Repair Manual Hitachi grinder

Hitachi grinder are very popular among Russian builders.There are two reasons: the high degree of reliability and lack of fakes.In addition, the Japanese brand, founded in 1910, reasonable price, a lot of innovation, high reliability.

Angle grinders (Bulgarian) Hitachi company are available in several varieties, depending on the capacity.
purpose of this article, suggest methods of repair Hitachi Bulgarians with their own hands.Repair LBM Hitachi, as a rule, the guarantee is performed at service centers.But reading the proposed instruction, you can easily perform repair grinder Hitachi.

Design Features Bulgarians Hitachi

Even in appearance, you can immediately say that in front of you Hitachi Bulgarian.Upper plastic casing Hitachi angle grinders consist of two parts of different colors and has an overlay of the original form.

outer contours of parts of the grinder housing, a special bright green-and-black color, additional handle with mandatory labeling model, inscription bright white - are the main differences between the appearance of the grinder Hitachi.

under the Hitachi brand produced several models of Bulgarians.We select the most popular: G13SE2, G13SR3, G23SEY, G23SRU.

figures in designation indicate the maximum diameter of the applicable cut-off wheel.
grinder Hitachi, indicated under 13 have a capacity of up to 1000 watts.Grinder with the numbers 13 are designed for a range of minor works to 125.
Bulgarians have with numbers 23 capacity of more than 1000 watts.Bulgarians have a designation used 23 drives and 230 can be carried out more complex work.
Feature bolgarok construction Hitachi is available to protect against overheating and improved cooling system.
All Hitachi grinder equipped with an additional handle.Structurally
grinder Hitachi family of each other do not differ.Although minor changes may occur.

repair tools grinder Hitachi

Run grinder Hitachi repair is impossible without tools.You should prepare a set of screwdrivers, short-circuited turns in the windings of the control device, the tester, pliers, open-end wrench.Do not do without improvised devices, if you want to repair their own hands Hitachi grinder.

Well, if you have a screwdriver and replaceable nozzle-screwdriver, properly fitted on slots unscrew screws.

of the devices you will need: Bearing Puller, press, vise, nastavki soft metal.

Strippers need to remove the gears and bearings.The grip is convenient to clamp individual grinder units.Open-end wrench to spin nut locking pinion.

During the repair can not do without lubricants, washes and paints.

need for cleaning rags or pieces of pure material.

Do not forget about proper workplace equipment.It should be well-lit.
All Hitachi grinder failure can be divided into two types: a fault on the electrical and mechanical problems.

Faults Hitachi grinder for electrical

grinder Hitachi suffer failure of switches, carbon brushes, wire breakage of the stator windings.
Like all electric tools, the emergence of a working electrical parts largely depends on the state of the carbon brushes.The grinder Hitachi carbon brushes set with built-in device, popularly called the "shot".The task of such a device, to prevent the inclusion of Hitachi Bulgarians with a high degree of wear of carbon brushes.
weak point in the design of electrical bolgarok Hitachi is the place to enter the power cable.At this point most often occurs breakage, fracture, bare wires.

motor Check

On malfunction Bulgarian indicates several things:

• rotation of the working body jerks;
• fall of speed and power angle grinders Hitachi;
• Spontaneous set speed;
• Strong heating of the stator housing;
• emergence of large sparks in the collector region;
• burning smell, smoke.

Fall power output due to the open or short circuit the rotor windings.

rotor repair

rotor repair Hitachi grinder is no different from any repair rotor grinders.Not every consumer will be able to eliminate this kind of problem.For this we need to have not only special equipment, but also the skills winder.It is preferable to send the failed rotor specialized service centers.

But fans get to the truth we suggest reading algorithm rotor rewind.

On rotor failure indicated by the appearance of burning in the reservoir area.Typically, burn slats, appears dark coating on the winding wires.

rotor should be removed from the housing:

• Remove the carbon brushes;
• Remove the gearbox cover;
• Unscrew the nut of the pinion;
• Pull the rotor from the gear case;
• Pull the rotor from the stator housing.

If there is IR-2 device, it is possible without disassembling the rotor, to measure a short circuit or an open winding turns.

Disassembly of faulty rotor begin to dismantle the armature shaft with the rotor bearing, the impeller.Bearings and impeller is recommended to remove the pliers to avoid damaging parts.If the collector is damaged and can not be restored, it must also be dismantled by means of a stripper.Pre Unsolder winding ends soldered to the commutator bars.It remains to remove the burnt winding.Hacksaw to cut off the winding end, count the number of turns in the multiple grooves, sketch a winding direction, determine the percentage of filling the slots of the armature core.With the help of a micrometer, measure the diameter of the wire being used.These data you will need if you decide to wind anchor Hitachi grinder hands.

to encourage consumers to purchase the rest of the new rotor in the service centers or online stores.

Stator Repair

On the failure of the stator often indicates significant overheating of the Bulgarian housing and spontaneous set of revolutions, is not amenable to regulation.The fault can be determined by pulling the stator from the casing:

• Disconnect the gear housing and the stator housing by removing the four screws;
• Remove the gearbox to the rotor from the stator housing;
• Remove the plastic protection of the stator;
• Remove the two screws fastening the stator and remove it.

stator breakage is readily determined by a tester.But interturn short circuit is best measured device IR-2 or an oscilloscope.Repair stator grinder Hitachi own hands can be performed at home.But you have to have certain skills.

The failed first stator understands:

• exempt carve contacts;
• From one end of the winding core is cut hacksaw;
• believed the number of stacked turns of wire, the winding direction, the percentage of fill slots;
• measured the diameter of the wire by means of a micrometer;
• Stripping core from traces of soot, droplets of molten copper wire.

stator Manufacturing described in detail on our web site.For those who will not be difficult to do the job.

few tips when winding:

• Use this wire diameter, which was used in the stator;
• If the volume of stator slots allows, is preferable to use heavy gauge wire, but do not overdo it;
• Try to stack tightly wound coils at controlling the shape of the winding;
• carefully linked coil mounting thread or cord;
• stator winding is wound necessarily soak paint or varnish impregnated using an alternating voltage across the LATR;
• At the end of the winding, clean middle of the stator core of the traces of paint, varnish.

Video rewinding the stator power

Repair of electrical control circuits grinder Hitachi

electric power control circuit is a simple structure.Perform the task in a smooth launch tool, the ability to adjust the frequency speed, enable or disable the tool.The structure of the control circuit includes the switch, speed control, motor, carbon brushes, power cable and switching elements.Consider the operation of the electrical part of Hitachi grinder on the example of two models: Hitachi G13SB3 and Hitachi G23SCY.

Schematic diagram grinder Hitachi G13SB3 LBM 125

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Meals poz.52 cable enters the terminal poz.53 which are connected to the switchpoz.42.At the entrance to the housing Bulgarian cable retainer clip poz.55.To switch connects suppressor poz.46 and wires to the carbon brushes poz.39.The Hitachi grinder used carbon brushes with hitchhiking.The size of the carbon brushes in the grinder Hitachi G13SR3 6.5 × 7.5 mm.Carbon brushes installed in the brush holder poz.38.The inclusion of Hitachi grinder is due to move poz.36 toggle button.

most common faults in the grinder Hitachi happen in case of failure of the supply cable to the login site, wear carbon brushes poz.39, refusal to work poz.42 switch.

are eliminated this kind of malfunction replacement of defective parts or pieces of wire.

Schematic diagram grinder Hitachi G23SCY LBM 230

Mechanical faults grinder Hitachi

The gear grinder Hitachi reliability admired.But with proper maintenance.

in case of overheating or intermittent jamming of the tool in contact with dust, a late replacement carbon brushes, no Bulgarian would not last long.

Much driven gear in Hitachi grinder to drive up to 125 mm is attached by means of key connection.Bulgarians have the disc to 230 mm gear is pressed onto the spindle shaft.Small drive gear in any design grinder Hitachi is keyed and secured with a nut.

gear repair grinder Hitachi

Reducer Hitachi grinder is made with high accuracy.The LBM is practically not felt the beat of teeth gear wheels.On wear special gear affected by incorrect operation.Consider repairing gearboxes Hitachi angle grinders two models: Hitachi G13SR3 and Hitachi G23SCY.

gear grinders Construction Hitachi G13SR3 disk 125

The grinder with a disc diameter of 125 mm crown wheel is mounted on poz.33 poz.26 spindle shaft with keyed connection poz.25.Precision manufacturing key connection prevents the formation of play idler shaft.The presence or absence can be determined by the backlash in opposite directions of rotation of the spindle shaft.When there is a large backlash gears must be replaced both at the same time as they are made in pairs.

Removing the driven gear shaft with gear grinder Hitachi disk 125

Understands shaft driven gear in the following sequence:

• wriggle out of four (4) M4 screw × 12 poz.24;
• poz.23 remove the cover to the shaft;
• dismantles poz.15 retaining ring and ring for shaft poz.17;
• shaft is extruded (knocked out) from the cover, which is mounted bearing poz.21.Bearing Type 6021DD;
• driven gear poz.33 removed from the shaft by a simple tap on the shaft;
• remove the key poz.25

To get poz.21 bearing, it is necessary to unscrew the 2 screws M4 × 10 poz.19 fixing cover poz.20 bearing.The grinder Hitachi G13SR3 bearings used in three types: 628 - mounted on a spindle gear, 626 - is mounted on the rotor by the pinion, 6201 - mounted on the rotor by the collector.

Removing the drive pinion shaft with Hitachi grinder rotor disk 125

To remove the pinion gear poz.33, it is necessary to hold the rotor position 8.The gear is fixed pos.4 M6 nut.With open-end wrench, unscrew the nut by turning counterclockwise.After removing the gear, remove the rotor from the gearbox housing.

Replacing bevel gears in a grinder Hitachi

The Hitachi grinder defective bevel gear pair changes.By replacing gears causes wear on the teeth, licking the destruction of several teeth.

gear grinders Construction Hitachi G23SCY disk 230

Reducer bolgarok disk up to 230 mm is significantly more powerful.In the gear structure 230 applied poz.24 clutch and damper poz.23.This structure acts as a clutch, preventing shock when working drive biting or emergency stop it.Coupling allows you to run smoothly grinders.

Removing the driven gear shaft with gear grinder Hitachi disk 230

to dismantle the gear reducer with the disc 230 should be used, making sure that no restoration work is not possible.

driven gear assembly Disassembly is no different from a similar showdown node grinder with the disc to 125 mm.The only difference in the gear grinder 230 poz.20 pressed onto the shaft poz.29.To remove the gear from the shaft by means of a better press, but also the means at hand fit.For example, a vise.The shaft mounted in the bearing poz.27.Bearing Type 6302DD.

The grinder Hitachi G23SCY used three types of bearings: 6302DD - mounted on a spindle gear, 6301DD - mounted on the rotor by the pinion, 6000VV - mounted on the rotor by the collector.

Rules lubrication gear bolgarok Hitachi

Lubricant quality in the gearbox is possible to determine the percentage of wear of bevel gears.The darker the grease, the more in it traces of metal shavings, the greater the likelihood of an increased percentage of wear of gears.The percentage of wear gear reducer easily determined by the contact patch.

To remove the old grease, use a special flushing liquid.To thoroughly remove all the old grease is recommended to warm up the gear case with a hair dryer to the conversion into a liquid lubricant.

new grease is applied to the gear housing in an amount less than half the volume of the body.For lubrication gear manufacturers to produce their own lubrication.But Russian producers have learned to do lubrication, not inferior in quality to foreign, but the price is significantly lower.

Conclusion:

reliability of Hitachi's bolgarok provided technological and organizational measures;

grinder Hitachi difficult to forge;

in Hitachi grinder implemented the basic principle of best value for money;