Hitachi PDA-100M Manual

TECHNICAL DATA
AND
SERVICE MANUAL
DISC GRINDER
PDA-100M
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. E270 Sept. 2005
MODEL
PDA-100M
P
Hitachi 
Power Tools

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 GWS6-100
B
MAKITA 9526B
C

Page
CONTENTS
1. PRODUCT NAME ...........................................................................................................................1
2. MARKETING OBJECTIVE .............................................................................................................1
3. APPLICATIONS ..............................................................................................................................1
4. SELLING POINTS ..........................................................................................................................2
5. SPECIFICATIONS ..........................................................................................................................5
6. COMPARISONS WITH SIMILAR PRODUCTS ..............................................................................6
6-1. Specification Comparisons ............................................................................................................ 6
6-2. Comparisons in Torque vs. Rotation Speed and Stator Coil Temperature Rise ............................ 7
7. PRECAUTIONS IN SALES PROMOTION .....................................................................................8
7-1. Handling Instructions ..................................................................................................................... 8
7-2. Caution Plate ................................................................................................................................. 8
7-3. Precautions on Usage ................................................................................................................... 8
8. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY ............................................................ 9
8-1. Disassembly .................................................................................................................................. 9
8-2. Reassembly ................................................................................................................................. 10
8-3. Lubrication Points and Types of Lubricant ................................................................................... 13
8-4. Tightening Torque ........................................................................................................................ 13
8-5. Wiring Diagram ............................................................................................................................ 13
8-6. Insulation Tests ............................................................................................................................ 14
8-7. No-load Current Value ................................................................................................................. 14
9. STANDARD REPAIR TIME (UNIT) SCHEDULES .......................................................................15
Assembly Diagram for PDA-100M

--- 1 ---
1. PRODUCT NAME
Hitachi Disc Grinder, Models PDA-100M [100 mm (4")]
2. MARKETING OBJECTIVE
The current Model PDA-100D has obtained high evaluation for its highly durable aluminum housing in the Asian
market. However, there is an increasing demand for a durable disc grinder having double-insulated construction
with a high insulation class resin housing. To cope with this demand, we developed the new Model PDA-100M
based on the current Model PDA-100D. The motor of the new Model PDA-100M is more durable than that of the
current Model PDA-100D thanks to the double insulation construction. We aim to expand our market share with
the new Model PDA-100M.
The main improvements are as follows:
The motor is so designed that commutation sparks are minimized during operation in order to increase the
service life of the brush, commutator and the motor.
The wear resistance of the coil is increased by attaching the protect tape to the coil end at the fan side of the
armature.
The iron bearing bushing is adopted as the bearing of the resin housing in order to increase durability of the
housing.
Use of thick copper wires increases the motor input and the overload durability owing to reduction of loss.
3. APPLICATIONS
Removal of casting fin and finishing of various types of steel, bronze, aluminum, and other metallic materials
and castings
Grinding of welded sections, or sections cut by acetylene torch
Grinding of slate, brick, marble and similar materials
1
2
Please expand the sales of the new Model PDA-100M as well as the conventional Model PDA-100D.
3
4

--- 2 ---
Easy-to-use snap switch
4. SELLING POINTS
Iron bearing bushing is provided
in the commutator-side bearing
chamber.
Convenient spindle lock Durable motor
Needle bearing for
extended durability
High power input: 715 W
PDA-100D: 620 W
B : 670 W
C : 710 W
Well balanced and ergonomic
design for easy operation
Hitachi original dust proof construction for long service life
against abrasion from dust
Application of adhesive to the commutator hook.
Extended armature wedge.
Protect tape
Vent is resistant to sucking gravel.

--- 3 ---
Durable motor
The motor of the Model PDA-100M is so designed that commutation sparks are minimized during operation in
order to increase the service life of the brush and the commutator. Table 1 shows the wear ratios of the brush
and the commutator as a result of continuous operation under the same loading conditions as general grinding
operation with respect to the current Model PDA-100D. The service life of the Model PDA-100M is about 1.5
times longer than the current Model PDA-100D and the running cost can be reduced.
Hitachi original dust proof construction for long service life against abrasion from dust
The Model PDA-100M is equipped with a motor whose durability is greater than the conventional models by
making the following improvements. The service life of the armature coil is 4 times longer than the
conventional models as a result of the gravel suction test (gravel is forcedly sucked in through the vents of the
tail cover).
The wedges at both ends of the armature coil are extended by 3 to 4.5 mm to protect the portions where the
peripheral speed is the fastest and apt to be disconnected by dust or gravel.
The protect tape covers the coil end at the fan side in order to protect the coil from being worn due to
collision with dust or gravel entered through the air vent and repelled by the fan.
The adhesive coating on the commutator hook prevents a break in the coil due to collision of dust or gravel
with the hook and a short circuit due to deformation of the hook.
Table 1
PDA-100D
1.0
1.0
Maker
Model
Carbon life ratio
Commutator life ratio
HITACHI
PDA-100M
1.4
1.5
0.9
1.1
1.0
1.0
BC
Table 2
PDA-100D
1.0
Maker
Model
Durability ratio
HITACHI
PDA-100M
4.0 0.8 1.0
BC
3 mm to 4.5 mm 3 mm to 4.5 mm

--- 4 ---
New vent construction is adopted to prevent dust or gravel from getting inside.
Model PDA-100M
(Dust or gravel is hard to be sucked in.)
Model PDA-100D
High power input
The motor of the Model PDA-100M is the same size as that of the durable Model PDA-100D. In addition, use
of thick copper wires increases the motor input owing to reduction of loss.

--- 5 ---
Depressed
center
wheel
5. SPECIFICATIONS
4,300 m/min (14,000 ft/min, 72 m/s)
Dimensions
Model
Item
O.D. 100 mm (4") x Thickness 6 mm (1/4")
x I.D. 16 mm (5/8")
Offset amount: 4 mm (5/32")
Max. peripheral speed
PDA-100M
AC single phase 50 or 60 Hz
Power source
Glassfiber reinforced polyamide resin (black)
Aluminum alloy die casting (metallic silver)
Aluminum alloy die casting
1.5 kg (3.3 lbs.)
2.5 kg (5.5 lbs.)
Corrugated cardboard box
Rotation speed (no-load)
Type of motor
Type of switch
Enclosure
Net: *1
Gross:
Packaging
Standard accessories*2Depressed center wheel [Outer dia.100 mm (4") ] ................. 1
Wrench ................................................................................... 1
Voltage, current and power input
12,000/min
AC single-phase commutator motor
Snap switch
Housing
Tail cover
Gear cover
Packing grand
Voltage (V)
110
220
230
240
Current (A)
6.8
3.4
3.3
3.2
Power input (W)
715
*1: Net weight excludes cord, depressed center wheel, wheel nut, wheel washer and wheel guard.
*2: Standard accessories are subject to change without prior notice.
Glassfiber reinforced polyamide resin (gray)
Weight

--- 6 ---
Maker
Model
Wheel diameter mm
No-load speed /min
Power input W
Power output W
Max. power output W
Lmm
Dimensions W mm
Hmm
Pmm
Weight * Catalog kg
Actual kg
Type of switch
HITACHI
100
12,000
715
430
870
260
76
63
200
1.5
1.6
Snap
6. COMPARISONS WITH SIMILAR PRODUCTS
6-1. Specification Comparisons
P: Perimeter
* Weight excludes cord, depressed center wheel, wheel nut, wheel washer and wheel guard.
100
12,000
620
300
800
254
67
60
200
1.7
2.0
Snap
B
PDA-100M PDA-100D
100
11,000
710
370
860
260
67
68
204
1.4
1.5
Snap
C
100
11,000
670
360
760
265
76
73
191
1.4
1.4
Snap

--- 7 ---
0
2,000
4,000
6,000
8,000
10,000
12,000
0
100
200
300
400
500
600
HITACHI PDA
-
100D
HITACHI PDA
-
100M
C
B
Rotation speed of spindle
Stator coil temp. rise :
B
HITACHI PDA
-
100D
C
HITACHI PDA
-
100M
Rotation speed of spindle (/min)
Load
0
Stator coil temp. rise (k)
Burn-out point
6-2. Comparisons in Torque vs. Rotation Speed and Stator Coil Temperature Rise
Figure 1 shows comparisons of the rotation speed and the stator coil temperature rise between a competitive
model 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 at a greater torque and a lower stator coil temperature rise at
the same torque.
Fig. 1 Comparisons in torque vs. rotation speed and stator coil temperature rise
Figure 1 indicates the following:
The motor speed of the Model PDA-100M is higher than that of B, C and Model PDA-100D at the same
torque. This means that the working efficiency of the Model PDA-100M is superior to B, C and Model
PDA-100D.
The stator coil temperature rise of the Model PDA-100M is lower than that of B, C and Model PDA-100D
thanks to the improved cooling mechanism and it is equivalent to that of the Model PDA-100D.
This means that the Model PDA-100M has a burn-resistant and tenacious motor.
1
2
Torque range