR SIN, MAL
* 46 500-234Z CORD 1 (CORD ARMOR D8.8) FOR KOR
4 - 10 - 3 -
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.

GP 2S2
DESCRIPTION REMARKS
501 936-553 WRENCH 12MM 1
502 936-638 WRENCH 17MM 1
503 324-548 SIDE HANDLE 1
504 330-061 FLANGED SLEEVE 1
505 330-060 SIDE HANDLE SLEEVE ASS'Y 1 INCLUD. 503, 504
DESCRIPTION REMARKS
601 932-624 COLLET CHUCK 3MM 1
602 985-135 COLLET CHUCK 8MM 1
603 985-136 COLLET CHUCK 1/8" 1
*604 939-103 MOUNTED WHEELS KA-4 D6 SHAFT (10 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*605 939-104 MOUNTED WHEELS KA-5 D6 SHAFT (10 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*606 939-107 MOUNTED WHEELS KA-8 D6 SHAFT (10 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*607 949-021 MOUNTED WHEELS KA-12 D6 SHAFT (10 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*608 949-022 MOUNTED WHEELS KA-13 D6 SHAFT (10 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*609 939-110 MOUNTED WHEELS KA-20 D3 SHAFT (20 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*610 939-115 MOUNTED WHEELS KC-20 D3 SHAFT (20 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*611 939-117 MOUNTED WHEELS KC-22 D3 SHAFT (20 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*612 939-118 MOUNTED WHEELS KC-23 D3 SHAFT (20 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*613 939-119 MOUNTED WHEELS KC-24 D3 SHAFT (20 PCS.) 1 EXCEPT FOR USA, CAN, MEX
*614 939-120 DRESSER C36PV 1 EXCEPT FOR USA, CAN, MEX
- 4 - Printed in Japan 4 - 10
(100422N)
*ALTERNATIVE PARTS
NO.
USED
CODE NO.
ITEM
NO.
STANDARD ACCESSORIES
NO.
USED
CODE NO.
ITEM
NO.
OPTIONAL ACCESSORIES