G 13YD G 13V - hitachi
Contents
1. 9 9 PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY 10 9 7 Precautions in Maintenance and PREDA edid Das ee Ere aaa e ede da ea i iaa 10 5 2 HII irepl ERE TTD I Dl Ba a a 2 a a le De 11 DEUM uic cir o iata aaa eta cada ca a EE 13 9 4 Connecting Internal Wires and Wiring Diagrams 16 9 5 Lubncation Polks and Types Of LNG ce ae a a le dai 1 FE TN metet ET 17 DIEI TEN I E treater 17 e NOEGO ET AG EE ai 17 10 STANDARD REPAIR TIME UNIT SCHEDULES nnmnnn ne 18 Assembly Diagrams for D 13YD and D 13V 1 PRODUCT NAME Hitachi Electronic Disc Grinder Model 13YD 125 mm 5 Model G 13 125 mm 5 Variable speed 2 MARKETING OBJECTIVE Market research indicates that many users require more compact and more powerful disc grinder In order to meet the requirement and also to meet the rival products we developed the new electronic disc grinder Models G 13YD and 13V equipped with the most powerful motor in this class G 13V has been introduced to meet the demand for variable speed Our market share is expected to grow with the release of these new models which broaden our lineup of disc grinders 3 APPLICATIONS e Removal of casting fin and finishing of various types of steel bronz2. 1 6 0 4 Nem Magnet 38 38 M6 left hand thread 1 3 0 3 Nem 6 4 kgfecm 1 2 0 3 ft lbs 3 3 kgfecm 0 9 0 2 ft lbs 20 5 kgf cm 1 5 0 4 ft lbs 18 4 kgfecm 1 3 0 3 ft lbs Tapping Screw D5 x 25 1 1 esses 2 9 0 5 Nem 30 5 kgf cm 2 2 0 4 ft lbs 1 1 Special Nut M7 5 5 2 0 0 5 Nem 2025 1 5 0 4 ft lbs 9 7 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 500 V Megohm Tester Dielectric strength test AC 4 000 V 1 minute with no abnormalities 230 V 240 V products 9 8 No load Current Value After no load operation for 30 minutes the no load current value should be as follows Voltage V 230 240 Current A max 2 9 2 8 10 STANDARD REPAIR TIME UNIT SCHEDULES MODEL Variable Fixed 10 20 30 40 50 60 min General Assembly Work Flow Wheel Guard Ass y Controller Set Switch Carbon Brush x2 Spring x 2 Tail Cover Cord Cord Armor Pinion Ball Bearing 628VV Bearing Holder Armature Dust Seal Ball Bearing 608VV Pushing Button Gear
3. 2472 CORD 500 4472 500 4392 CORD 930 108 CORD CLIP 937 631 CORD CLIP 305 720 TAPPING SCREW W FLANGE D4X12 984 750 TAPPING SCREW W FLANGE D4X16 980 063 TERMINAL 953 327 CORD ARMOR D8 8 314 603 SWITCH 1P SOLDER TYPE 955 509 SWITCH 1P SCREW TYPE 984 750 TAPPING SCREW W FLANGE D4X16 ARMOR D8 8 ARMOR D8 8 FOR NOR SWE DEN ARMOR D8 8 FOR SUI ARMOR D8 8 FOR AUS TILL 1 2001 SINCE 2 2001 TILL 1 2001 SINCE 2 2001 FOR CORD FOR AUS ND m m m LL 12 00 ALTERNATIVE PARTS 3 STANDARD ACCESSORIES G 13V CODE NO DESCRIPTION REMARKS 938 332Z WRENCH 302 142 SIDE HANDLE CODE NO DESCRIPTION 1 REMARKS 937 8252 RUBBER PAD 937 8262 WASHER NUT 314 062 SANDING DISCS 125MM C P16 10 PCS 314 063 SANDING DISCS 125MM C P20 10 PCS 314 064 SANDING DISCS 125MM C P24 10 PCS 314 065 SANDING DISCS 125MM C P30 10 PCS 314 066 SANDING DISCS 125MM C P36 10 PCS 314 067 SANDING DISCS 125MM C P40 10 PCS 314 068 SANDING DISCS 125MM C P50 10 PCS 314 069 SANDING DISCS 125MM C P60 10 PCS 314 070 SANDING DISCS 125MM C P80 10 PCS 314 071 SANDING DISCS 125MM C P100 10 PCS 314 072 SANDING DISCS 125MM C P120 10 PCS 310 39
4. Wiring Diagrams Noise Suppressor 50 50 Connect the internal wires according to Figs 11 to 13 Numbers to 2 the following figures correspond to the internal wires of Stator A NG TON NER LA Connect to the Brush Holder 41 lt 41 gt Side A Connect to the Brush Holder 41 lt 41 gt Side B Terminal 48 lt 48 gt Fig 11 Pillar Terminal 46 lt 46 gt Fig 12 Stator A Connector Pillar Terminal 12 lt 12 gt 51 lt 51 gt 46 d Black Blue Black or Black Noise Suppressor Controller Set 50 lt 50 gt ton 45 45 O 54 lt 54 gt Switch 59 lt 59 gt Black i Brown 3 Black LO 07 or ex _Terminl 71 3 Black 48 48 L1 3 Fig 13 16 9 5 Lubrication Points and Types of Lubricant e Pinion chamber of Gear Cover Ass y 4 4 Nippeco grease SEP 3A 6 g Generously rub grease onto the gear and pinion e Metal nee dele de 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 9 6 Tightening Torque Tapping Screws D4 47 47 53 53 56 56 56A 56A 60 lt 60 gt EE EE 2 0 0 5 Nem Seal Lock Screws W SP Washer M4 18 18 23 23 1 8 0 5 Nem Machine Screw 5 x 20 27 lt 27 gt
5. 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 lt 20 gt 3 When replacing the Armature 9 9 or the Ball Bearing 15 15 at the commutator side be sure to replace the Dust Seal 14 lt 14 gt with new one together The Dust Seal 14 14 is an important part to ensure the dust resistance of the ball bearing Replace the Dust Seal 14 14 with new one without fail Press fit the Ball Bearing 15 15 to the position specified in Fig 7 Thrust Washer 13 13 Dust Seal 14 lt 14 gt Ball Bearing 15 15 Armature shaft Magnet 38 38 Fig 7 4 Tighten the Tapping Screw W Flange D4 x 16 60 lt 60 gt with a small diameter screwdriver 3 5 mm to 4 0 mm in diameter as shown in Fig 8 213 5 When connecting the Earth Terminal 49 49 to the internal wire the middle wire among three of the Noise Suppressor 50 lt 50 gt strip the insulation sheath on the internal wire by about 6 mm and press connect it together with the Earth Terminal 49 49 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 Pigtail
6. 19 370 SLIDE BAR 314 429 SPRING 319 897 CONTROLLER SET 938 307 PILLAR TERMINAL 301 653 TAPPING SCREW W FLANGE D4X20 BLACK 311 741 TERMINAL 314 854 EARTH TERMINAL 317 491 NOISE SUPPRESSOR 959 140 CONNECTOR 50091 10 PCS 2 ALTERNATIVE PARTS 12 00 R INCLUD 3 16 INCLUD 27 28 INCLUD 6 17 INCLUD 55A 56A aa a m m A N PARTS CODE NO 319 371 DESCRIPTION TAIL COVER REMARKS G 13YD 301 653 TAPPING SCREW W FLANGE D4X20 BLACK 500 4092 CORD CORD ARMOR D8 8 500 447Z CORD CORD ARMOR D8 8 FOR SUI 500 247Z 930 108 CORD CORD CLIP CORD ARMOR D8 8 FOR NOR SWE DEN TILL 1 2001 937 631 CORD CLIP SINCE 2 2001 305 720 TAPPING SCREW W FLANGE D4X12 TILL 1 2001 984 750 TAPPING SCREW W FLANGE D4X16 SINCE 2 2001 980 063 953 327 TERMINAL CORD ARMOR D8 8 314 603 SWITCH 1P SOLDER TYPE 984 750 TAPPING SCREW W FLANGE D4X16 de m m 12 00 ALTERNATIVE PARTS STANDARD ACCESSORIES G 13
7. 2 DIAMOND WHEEL SEGMENT 125MM D22 HOLE 310 338 SUPER WASHER A ALTERNATIVE PARTS Printed in Japan 12 00 001225N Q Hitachi Koki Co Ltd
8. 800 11 000 2 1 2 2 5 16 63 dia 59 dia Grip diameter mm Bi 2 Ye S Grip perimeter mm 207 8 5 32 195 7 11 16 Dimensions L mm 290 11 7 16 285 11 1 4 H mm 63 2 1 2 73 2 7 8 W mm 72 2 27 32 76 3 Weight ka 1 7 3 7 lbs 1 6 3 5 Ibs Actual weight 1 6 3 5 Ibs Grip diameter Grip perimeter Weight excludes cord side handle depressed center wheel wheel washer and wheel guard 6 2 Comparisons in Torque vs Rotation Speed and Stator Coil Temperature Rise Fig 3 shows 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 has both a minimum drop of rotation speed even at a higher torque and a lower stator coil temperature rise at the same torque G 13V B2 Dial 6 Maximum speed Dial 1 Minimum speed Rotation speed of spindle 10 000 deer HITACHI G 13YD G 13V dial 6 8 000 B1 B2 dial 6 6 000 HITACHI G 13V dial 1 HITACHI G 13YD G 13V dial 6 B1 B2 dial 6 4 000 200 HITACHI i G 13V dial 1 Rotation speed of spindle min 2 000 31100 Stator coil temp rise k Stator coil temp rise di Load mL Fig 3 Comparison in torque vs rotation sp
9. Cover Ass y Lock Pin Gear l Bearing Cover Ball Bearing 6201DD Felt Packing Packing Gland Key Spindle Fringer Housing Stator Slide Bar Spring 18 LIST NO E241 HITACHI ELECTRIC TOOL PARTS LIST ELECTRONIC DISC GRINDER 2000 12 25 E1 Model G 13YD PARTS G 13YD CODE NO DESCRIPTION REMARKS 937 807 TAPPING SCREW D5X25 317 807 GUARD PLATE 301 944 PUSHING BUTTON 316 484 GEAR COVER ASS Y 301 941 SPECIAL NUT M7 316 437 PINION 628 VVC BALL BEARING 628VVC2PS2 L 316 480 BEARING HOLDER 360 540E ARMATURE 230V 316 479 FAN GUIDE 982 021 HEX HD TAPPING SCREW D4X70 340 484E STATOR A 230V 311 737 THRUST WASHER 319 386 DUST SEAL 608 VVM BALL BEARING 608VVC2PS2L 301 943 LOCK PIN 316 438 GEAR 997 263 SEAL LOCK SCREW W SP WASHER M4X10 316 490 BEARING COVER 620 1DD BALL BEARING 6201DDCMPS2L 301 946 FELT PACKING 317 823 PACKING GLAND 307 127 SEAL LOCK SCREW W SP WASHER M4X12 940 220 WOODRUFF KEY 2 5X8 317 804 SPINDLE 301 945 FRINGER 949 241 MACHINE SCREW M5X20 10 PCS 949 454 SPRING WASHER MS 10 PCS 994 323 WHEEL GUARD ASS Y 937 817Z WHEEL WASHER 316 822 D C WHEELS 125MM A36Q 25 PCS 994 324 WHEEL NUT M14 316 436 GEAR ASS Y 314 428 SLIDE KNOB 317 802 HOUSING NAME PLATE 995 662 RUBBER RING 318 721 MAGNET HITACHI LABEL 999 076 CARBON BRUSH AUTO STOP TYPE 1 PAIR 317 810 BRUSH HOLDER 308 536 SPRING 3
10. HITACHI POWER TOOLS ELECTRONIC DISC GRINDER TECHNICAL DATA 13YD AND SERVICE MANUAL LIST Nos E241 E242 Feb 2001 SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT Notice for use Specifications and parts are subject to change for improvement Refer to Hitachi Power Tool Technical News for further information CONTENTS Page IL PRODUET 1 2 MARKETING OBJECTIVE aie tn i aaa n aerea iaia zia 1 3 APPLICATIONS 1 4 SELLING POINTS 1 5 SPECIFICATIONS aurelio iii 3 6 COMPARISONS WITH SIMILAR PRODUCTS rrnnnnnnnnnvvnvnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnvnnnnnnnnnnnn 4 EL COTDEFIBDIES rire rea 4 6 2 Comparisons in Torque vs Rotation Speed and Stator Coil Temperature Rise 5 7 PRECAUTIONS IN SALES PROMOTION eee ss oco iii i aia iii a i 6 fi NAGI INSTOCHAMA m 6 TA Caton on Name Phal RR RR LESS 6 FRESE em 6 7 4 Operation Phenomena to Be Noted in Sales Promotion 7 8 FUNCTION AND OPERATION OF THE CONTROL CIRCUIT 8 e Conte Cpu ENN ssaa 8 A EBC RR oa EP 8 8 3 Motor Characteristics and Voltage Applied to the Motor
11. Spring end 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 turbine oil Mixture ratio 1 1 weight ratio Volume 0 5 cc cada 8 Precautions in replacing the Controller Set 45 lt 45 gt Cord Clip 55 55 55 55A and Tapping Screws 56 56 56 56A Note that the Controller Set 45 45 Cord Clip 55 55 55 55A and Tapping Screws 56 56 56A 56A vary depending on the production months em A THROUGH JAN 2001 INTER B SINCE FEB 2001 NAME ITEM GODE PART NAME SUPPLY CHANGE ITEM CODE PART NAME REMARKS NO NO ABILITY NO NO G13YD 45 319372 CONTROLLER DISCONTINUED nor 45 319372 CONTROLLER INCLUD 54 55 55 930108 CORD CLIP CONTINUED NTER 55A 937631 CORD CLIP 56 305720 TAPPING SCREW CONTINUED CHANGE 56A 984750 TAPPING SCREW W FLANGE D4 X 12 ABLE W FLANGE D4 X 16 G13V 45 319377 CONTROLLER DISCONTINUED 45 319377 CONTROLLER INCLUD 54 55 55 930108 CORD CLIP CONTINUED __ INTER 55A 930108 CORD CLIP 56 305720 TAPPING SCREW CONTINUED CHANGE 56A 305720 TAPPING SCREW W FLANGE D4 X 12 ABEE W FLANGE D4 X 16 15 9 4 Connecting Internal Wires and
12. T WASHER 319 386 DUST SEAL 608 VVM BALL BEARING 608VVC2PS2L 301 943 LOCK PIN 316 438 GEAR 997 263 SEAL LOCK SCREW W SP WASHER M4X10 316 490 BEARING COVER 620 1DD BALL BEARING 6201DDCMPS2L 301 946 FELT PACKING 317 823 PACKING GLAND 307 127 SEAL LOCK SCREW W SP WASHER M4X12 940 220 WOODRUFF KEY 2 5X8 317 804 SPINDLE 301 945 FRINGER 949 241 MACHINE SCREW 5 20 10 PCS 949 454 SPRING WASHER M5 10 PCS 994 323 WHEEL GUARD ASS Y 937 8172 WHEEL WASHER 316 822 D C WHEELS 125MM A36Q 25 PCS 994 324 WHEEL NUT M14 316 436 GEAR ASS Y 314 428 SLIDE KNOB 317 802 HOUSING NAME PLATE 995 662 RUBBER RING 318 721 MAGNET HITACHI LABEL 999 076 CARBON BRUSH AUTO STOP TYPE 1 PAIR 317 810 BRUSH HOLDER 308 536 SPRING 319 370 SLIDE BAR 314 429 SPRING 319 899 CONTROLLER SET 938 307 PILLAR TERMINAL 301 653 TAPPING SCREW W FLANGE D4X20 BLACK 311 741 TERMINAL 314 854 EARTH TERMINAL 994 273 NOISE SUPPRESSOR 959 140 CONNECTOR 50091 10 PCS 2 ALTERNATIVE PARTS 12 00 A INCLUD 3 16 INCLUD 27 28 INCLUD 6 17 INCLUD 55A 56A FOR NOISE SUPPRESSOR nm A 1 m m A m mm jii i A AAA N md md m AA N m a md mmm PARTS G 13V CODE NO DESCRIPTION REMARKS 319 376 TAIL COVER 301 653 TAPPING SCREW W FLANGE D4X20 BLACK 500 4092 CORD 500
13. YD CODE NO DESCRIPTION i REMARKS 938 332Z WRENCH 302 142 SIDE HANDLE CODE NO DESCRIPTION i REMARKS 937 8252 RUBBER PAD 937 8262 WASHER NUT 314 062 SANDING DISCS 125MM C P16 10 PCS 314 063 SANDING DISCS 125MM C P20 10 PCS 314 064 SANDING DISCS 125MM C P24 10 PCS 314 065 SANDING DISCS 125MM C P30 10 PCS 314 066 SANDING DISCS 125MM C P36 10 PCS 314 067 SANDING DISCS 125MM C P40 10 PCS 314 068 SANDING DISCS 125MM C P50 10 PCS 314 069 SANDING DISCS 125MM C P60 10 PCS 314 070 SANDING DISCS 125MM C P80 10 PCS 314 071 SANDING DISCS 125MM C P100 10 PCS 314 072 SANDING DISCS 125MM C P120 10 PCS 310 392 DIAMOND WHEEL SEGMENT 125MM D22 HOLE 310 338 SUPER WASHER AAA m m m m m Ll A ALTERNATIVE PARTS Printed in Japan 12 00 001225N LIST NO E242 HITACHI ELECTRIC TOOL PARTS LIST ELECTRONIC DISC GRINDER 2000 12 25 E1 Model G 13V PARTS G 13V CODE NO DESCRIPTION REMARKS 937 807 TAPPING SCREW D5X25 317 807 GUARD PLATE 301 944 PUSHING BUTTON 316 484 GEAR COVER ASS Y 301 941 SPECIAL NUT M7 316 437 PINION 628 VVC BALL BEARING 628VVC2PS2 L 316 480 BEARING HOLDER 360 540E ARMATURE 230V 319 898 FAN GUIDE 982 021 HEX HD TAPPING SCREW D4X70 340 484E STATOR 230V 311 737 THRUS
14. ant rotation speed even when there are fluctuations in the load 4 Ramp generator Generates the voltage which determines the acceleration of the motor The soft start function when the motor is turned on is achieved through a gradual increase of the voltage generated by this circuit When fully charged the voltage of the ramp generator becomes equal to the standard voltage above 5 Differential amplifier Compares the voltage from the ramp generator voltages received from the F V converter which is proportionate to the actual motor rotation speed and amplifies the result This circuit functions as follows to maintain a constant rotation speed Motor rotation speed decreases or increases gt frequency signal decreases or increases gt output voltage of the F V converter decreases or increases output voltage of the differential amplifier increase or decreases 6 Load current detecting circuit Detects the load current by means of a low resistance resistor which is in series with the motor and the triac 7 Load current control circuit When the detected load is excessive overload this circuit sends a command control signal to reduce power to the motor 8 Phase control circuit Generates the trigger signals necessary to turn the triac on and delivers them to the gate of the triac The conductive angle of the triac is determined by the timing of the generated trigger signals When starting the tool Controlled by t
15. d 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 lt 24 gt contacts the Ball Bearing 20 20 and the Spindle 25 25 cannot be pushed down any more Be careful not to deform the Fringer 26 lt 26 gt 3 Turn the Packing Gland 22 22 upside down and fix it then push down the Spindle 25 lt 25 gt 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 lt 20 gt Ush Gear puller J 128 24 24 NARA Push 25 lt 25 gt 25 lt 25 gt Steel plate 17 lt 17 gt 24 lt 24 gt 26 lt 26 gt 24 lt 24 gt Step 2 Step 3 Step 4 Fig 6 12 9 3 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 a faster rate 2 Be sure to
16. d normal rotation speed the overload protection circuit will immediately reactuate 3 When beginning operation if the Depressed Center Wheel or cut off wheel is pressed against the workpiece before the tool has reached full rotation speed there is a chance that the overload protection circuit will be actuated Instruct the customer never to turn the switch on with the Depressed Center Wheel in contact with the workpiece or to press the wheel against the workpiece immediately after the switch has been turned on It is strongly recommended that operation be begun only after a constant normal rotation speed has been attained 4 Failure of the control circuit may result in abnormally high rotation speed If the control circuit in the tool should malfunction the rotation speed may increase excessively and continued use of the tool would be extremely hazardous In such a case when rotation speed increases abnormally the operator will become aware of abnormal noise from the motor and or gears Should such a phenomenon occur the customer is advised to immediately shut off the tool and bring it to the nearest Hitachi authorized sales outlet or repair center for inspection and repair 5 There may be minor variation in the operation of the overload protection circuit Although the tool is designed to minimize variation of the operation of the overload protection circuit there may nonetheless be some variation caused by fluctuation in the power sup
17. d the Bearing Holder 8 8 from both sides and fix the hooks with the wing bolts 6 Place the J 204 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 Remove the Magnet 38 lt 38 gt Note that the magnet is left hand threaded 2 Insert the hooks of the J 204 bearing puller between the commutator and the Dust Seal 14 14 from both sides and fix the hooks with the wing bolts 3 Place the J 204 bearing puller on a supporting jig and push down on the armature shaft with a hand press to remove the Dust Seal 14 14 together with the Ball Bearing 15 15 Replace the Dust Seal 14 14 with new one because it is damaged by the removal of the Ball bearing 15 lt 15 gt 3 Disassembly of the controller 1 Remove the Tail Cover 52 52 Disconnect the internal wire from the Switch 59 59 and remove the Connector 51 51 and the Terminal 48 48 from the internal wire 2 Remove the neutral conductor of the Noise Suppressor 50 50 from the Housing 35 lt 35 gt 3 Remove the Tapping Screws 47 47 56 56 56A 56A 60 lt 60 gt NOTE When removing the Tapping Screw W Flange D4 x 16 60 lt 60 gt use a small diameter screwdriver 8 5 mm to 4 5 mm in diameter 4 Disassembly of the stator ass y 1 Remove the Ar
18. e 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 Equipped with four electronic control devices Wear resistance of armature coil 1 Constant speed control 2 times higher than B2 2 Soft start speed control 8 Overload protection control 4 Variable speed control G 13V only High power with maximum output of 1 730 W mm B1 and B2 1 330 W Excellent overload durability 1 1 times higher than B1 and B2 Excellent overload durability The Models G 13YD and G 13V provide excellent overload durability thanks to an improved cooling mechanism and a high power motor Practical test data Comparison of torque when the stator coil temperature rise is 200 K c o ov 100 0 50 100 Fig 1 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 G 13YD and 13V Varnish and adhesive B1 and B2 Varnish Coating of heat resistant adhesive Fig 2 5 SPECIFICATIONS peripheral speed 4 800 m min 15 756 ft min 80 m s Item Mode G 13YD G 13V O D 125 mm 5 mensions x Thickness 6 mm 1 4 center x 22 mm 7 8 whee
19. eed and stator coil temperature rise G 13YD G 13V Fig 3 indicates 1 Because the Models G 13YD and G 13V are equipped with high power motors and improved cooling mechanisms the stator coil temperature rise is lower than that of B1 and B2 at the same torque and the motors are resistant to be burnt out 2 The rotation speed of the Models G 13YD and G 13V is higher than that of B1 and B2 at the same torque under heavy load conditions This shows that the Models G 13YD and G 13V ensure excellent performance 7 PRECAUTIONS IN SALES PROMOTION In the interest of promoting the safest and most efficient use of the Models G 13YD and 13V Electronic 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 contents 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 effici
20. ent 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 1 Check the power source voltage Ensure that the power source voltage conforms with the power specifications listed on the Name Plate Never operate the Models G 13YD and G 13V on a direct current DC power source The control circuit in this tool functions through a phase control system utilizing a triac and will not function if DC power is applied Subsequent uncontrolled increase of motor rotation speed could be extremely hazardous 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 1 For Australia CAUTION Read thoroughly HANDLING INSTRUCTIONS before use 7 3 Precautions on Usage 1 The wheel guard must be aligned in relation to the side handle mounting position As illustrated in Figs 4 and 5 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 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 immediatel
21. he soft start circuit the phase control circuit generates trigger signals to gradually increase the conductive angle of the triac Constant speed operation When there are variations in the rotation speed the phase control circuit generates trigger signals to keep the rotation speed as close as possible to the present rotation speed determined by the standard voltage circuit In short when the load increases and causes the rotation speed to decrease the conductive angle of the triac is increases and the voltage applied to the motor is increased In this way the rotation speed is kept as close as possible to the standard rotation speed Overload function When the load increases and load current exceeds a predetermined value the load current control circuit causes the phase control circuit to generate a trigger signal equal to the conductive angle 8 3 Motor Characteristics and Voltage Applied to the Motor Phase control voltage waveform Soft start characteristics when starting the tool Conductive Angle a a dn Di 5 5 N LA E m When electronic Voltage lied to N not applied E e motor increases duail gradually 13V LA 7 Dial N Rotation Speed 6 G13YD N O Switch ON determined by 7 Time the Standard Voltage Circuit 13V Dial seen X As the load increases N the voltage applied to the motor increases G 13V Dial V
22. l Max practical Type A 36 Q BF Power source AC single phase 50 or 60 Hz Voltage current and input Voltage V Current A Power input W 230 5 1 1 110 240 4 9 1 110 No load speed 10 000 min 2 800 10 000 min Type of motor AC single phase commutator motor Type of switch Slide switch Material Housing Green Tail cover Black Glassfiber reinforced polyamide resin Enclosure Gear cover packing gland Aluminum alloy die casting Painting Gear cover packing gland Metallic silver Weight Net 1 7 kg 3 7 lbs Gross 2 9 kg 6 3 Ibs Packaging Corrugated cardboard box Standard accessories Depressed center wheel 125 mm 5 1 Side ca tata br A 1 Miei E 1 Net weight excludes cord side handle depressed center wheel wheel nut wheel washer and wheel guard Relationship between dial settings and rotation speeds of the Model G 13V reference El 1 E 0 000 o 8 000 Q o O 6 000 9 DI 4 000 5 5 2000r 1234 5 6 Dial 6 COMPARISONS WITH SIMILAR PRODUCTS 6 1 Specification Comparisons Maker HITACHI B1 B2 Model 13YD G 13V Wheel diameter mm 125 5 125 5 Power input W 1 110 1 020 Output W 720 570 Max output W 1 730 1 330 No load speed min 10 000 2 800 10 000 11 000 2
23. mature 9 9 and then pull out the two Brush Holders 41 41 from the Housing 35 35 2 Remove the Controller Set 45 45 from the Housing 35 lt 35 gt 3 4 5 Remove the internal wire coming from Stator A 12 12 from the Brush Holder 41 lt 41 gt Remove the Fan Guide 10 10 from the Housing 35 lt 35 gt Loosen the two Hex Hd Tapping Screws D4 x 70 11 11 to remove Stator A 12 12 from the IO Lc WH Housing 35 35 If Stator A 12 12 cannot be removed easily heat the Housing 35 35 to about 60 C Then Stator A 12 12 can be removed did 5b Disassembly of the slide knob 1 Loosen the Tapping Screw W Flange D4 x 20 Black 53 53 to pull out the Tail Cover 52 52 2 Hold the Housing 35 35 and raise the Slide Bar 43 43 until the Slide Knob 34 34 moves to the ON position 3 Check that the Slide Knob 34 34 has not moved to the ON LOCK position and push down the Slide Knob 34 34 until it clicks while keeping the Slide Bar 43 43 raised 4 Raise the Slide Knob 34 34 straight up and remove it keeping the Slide Bar 43 43 raised 6 Disassembly of the gear Fig 6 1 Loosen the four Seal Lock Screws W SP Washer M4 x 12 23 23 fixing the Packing Gland 22 lt 22 gt and remove the Packing Gland 22 22 from the Gear Cover Ass y 4 4 2 Support the bottom of the Packing Glan
24. mature with a rated torque of 1 27 0 29 Nem 13 3 kgf cm 0 9 0 2 ft lb NOTE When disassembled never place the Magnet 38 38 in the vicinity of metal particles or shavings Should such metal particles adhere to the magnet they could cause malfunction of the control circuit and or serious damage to the commutator side ball bearing of the armature 6 Controller troubleshooting chart To determine replacement of the Controller Armature Stator Magnet and 608VVC2PS2 L Ball Bearing Does Motor Rotate Is rotation speed too high or low No Check wiring of Armature Stator Carbon Brushes and Switch Replace the Controller Check Armature Stator and Magnet Replace Controller Does Overload Protection Circuit Work normally Replace the Controller cq 9 2 Disassembly 1 Disassembly of the armature 1 Loosen the Tapping Screw W Flange D4 x 20 Black 53 53 to pull out the Tail Cover 52 52 2 Remove the two Carbon Brushes 40 40 from the Brush Holders 41 415 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 35 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 5 Insert the hooks of the J 204 bearing puller between the Ball Bearing 7 7 an
25. oltage applied to the ist motor is decreased and the motor stops i Current Value determined by the Load Current Control Circuit A pa 0 No load Over ioad Protection Circuit Actuates Se LJAN zig 9 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 13YD and the Bold numbers to those in the Parts List and the exploded assembly diagram for G 13V 9 1 Precautions in Maintenance and Repair 1 Without fail remove the plug from the power outlet to prevent accidental starting of the tool 2 Remove the depressed center wheel to prevent it from being damaged 3 Do not strike the main body of the tool with a hammer or similar tool The electronic control circuit built into the Controller Set 45 45 can be damaged by the impact of a hammer or similar tool Under no circumstances should such tools be used when the controller set is assembled in the main body 4 Do not attempt to remove or replace internal parts of the Controller Set 45 45 The controller set is the very brain of the tool and should never be disassembled 5 When reassembling the tool ensure without fail that the Magnet 38 38 is properly installed Also note that the magnet is left hand threaded and must be turned counterclockwise to mount it on the Armature 9 9 On reassembly tighten the magnet onto the ar
26. ply or ambient temperature Accordingly the following points should be noted a When the ambient temperature is low the point current load at which the overload protection circuit activates will be higher b After several minutes of operation when the main body of the tool becomes warm the overload protection circuit will activate at a load current approximately 1596 lower than immediately after starting operation 8 FUNCTION AND OPERATION OF THE CONTROL CIRCUIT 8 1 Contorl Circuit Block Diagram Switch Motor Trac AC Power Source Standard Voltage Circuit F V Converter 1 i l Ramp Generator Differential Amplifier Soft Start and Constant Speed Controi Circuit Model G 13V only Phase Control Circuit I e L Load Current Detecting circuit e Load Current Control Circuit Gmi Over load Protection Circuit 8 2 Function of Each Block 1 Rotation speed detector Generates a frequency signal proportionate to the actual rotation speed of the motor A magnetic sensor in the controller monitors changes in the magnetic flux from a magnet and generates a frequency signal 2 F V converter Converts the frequency signal produced by the rotation speed detector into DC voltage 8 Standard voltage circuit Generates a standard voltage which determines the no load rotation speed of the motor and serves as a reference in maintaining const
27. y 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 7 4 Operation Phenomena to Be Noted in Sales Promotion 1 The overload protection circuit tends to be easily actuated by certain types of work If excessive pressure is applied on the tool during cutting or similar heavy duty operation the overload protection circuit will be actuated and the motor will be automatically stopped This is because the overload protection circuit detects the increased flow of current caused by the excessive pressure on the tool and automatically turns off the motor to protect it from possible overload burnout The customer should be advised that the Models G 13YD and G 13V are specifically designed to perform more efficiently and faster with considerably less applied pressure than is required for conventional disc grinders and that skillful use of the tools with minimal applied pressure will avoid actuating the overload protection circuit 2 The customer should be advised to immediately remove the tool from the workpiece when the overload protection circuit has been actuated and not to resume operation until the tool has again reached normal rotation speed In this case it takes slightly longer for the tool to reach normal rotation speed than at the time of soft start about three seconds If the user attempts to resume operation before the tool has reache
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