Hitachi PDA-100M User manual

PRODUCT NAME
Hitachi Disc Grinder
Model PDA-100M
LIST No.
PDA-100M: E270
Sep. 2005
International Sales Division
PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY--------------------------------------------------------- 1
1. Disassembly ----------------------------------------------------------------------------------------------------- 1
2. Reassembly ------------------------------------------------------------------------------------------------------ 2
3. Lubrication Points and Types of Lubricant ---------------------------------------------------------------- 5
4. Tightening Torque ---------------------------------------------------------------------------------------------- 5
5. Wiring Diagram ------------------------------------------------------------------------------------------------- 5
6. Insulation Tests -------------------------------------------------------------------------------------------------- 6
7. No-load Current Value ----------------------------------------------------------------------------------------- 6
STANDARD REPAIR TIME (UNIT) SCHEDULES -------------------------------------------------------------------- 7
CONTENTS Page
P

1

--- 2---
(4) Disassembly of the gear
1) Loosen the four Seal Lock Screws (W/Sp. Washer) M4 x 12 [21] that secure the Packing Gland [20] to the
Gear Cover Ass'y [3] and remove the Packing Gland [20] from the Gear Cover Ass'y [3].
2) Remove the Retaining Ring for D11 Shaft [13] that secures the gear to the Spindle [23].
3) Remove the Wave Washer [14] and the gear from the Spindle [23].
Fig. 1
1-2. Reassembly
Push the parts together in the reverse order of disassembly, with the precautions given below.
(1) Ensure that the terminals of the stator are not bent or otherwise damaged.
(2) Generously lubricate the teeth of the gear and the pinion with grease. Rub grease onto the teeth with your
fingers so that the grease reaches each tooth bottom. Note that the gear and the pinion may wear faster than
normal if under-lubricated.
(3) Be sure to soak the inner diameter of the Felt Packing [19] with machine oil. Otherwise, its dust-sealing
function will fail to work properly, resulting in earlier damage of the Ball Bearing 6201VVCMPS2L [18].
(4) When replacing the Armature [7] and the Ball Bearing 608VVC2PS2L [12] on the commutator side, press
inward on the Dust Seal [11] while taking care of its direction until the end face of the Dust Seal [11] contacts
against the end surface of the Armature [7] and make sure that Dust Seal [11] cannot be turned freely by
hand. (See Fig. 1).
The Dust Seal [11] is an important element for improved dust protection of the Ball Bearing 608VVC2PS2L
[12]. Be sure to replace with a new one each time.
Armature shaft
Ball Bearing 608VVC2PS2L [12]
Dust Seal [11]
(5) When connecting the Earth Terminal [41] to the internal wire (the middle wire among three) of the Noise
Suppressor [45], strip the insulation sheath on the internal wire by about 6 mm and press-connect it together
with the Earth Terminal [41] with a clamping tool available on the market.
Fig. 2
Solderless connection

--- 3---
(6) Mount the Cord [54] according to the following
procedure when replacing the standard cord (cord
armor is integrally molded).
1) Remove the standard cord (cord armor is integrally
molded) according to the procedure of 8-1 (3).
2) Strip the coating on the internal wire of the Cord
[54] about 10 mm from the tip and crimp the
Terminal [50] to the brown or black internal wire as
shown in Fig. 3.
3) Insert the Cord [54] into the Cord Armor D8.8 [51].
4) Cut off the rib for holding the cord of Tail Cover (B)
[46] with nippers as shown in Fig. 4.
5) Mount the Cord [54] and the Cord Armor D8.8 [51]
to Tail Cover (A) [35] and secure them with the
Cord Clip [52] and two Tapping Screws (W/Flange)
D4 x 16 [53] as shown in Fig. 5.
6) Mount each internal wire reversing the removal
procedure. Then mount Tail Cover (B) [46] to Tail
Cover (A) [35] and secure them with the Tapping
Screw (W/Flange) D4 x 25 (Black) [47].Fig. 4
Fig. 5
Fig. 3
Terminal [50]
Cord [54]
Caulking
A
Stripped
length
10 mm
White
or blue
40 mm
85 mm
Black or brown
A --- A
Tail Cover (B) [46]
A
Approximately
2 mm
(a) For Taiwan (b) For Singapore and Malaysia
(c) For other countries
: Cut off

--- 4---
Fig. 6
Bottom of the housing
(7) Connect the internal wires of Stator (A) [10] correctly as shown in Fig. 6and Fig. 7.
(8) Connect each internal wire correctly as shown in Fig. 7being careful not to put them between the parts.
Brush Holder [40]
Internal wire from Cord [54]
Machine Screw (W/Washer) M3.5 x 6 [48]
Guide plate
Machine Screw (W/Washer) M3.5 x 6 [48]
Switch (1P Screw Type) [49]
: Tail Cover (A) [35]
Internal wire from Stator (A) [10]
Internal wire from Noise Suppressor [45]
Fig. 7
Internal wire coming from
the Noise Suppressor [45]
Insert the terminal securely then push
and fold the terminal toward the outside
of the housing as much as possible.
(9) When replacing the Gear Cover Ass'y [3], lubricate the needle bearing part with mixed oil.
Mixed oil: A mixture of Hitachi Power Tool Grease No. 2 (Unilube No. 00 Code No. 939302 is recommended)
and turbine oil
Mixture ratio ......... 1:1 (weight ratio) Quantity ........... 0.5 cc
OFF side
ON side

--- 5---
1-3. Lubrication Points and Types of Lubricant
Pinion chamber of Gear Cover Ass'y [3] ..................... Nippeco grease (SEP-3A) 5 g
(Code No. 930035 is recommended.)
Generously rub grease onto the gear and pinion.
Needle bearing ............................................................ Mixed oil 0.5 cc
Mixed oil: Mixture of Hitachi Power Tool Grease No. 2
(Unilube No. 00, Code No. 939302) and
turbine oil
Mixture ratio ................ 1:1 (weight ratio)
1-4. Tightening Torque
Tapping Screws D4 [9] [36] [37] [47] [53] .............................. 2.0 0.5 N•m (20 5 kgf•cm, 1.5 0.4 fb-lbs.)
Seal Lock Screws (W/Sp. Washer) M4 [16] [21] .................... 1.8 0.4 N•m (18 4 kgf•cm, 1.3 0.3 fb-lbs.)
Tapping Screw D5 x 25 (Black) [1] ......................................... 2.9 0.5 N•m (30 5 kgf•cm, 2.2 0.4 fb-lbs.)
Machine Screw (W/Sp. Washer) M5x16 (Black) [25] ............... 1.6 0.4 N•m (16 4 kgf•cm, 1.2 0.3 fb-lbs.)
Special Nut M7 [4] .................................................................. 6.4 1.0 N•m (65 10 kgf•cm, 4.7 0.7 fb-lbs.)
Brush Cap [38] ........................................................................ 0.6 0.2 N•m (6 2 kgf•cm, 0.4 0.1 fb-lbs.)
1-5. Wiring Diagram
(1) For Taiwan (2) For Singapore
(3) For other countries
Noise
suppressor
Fig. 8

--- 6---
1-6. Insulation Tests
On completion of disassembly and repair, carefully measure the insulation resistance and conduct a dielectric
strength test.
Insulation resistance: 7 M Ωor more with 500 V DC megohm tester
Dielectric strength test: AC 4,000 V/1 minute with no abnormalities .................... 220 V --- 240 V products
AC 3,500 V/1 minute with no abnormalities .................... 110 V --- 127 V products
1-7. No-load Current Value
After no-load running for 30 minutes, the no-load current value should be as follows.
Voltage (V)
Current (A) max.
110
2.6
220
1.2
240
1.2
230
1.2

--- 7---
2. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL 10 20 30 40
Fixed
Variable
Work Flow
Gear Cover
Ass'y
Pushing Button
Lock Pin
60 min.
50
Packing Gland
Ball Bearing
(6201VV)
Spindle
Gear and
Pinion Set
Switch
Tail Cover (A)
Tail Cover (B)
Cord
Cord Armor
Wheel Guard
Ass'y
Armature
Ball Bearing
(628VV)
Bearing Holder
Dust Seal
Ball Bearing
(608VV)
General Assembly
PDA-100M
Housing Ass'y
Stator

ELECTRIC TOOL PARTS LIST
LIST NO. E270
DISC GRINDER
Model PDA-100M
2005
•
9
•
5
(E1)
Hitachi Power Tools
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
19
20
21
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41 42
43
44
45
46
47
48
49
50
51
52
53
54
10
501 502
18
22

* ALTERNATIVE PARTS--- 2 ---
ITEM
NO. CODE NO. DESCRIPTION REMARKS
NO.
USED
PARTS
9 -- 05
PDA-100M
1320-523 TAPPING SCREW D5X25 (BLACK) 4
2301-944 PUSHING BUTTON 1
3316-484 GEAR COVER ASS’Y 1 INCLUD. 2, 15
4301-941 SPECIAL NUT M7 1
5628-VVC BALL BEARING 628VVC2PS2-L 1
6316-480 BEARING HOLDER 1
*7360-744C ARMATURE 110V 1
*7360-744G ARMATURE 220V 1
*7360-744E ARMATURE 230V 1
*7360-744F ARMATURE 240V 1
8319-898 FAN GUIDE 1
9319-358 TAPPING SCREW (W/FLANGE) D4X70 2
*10 340-649C STATOR (A) 110V 1
*10 340-649E STATOR (A) 220V-240V 1
11 315-877 DUST SEAL 1
12 608-VVM BALL BEARING 608VVC2PS2L 1
13 316-487 RETAINING RING FOR D11 SHAFT 1
14 316-486 WAVE WASHER 1
15 301-943 LOCK PIN 1
16 997-263
SEAL LOCK SCREW (W/SP. WASHER) M4X10 2
17 316-490 BEARING COVER 1
18 620-1VV BALL BEARING 6201VVCMPS2L 1
19 301-946 FELT PACKING 1
20 316-489 PACKING GLAND 1
21 307-127
SEAL LOCK SCREW (W/SP. WASHER) M4X12 4
22 302-047 WOODRUFF KEY 1
23 316-485 SPINDLE 1
24 301-945 FRINGER 1
25 308-386
MACHINE SCREW (W/SP. WASHER) M5X16 (BLACK) 2
26 301-949 SET PLATE 1
27 301-948 WHEEL GUARD ASS’Y 1 INCLUD. 25, 26
28 320-497 WHEEL WASHER 1
29 316-820 D. C. WHEELS 100MMX4T A36Q (25 PCS.) 1
30 321-795 WHEEL NUT (C) 1
31 321-450 GEAR AND PINION SET 1
32 HITACHI LABEL 1
33 325-140 HOUSING 1
34 NAME PLATE 1
35 325-143 TAIL COVER (A) 1
36 302-086 TAPPING SCREW (W/FLANGE) D4X20 (BLACK) 1
37 306-664 TAPPING SCREW (W/FLANGE) D4X40 1
38 936-551 BRUSH CAP 2
39 999-021 CARBON BRUSH (1 PAIR) 2
40 313-777 BRUSH HOLDER 2
*41 314-854 EARTH TERMINAL 1 FOR TPE
*42 980-063 TERMINAL 1 FOR NOISE SUPPRESSOR
*43 938-307 PILLAR TERMINAL 1 FOR SIN, IND
*44 959-140 CONNECTOR 50091 (10 PCS.) 1 EXCEPT FOR SIN, IND
*45 994-273 NOISE SUPPRESSOR 1 FOR TPE
*46 325-141 TAIL COVER (B) 1
*46 325-142 TAIL COVER 1 FOR SYR

* ALTERNATIVE PARTS --- 3 ---
ITEM
NO. CODE NO. DESCRIPTION REMARKS
NO.
USED
PARTS
9 -- 05
PDA-100M
47 304-035 TAPPING SCREW (W/FLANGE) D4X25 (BLACK) 1
48 305-499 MACHINE SCREW (W/WASHER) M3.5X6 2
49 955-509 SWITCH (1P SCREW TYPE) 1
*50 980-063 TERMINAL 1 FOR CORD
51 953-327 CORD ARMOR D8.8 1
52 937-631 CORD CLIP 1
*53 984-750 TAPPING SCREW (W/FLANGE) D4X16 2 FOR SYR
*54 500-231Z CORD 1
*54 500-409Z CORD 1 FOR INA, IND
*54 500-447Z CORD 1 FOR SYR
*54 500-468Z CORD 1 FOR THA
*54 500-470Z CORD 1 FOR TPE

* ALTERNATIVE PARTS
--- 4 --- 9 -- 05
OPTIONAL ACCESSORIES
ITEM
NO. CODE NO. DESCRIPTION REMARKS
NO.
USED
STANDARD ACCESSORIES
ITEM
NO. CODE NO. DESCRIPTION REMARKS
NO.
USED
PDA-100M
501 313-933 WRENCH 1
* 502 302-142 SIDE HANDLE 1 FOR TPE, SIN, KUW
601 302-098 GUIDE BASE 1
602 302-099 WHEEL GUARD FOR 100MM CUT-OFF WHEEL 1
603 984-646
WHEEL NUT FOR 100MM CUT-OFF WHEEL 1
604 323-918
DUST COLLECTION ADAPTER (DISC GRINDER) 1
605 314-053 SANDING DISCS 100MM C-P24 (10 PCS.) 1
606 314-054 SANDING DISCS 100MM C-P30 (10 PCS.) 1
607 314-057 SANDING DISCS 100MM C-P50 (10 PCS.) 1
608 314-059 SANDING DISCS 100MM C-P80 (10 PCS.) 1
609 314-061 SANDING DISCS 100MM C-P120 (10 PCS.) 1
610 314-051 SANDING DISCS 100MM C-P16 (10 PCS.) 1
611 314-052 SANDING DISCS 100MM C-P20 (10 PCS.) 1
612 314-055 SANDING DISCS 100MM C-P36 (10 PCS.) 1
613 314-056 SANDING DISCS 100MM C-P40 (10 PCS.) 1
614 314-058 SANDING DISCS 100MM C-P60 (10 PCS.) 1
615 314-060 SANDING DISCS 100MM C-P100 (10 PCS.) 1
616 954-021 SIDE HANDLE 1
617 935-513 WASHER NUT M10XP1.5 1
618 936-548 WASHER 1
619 936-558Z RUBBER PAD 1
Printed in Japan
(050905N)