Hitachi C 5YA Manual

POWER TOOLS
TECHNICAL DATA
AND
SERVICE MANUAL
DUSTLESS CIRCULAR SAW
C 5YA
SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT
LIST No. 0589 Oct. 1999
C
MODEL
C 5YA

Page
CONTENTS
[ Business Section ]
1. PRODUCT NAME •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
2. MARKETING OBJECTIVE •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
1
3. APPLICATIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
1
4. SELLING POINTS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
1
4-1. Selling Point Descriptions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2
5. SPECIFICATIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
5
6. PRECAUTIONS IN SALES PROMOTION •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
6
6-1. Handling Instructions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
6-2. Cautions on Name Plate •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
6-3. Precautions in Use •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
[ Service Section ]
7. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
7-1. Disassembly •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
7-2. Reassembly •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10
7-3. Lubrication •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
7-4. Tightening Torque •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
7-5. Insulation •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
7-6. Cleaning the Cover •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
7-7. Wiring Procedure ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13
7-8. Wiring Diagram •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 13
8. STANDARD REPAIR TIME (UNIT) SCHEDULES •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
14
[ Appendix ]
Assembly Diagram for C 5YA •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 15

--- 1 ---
1. PRODUCT NAME
Hitachi Dustless Circular Saw, Model C 5YA
2. MARKETING OBJECTIVE
There have been a persistant demand to develop an efficient dust collecting circular saw, particularly for cutting
fiber cement board materials in international markets such as New Zealand, etc.
Excessive particles produced during cutting operations may be harmful to the operator's health if an operator does
not wear a bothersome dust-mask or similar device. Responding to those market requirements for a much
cleaner cutting environment than conventional circular saws can provide, Hitachi is pleased to introduce the dust-
collecting Circular Saw, Model C 5YA with adapter for connection to an appropriate power vacuum cleaner or
Hitachi's exclusively designed dust collector or similar dust-collecting equipment. Increasing market requirements
for human-friendly power tools should result in a significant sales performance.
3. APPLICATIONS
(1) Cutting of T (Thickness) 7 or T9 mm fiber cement board
(2) Cutting of various types of gypsum board materials
4. SELLING POINTS
In case of shallow cutting,
less dust with slide cover
Comfortable low-dust cutting
Nearly dustless cutting with
vacuum cleaner or similar device
Equipped with shaft lock
Right angle adjustment
Saw blade cutting edge
indicator

--- 2 ---
4-1. Selling Point Descriptions
(1) Few dust with slide cover
The Model C 5YA is equipped with a slide cover that shields the clearance at the cutting edge (Fig. 1).
This slide cover reduces scattering of chips from the cutting edge portion even if the cutting depth is shallow
and improves dust collection efficiency.
(2) Nearly dustless cutting with vacuum cleaner or similar device
The hose of the dust collector can be directly mounted to the dust box through the rubber adapter according
to the steps below (Fig. 2).
(1) Remove the rubber cap from the rear of the dust box.
(2) Connect the dust collector's hose firmly to the rubber adapter. Insert the rubber adapter into the outlet of
the dust cap.
Fig. 1
Fig. 2
Slide cover Flow of chips
Saw blade
Cutting edge Base
Dust collector
Hose
Dust cap
Outlet
Rubber adapter
Rubber cap
Dust box

--- 3 ---
(3) Adjusting right angle
The angle between the base and the saw blade can
be finely adjusted to a right angle (Fig. 3). The
adjustable range is 90 1.5 . Thanks to this
function, accurate cutting is achieved even when
cutting thick or overlaid workpieces.
(4) Indicator of saw blade
The Model C 5YA is equipped with a movable slide
plate that makes saw blade adjustment easier.
This slide plate can guide the saw blade edge
according to cutting depth (Fig. 4).
Three lines are marked on the bottom of the base.
These lines indicate the standard blade edge
positions and cutting depth according to thickness
of workpieces. Viewing from the bottom (Fig. 5),
the right perpendicular lines indicate the standard
blade edge positions at the maximum cutting
depth.
Fig. 3
Fig. 4
Fig. 5
Saw blade
M4 screw
Base 90 fine adjustment screw
(M6 nylock screw)
Slide plate
Lines for standard
blade edge positions
Base
Align the blade edge
with the end surface
of the slide plate.

--- 4 ---
(5) All-new design
The Model C 5YA has an innovative design with rounded appearance.
(6) Cutting depth scale
The cutting depth scale is marked in millimeters on the safety cover. By aligning the bottom of the base with
the scale, you can easily set the desired cutting depth. The scale is graduated in 3-millimeter units. Ignore
the numeric values in parentheses as they are specified for Japan use only.
(7) Spindle lock mechanism
The Model C 5YA is equipped with the same spindle lock mechanism as the compact circular saws for easy
saw blade replacement.
(8) Other selling points
A finger rest is provided on the base for accurate cutting (Fig. 6).
A relief groove is provided on the bottom of the base to prevent snagging during operation (Fig. 7).
Some dividers are arranged in the dust box to
improve dust collection efficiency and to prevent
leakage of chips (Fig. 8).
Fig. 6 Fig. 7
Fig. 8
Base
Finger rest
Relief groove Base
Dust box
Flow of chips
Divider
Chips

--- 5 ---
5. SPECIFICATIONS
Power supply Power source
Type of switch
Power input
Weight
Packaging
Cord
Standard accessories
Optional accessories
Tungsten carbide tipped (TCT) saw blade
125 mm
Trigger switch with stopper
1,000 W
Corrugated cardboard box [240 mm (D) x 325 mm (W) x 190 mm (H)]
Type : Two-core cabtire cable
Overall length : 5 m
Nominal cross-sectional area : 0.75 mm2
Outside diameter : 7 mm
Dust collector (Models RP 30SA and RP 30Y)
Diamond wheel
TCT saw blade (125 mm)
Saw blade diameter
Cutting depth 0 --- 37 mm
Standard saw blade
Voltage
AC single phase 50/60 Hz
230 V
Type of motor Single-phase series commutator motor
Housing ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Nylon resin (green)
Handle cover ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••Nylon resin (green)
Gear cover ••••••••••••••••••••••••••••••••••• Die-cast aluminum alloy (silver green)
Base •••••••••••••••••••••••••••••••••••••••••••••••••••••• Die-cast aluminum alloy (silver)
Dust box ••••••••••••••••••••••••••Polycarbonate resin [transparent (smoky gray)]
Enclosure
Full-load current 4.6 A
Rotation speed No-load : 5,000/min.
Full-load : 3,200/min.
Net : 3.1 kg (excluding the cord)
Gross : 4.4 kg
Guide ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1
Box wrench ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••1
External
diameter Hole diameter Tip width Thickness Number of
teeth
125 mm (5")
20 mm 1.7 mm 1.2 mm 18
Dimensions

--- 6 ---
CAUTION
Read thoroughly HANDLING INSTRUCTIONS
before use.
6. PRECAUTIONS IN SALES PROMOTION
In the interest of promoting the safest and most efficient use of the Model C 5YA Dustless Circular Saw 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 on the Name Plate attached to each tool.
6-1. 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 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 Circular Saw are listed in the Handling Instructions to enhance the safe, 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.
6-2. Cautions on Name Plate
Each tool is provided with a Name Plate which lists the following basic safety precaution in the use of the tool.
6-3. Precautions in Use
While basic precautions in use are listed in the Handling Instructions and Name Plate, be particularly careful to
ensure that the customer fully understands the following special precaution.
(1) When cutting into a wall directly, dust collection efficiency may be decreased because of the variety of
collected chips produced.

--- 7 ---
7. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY
Disassembly and reassembly procedures which require particular precautions are described below.
The [Bold] numbers in the descriptions below and the circled numbers in the following figures correspond to the
item numbers in the Parts List and the exploded assembly diagram for the Model C 5YA.
Be sure to unplug the Model C 5YA from the wall outlet before performing disassembly or replacement of the saw
blade.
7-1. Disassembly
7-1-1. Removal of the Dust Box Ass'y (Fig. 8)
(1) Release the Lever [60], and adjust the Base Ass'y
[54] to the minimum cutting depth position, then
secure the Lever [60] in this position.
(2) Loosen the Machine Screw M6 x 55 [17] and remove
the Dust Box Ass'y [14] from the Gear Cover [34].
7-1-2. Removal of the TCT Saw Blade (Fig. 9)
(1) Push the Lock Lever [31] to secure the Armature
[30]. Loosen the Bolt (W/Washer) M7 x 17.5 [13]
with the attached Box Wrench 10 mm [502] to
remove Washer (B) [12], the TCT saw blade and
Washer (A) [11].
7-1-3. Disassembly of the Safety Cover Ass'y (Fig. 10)
(1) Remove the Return Spring [7] from the Gear Cover
[34] and Safety Cover (A) Ass'y [6].
(2) Loosen the three Seal Lock Flat Hd. Screws M4 x 12
[10] to remove the Bearing Cover [9] and Safety
Cover (A) Ass'y [6].
Fig. 8
Fig. 9
Fig. 10
14
34 17
16
54
60
13
12
11
34
34 5678910

--- 8 ---
7-1-4. Removal of the Housing Ass'y (Fig. 11)
(1) Loosen the Brush Cap [41] with a flat-blade screwdriver and remove the Carbon Brushes [40].
(2) Loosen the three Machine Screws (W/Washers) M5 x 45 (Black) [19] and remove the Housing Ass'y [22] from
the Gear Cover [34].
7-1-5. Removal of the Base Ass'y (Fig. 11)
(1) Remove the Retaining Ring (E-type) For D10 Shaft
[59], then remove the Hex. Bolt M8 x 8.5 [58], Lever
[60] and Bolt Washer M8 [61].
(2) Pull out the Roll Pin D6 x 30 [56] which connects the
Base Ass'y [54] with the Gear Cover [34].
7-1-6. Removal of the Spindle and Gear Set (Fig. 12)
(1) Loosen the two Seal Lock Flat Hd. Screws M5 x 12
[4]. Tap the end surface of the Gear Cover [34] with
a wooden hammer, then the parts shown in Fig. 12
can be removed.
(2) Push the end surface of the spindle using a hand
press to remove the Ball Bearing 6002DDCMPS2L
[8].
(3) Remove the Ball Bearing 626VVC2PS2L [1] with a
bearing puller.
Fig. 11
Fig. 12
34
56
54
22
19
40
41
58 59
60 61
8
4
3
2
1

--- 9 ---
7-1-7. Removal of the Armature (Fig. 13)
(1) Remove the Lock Lever [31] and tap the end surface of the Housing Ass'y [22] with a wooden hammer. The
Armature [30] and Fan Guide [29] can then be removed.
(2) Remove the Fan Guide [29], Rubber Washer [24] and Bearing Lock [23].
(3) Remove the Ball Bearing 6001VVCMPS2L [32] and Ball Bearing 608VVC2PS2L [25] with a bearing puller, and
remove Washer (A) [26].
Fig. 13
32
31
30
29
26
25
24
23
22
B

--- 10 ---
7-2. Reassembly
Reassembly can be accomplished by following the disassembly procedures in reverse. However, special
attention should be given to the following items.
7-2-1. Reassembly of the Rubber Ring [33]
Ensure that the Rubber Ring [33] is properly inserted into the groove of the bearing chamber in the Gear Cover
[34]. During reassembly, be careful not to damage the Rubber Ring [33].
7-2-2. Assembling the Wiring Block [27] and Stator [28] (Figs. 14 and 15.)
(1) When installing the Stator [28] in the Housing Ass'y [22], attach the Wiring Block [27] to the Stator [28] and
press-fit them into the Housing Ass'y [22].
(2) The brush terminals of the Wiring Block [27] are automatically connected to the Brush Holders [39] when the
Stator [28] is press-fitted. At this time, check that the brush terminals do not extend beyond the end of Brush
Holders [39]. If they do, push them in with a flat-blade screwdriver.
Fig. 15
See Fig. 15
Female terminals
(4 prongs)
Male terminals
(4 prongs)
Brush terminals
(2 prongs)
[End surface of brush holders]
The brush terminals should not
extend beyond this surface.
Fig. 14
28
27
22
39
28

--- 11 ---
7-2-3. Reassembly of the Bearing Lock [23] and Rubber Washer [24] (Fig. 16)
Before reassembling the Armature [30], be sure to install the Bearing Lock [23] and Rubber Washer [24] in the
bearing chamber of the Housing Ass'y [22] in order. Ensure that the Rubber Washer [24] is reassembled in the
proper direction.
Steel washer side
Rubber side
Order of reassembly
Fig. 16
22
23 24
25
Fig. 17
26
Clearance
7-2-4. Replacement of the Ball Bearing 608VVC2PS2L [25]
When replacing the Ball Bearing 608VVC2PS2L [25] only, ensure that
Washer (A) [26] is reassembled in the proper direction and there is a
clearance between the Ball Bearing 608VVC2PS2L [25] and Washer (A)
[26]. (Fig. 17)

--- 12 ---
7-3. Lubrication
•The gear chamber of the Gear Cover [34] •••••••••••••••••••••••••••••••••••••••••••••••••••• Nippeco Grease (SEP-3A) 8 g
Apply grease to the gear and pinion well.
7-4. Tightening Torque
•Bolt (W/Washer) M7 x 17.5 [13] ••••••••••••••••••••••••••••••••••••••••••••••••••••• 100 20 kgf•cm
•Seal Lock Flat Hd. Screw M5 x 12 [4] ••••••••••••••••••••••••••••••••••••••••••••• 35 7 kgf•cm
•Seal Lock Flat Hd. Screw M4 x 12 [10] ••••••••••••••••••••••••••••••••••••••••••• 18 4 kgf•cm
•Machine Screw (W/Washers) M5 x 45 (Black) [19] •••••••••••••••••••••••••• 35 7 kgf•cm
•Tapping Screw (W/Washers) D5 x 60 [46] ••••••••••••••••••••••••••••••••••••••• 30 5 kgf•cm
•Tapping Screw (W/Flange) D4 [20] [45] •••••••••••••••••••••••••••••••••••••••••• 20 5 kgf•cm
•Hex. Socket Set Screw M5 x 8 [38] •••••••••••••••••••••••••••••••••••••••••••••••• 7.5 2.5 kgf•cm
•Brush Cap [41] ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10 5 kgf•cm
•Machine Screw M6 x 55 [17] •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 18 4 kgf•cm
7-5. Insulation
After overhaul, insulation testing and measurement of insulation resistance must be accomplished.
7-6. Cleaning the Cover
Clean the exterior of the tool with a soft cloth moistened with soapy water, and dry thoroughly.
Chloric solvent, gasoline, and thinner will cause plastic components to dissolve.

--- 13 ---
7-7. Wiring Procedure (Figs. 18 and 19)
Wiring should be carried out by referring to Figures 18 and 19. During installation, be careful not to pinch the
leadwires between the housing and the handle cover.
Fig. 18
Fig. 19 (Expanded drawing of switch)
7-8. Wiring Diagram (Fig. 20)
Fig. 20
Leadwire from cord
Leadwire from stator Insulator
Blue
Blue
Brown
Black
Leadwires
from stator
Noise suppressor
Armature
Stator Switch
Blue
Black
Blue
Brown
Cord
48
37
Fig. 17
Leadwires from cord

--- 14 ---
8. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL 10 20 30 40
Fixed Variable
C 5YA Work Flow
Cord
Switch (C)
Handle Cover
Armature
Ball Bearing
6001VVCMPS2L
Ball Bearing
608VVC2PS2L
Lock Lever
Rubber
Washer
Washer (A)
Dust Box Ass'y
TCT Saw Blade
Safety Cover
(A) Ass'y
Return Spring
Seal
Packing (B)
60 min.
50
Housing Ass'y
Stator
Ball Bearing
626VVC2PS2L
Spindle and
Gear Set
Bearing Holder
Ball Bearing
6002DDCMPS2L
Gear Cover
Rubber Ring
Base Ass'y
General Assembly

--- 15 ---
Assembly Diagram for C 5YA

--- 16 ---
PARTS
C 5YA
: ALTERNATIVE PARTS
ITEM
NO. CODE NO. DESCRIPTION NO. USED
REMARKS
1 626-VVM BALL BEARING 626VVC2PS2L 1
2 318-308 SPINDLE AND GEAR SET 1
3 307-925 BEARING HOLDER 1
4 305-568 SEAL LOCK FLAT HD. SCREW M5X12 2
5 310-843 SEAL PACKING (B) 1
6 310-640 SAFETY COVER (A) ASS’Y 1 INCLUD.5
7 944-344 RETURN SPRING 1
8 600-2DD BALL BEARING 6002DDCMPS2L 1
9 310-637 BEARING COVER 1
10 993-244 SEAL LOCK FLAT HD. SCREW M4X12 3
11 318-309 WASHER (A) 1
12 318-310 WASHER (B) 1
13 957-749 BOLT (W/WASHER) M7X17.5 1
14 310-642 DUST BOX ASS’Y 1 INCLUD.15,18
15 HITACHI LABEL 1
16 995-634 WASHER (B) D12.5 1
17 949-788 MACHINE SCREW M6X55 (10 PCS.) 1
18 313-568 CAP 1
19 302-434
MACHINE SCREW (W/WASHERS) M5X45 (BLACK) 3
20 301-653 TAPPING SCREW (W/FLANGE) D4X20 (BLACK) 3
21 NAME PLATE 1
22 311-954 HOUSING ASS’Y 1 INCLUD.38,39
23 931-701 BEARING LOCK 1
24 308-058 RUBBER WASHER 1
25 608-VVM BALL BEARING 608VVC2PS2L 1
26 982-631 WASHER (A) 1
27 311-958 WIRING BLOCK 1
28 340-347E STATOR 220V-230V 1
29 307-917 FAN GUIDE 1
30 360-350E ARMATURE 220V-230V 1
31 307-918 LOCK LEVER 1
32 600-1VV BALL BEARING 6001VVCMPS2L 1
33 958-130 RUBBER RING 1
34 310-636 GEAR COVER 1
35 310-842 CUSHION 1
36 949-793 FLAT HD. SCREW M5X20 (10 PCS.) 1
37 500-439Z CORD 1
38 938-477 HEX. SOCKET SET SCREW M5X8 2
39 957-051 BRUSH HOLDER 2
40 999-043 CARBON BRUSH (1 PAIR) 2
41 935-829 BRUSH CAP 2
42 953-327 CORD ARMOR D8.8 1
43 980-063 TERMINAL 1
44 937-631 CORD CLIP 1
45 984-750 TAPPING SCREW (W/FLANGE) D4X16 2
46 309-467 TAPPING SCREW (W/WASHER) D5X60 2
47 305-499 MACHINE SCREW (W/WASHER) M3.5X6 4
48 302-470 SWITCH (C) (1P SCREW TYPE) W/O LOCK 1
49 311-955 HANDLE COVER 1
50 980-063 TERMINAL 2
51 311-935 NOISE SUPPRESSOR 1
*
8
----
99

--- 17 ---
PARTS
C 5YA
ITEM
NO. CODE NO. DESCRIPTION NO. USED
REMARKS
52 307-898 WING BOLT M6X18 1
53 941-056 SPRING 1
54 310-638 BASE ASS’Y 1 INCLUD.52,53,55,57
55 308-109 SLOTTED HD. SET SCREW (SEAL LOCK) M6X8 1
56 949-515 ROLL PIN D6X30 (10 PCS.) 1
57 310-639 SLIDE PLATE 1
58 301-713 HEX. BOLT M8X8.5 1
59 670-514 RETAINING RING (E-TYPE) FOR D10 SHAFT 1
60 983-863 LEVER 1
61 949-433 BOLT WASHER M8 (10 PCS.) 1
: ALTERNATIVE PARTS
*8
----
99

--- 18 ---
: ALTERNATIVE PARTS
*
STANDARD ACCESSORIES
C 5YA
ITEM
NO. CODE NO. DESCRIPTION NO.
USED
REMARKS
501 302-756 GUIDE 1
502 940-543 BOX WRENCH 10MM 1
8
----
99
Printed in Japan
(990830 N)
OPTIONAL ACCESSORIES
ITEM
NO. CODE NO. DESCRIPTION NO.
USED
REMARKS
601 313-041 DIAMOND WHEEL (SEGMENT) 106MM-D20 HOLE 1
602 310-632 TCT SAW BLADE (A) 125MM-D20 HOLE-NT18 1