Repair manual for Bulgarian Hitachi

Bulgarians Hitachi are very popular among Russian builders. There are two reasons: high degree of reliability and absence of fakes. In addition, the Japanese brand, founded in 1910, an affordable price, a lot of innovation, high reliability.
Angular grinding machines( grinders) from Hitachi are available in several versions, depending on capacity.
The purpose of this article is to suggest methods for repairing Hitachi Bulgarians with their own hands. Repair of Ushm Hitachi, as a rule, under warranty is performed in the service centers. But having familiarized yourself with the proposed instruction, you can easily repair the Bulgarian Hitachi.

Features of the design of Bulgarians Hitachi

Even in appearance you can immediately say that before you Bulgarian Hitachi. The upper plastic case of Ushma Hitachi consists of two parts of different colors and has patches of the original form.

The external contours of the parts of the housing of the Bulgarian, a special bright green and black color, an additional handle with the obligatory model designation, an inscription of bright white color - these are the main differences between the look of the Bulgarian Hitachi.

Several models of Bulgarians are produced under the Hitachi brand. We will highlight the most popular: G13SE2, G13SR3, G23SEY, G23SRU.

The numbers in the designation indicate the maximum diameter of the cutting disc used.
Bulgarians Hitachi, indicated by the number 13 have a power of up to 1000 watts. Bulgarians with numbers 13 are designed to perform small works with a circle of 125.
Bulgarians with figures of 23 power more than 1000 watts. Bulgarians with the designation 23 use disks 230 and more complex work can be performed.
Feature of the design of Bulgarian Hitachi is the availability of protection against overheating and an improved cooling system.
All Bulgarians Hitachi are equipped with an additional handle.
Structurally, the Bulgarians of the Hitachi family do not differ from each other. Although insignificant changes can occur.

Tool for repairing the Bulgarian Hitachi

It is impossible to repair the Bulgarian Hitachi without a tool. You should prepare a set of screwdrivers, a device for monitoring short-circuiting turns in windings, a tester, pliers, carabiner keys. You can not do without tooling if you want to repair the Hitachi grinder with your own hands.

Well, if you have a screwdriver and replaceable screwdriver bits, correctly selected by the slots of the screws to be unscrewed.

Of the devices you will need: bearing remover, press, vice, soft metal.

Pullers are needed for removing gears and bearings. In the vice it is convenient to clamp the individual knots of the Bulgarian. With the wrench, the fixing nuts of the drive pinion are untwisted.

When carrying out repairs, you can not do without lubricants, washes, or paints.

For cleaning, you will need rags or pieces of clean material.

Do not forget about the correct equipment of the workplace. It should be well lit.
All faults of the Hitachi grinder can be divided into two types: electrical faults and mechanical faults.

Hitachi grinder malfunctions on electrical part

Bulgarians Hitachi suffers from failure of switches, carbon brushes, wire stator windings breakage.
As with all electrical tools, the appearance of the electrical parts is largely dependent on the state of the carbon brushes. In Bulgarian Hitachi coal brushes with the built in device, in the people called "shot" are installed. The task of such a device is to prevent the inclusion of Hitachi Bulgarians with a high degree of wear of carbon brushes.
The weak point in the design of the electric part of the Hitachi Bulgarians is the place of input of the power cable. In this place most often there is a breakage, a break, a bare cable.

Checking the electric motor

There are several points to the incorrect operation of the bolgar:

• Rotating the workpiece with jerks;
• Drop in speed and power of Ushm Hitachi;
• Spontaneous speed dial;
• Strong heating of the stator housing;
• Appearance of significant sparking in the collector area;
• Appearance of the smell of burning, smoke.

The drop in the power of the power tool is due to the breakage or short circuit of the rotor windings.

Repair of rotor

Repair of the rotor of the Bulgarian Hitachi is no different from repairing the rotor of any Bulgarians. Not every consumer can eliminate this kind of malfunction. For this it is necessary to have not only special instruments, but also the skills of the winding machine. Preferably, the defective rotor is sent to specialized service centers.

But for fans to get to the bottom of the truth, we recommend you familiarize yourself with the algorithm of rewinding the rotor.

The output of the rotor is indicated by the appearance of burning in the vicinity of the collector. As a rule, lamellas burn out, a dark coating appears on the wires of the winding.

The rotor should be removed from the body:

• Remove carbon brushes;
• Remove the gearbox cover;
• Remove the drive pinion nut;
• Pull the rotor out of the gear housing;
• Pull the rotor out of the stator housing.

If there is an IR-2 device, you can, without analyzing the rotor, measure the presence of a short circuit of turns or breakage of the windings.

The dismantling of the failed rotor begins with the dismantling of the shaft of the rotor bearing armature, the impeller. It is recommended to remove bearings and impeller with special pullers, so as not to damage the parts. If the collector is damaged and can not be repaired, it must also be dismantled using a puller. Pre-solder the ends of the windings soldered to the collector sipes. It remains to remove the burnt winding. Cut the end of the winding with a hacksaw, count the number of turns in several grooves, draw the winding direction, determine the percentage of filling the grooves of the armature core. Using a micrometer, measure the diameter of the wire used. This data will be needed if you decide to wind the anchor of the Hitachi Bulgarians with your own hands.

For other customers, we recommend purchasing a new rotor in service centers or online stores.

Repair of stator

The stator's failure is most often indicated by a significant overheating of the case of the Bulgarian and a spontaneous set of revolutions that can not be regulated. The fault can be determined by pulling the stator out of the housing:

• Disconnect the gear housing and the stator housing by removing the four screws;
• Pull out the gear unit with the rotor from the stator housing;
• Remove the plastic stator protection;
• Remove the two screws securing the stator and pull it out.

The stator breakage is easily determined by the tester. But inter-turn short-circuit is best measured with an IR-2 or an oscilloscope. Repair stator Bulgarki Hitachi own hands can be performed at home. But you need to have some skills.

The failed stator is first disassembled:

• The outgoing contacts are released;
• From one end of the core, the winding is cut with a metal hacksaw;
• It is counted the number of laid turns of the wire, the direction of winding, the percentage of filling the grooves;
• The diameter of the wire used is measured with a micrometer;
• The core is peeled off traces of carbon deposits, drops of molten copper wire.

The manufacture of stator is described in detail on the pages of our website. For those who wish, it will not be difficult to carry out this work.

Some useful tips for winding:

• Use a wire of the same diameter as that used in the stator;
• If the volume of the stator slots allows, it is preferable to use a larger wire, but do not overdo it;
• Try to tightly wrap the windings while winding, controlling the shape of the winding;
• Carefully tie the winding with a mounting thread or cord;
• The winding of the wound stator must be impregnated with paint or varnish, using an alternating voltage during impregnation through LATR;
• After winding, clean the center of the stator core from traces of paint, varnish.

Video of stator winding of power tool

Repair of electric control circuits for grinders Hitachi

Electric control circuits for power tools are a simple design. Perform the task of smooth running the instrument, the possible adjustment of the speed of revolutions, switching on and off the tool. The control circuit includes a switch, a speed controller, an electric motor, carbon brushes, a supply cable and switching elements. Consider the work of the electric part of the Bulgarian Hitachi on the example of two models: Hitachi G13SB3 and Hitachi G23SCY.

Schematic diagram of the Bulgarian Hitachi G13SB3 Ushm 125

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The power supply via cable pos.52 goes to the terminals pos.53, connected to the switch pos.42.At the entrance to the case of the Bulgarian, the cable is fixed with a clip pos. A noise cancellator pos. 46 and wires to carbon brushes pos. 39 are connected to the switch. In the Bulgars of Hitachi, carbon brushes with a hitchhiking are used. The size of carbon brushes in the Bulgarian Hitachi G13SR3 6.5 × 7.5 mm. Carbon brushes are installed in the brush holder pos.38.Turning on the Hitachi grinder occurs by moving the shift button pos.36.

The most frequent faults in Bulgarians Hitachi occur when the supply cable fails at the entrance point, the wear of the carbon brushes at position 39, the failure of the switch in pos. 42.

This kind of malfunction is eliminated by replacing a failed part or piece of wire.

Schematic diagram of the Bulgarian Hitachi G23SCY Ushm 230

Mechanical faults of the Bulgarian Hitachi

The reliability of the reducers in the Bulgarians Hitachi is admirable. But this is with proper use.

In case of overheating or periodic jamming of the tool, if dust gets in, untimely replacement of carbon brushes no bulgarian will last long.

The big driven gear in the Bulgars Hitachi with a disc of up to 125 mm is attached using a keyed connection. For Bulgarians with a disc up to 230 mm, the pinion is pressed onto the spindle shaft. The small driving gear in any design of the Bulgarian Hitachi is fixed with a key and fixed with a nut.

Repair of the Bulgarian reducer Hitachi

The reducer of the Bulgarian Hitachi is manufactured with high precision. In the ushm, the beating of the teeth of the gear wheels is almost not felt. The wear of gears is particularly affected by improper operation. Consider the repair of gearboxes Ushm Hitachi on two models: Hitachi G13SR3 and Hitachi G23SCY.

Design of the Hitachi G13SR3 grinder with a disk up to 125

In Bulgarians with a disk diameter of up to 125 mm, the driven gear pos.33 is attached to the spindle shaft pos. 26 using a keyed connection pos.25.The accuracy of the keyed connection excludes the formation of a backlash of the driven gear on the shaft. The presence or absence of play can be determined by rotating the spindle shaft in different directions. If there is a large gap, both gears must be replaced at the same time, since they are produced in pairs.

How to remove the driven gear from the reducer shaft of the Bulgarian Hitachi with the disc up to 125

The shaft of the driven gear is disassembled in the following order:

• Four( 4) M4 × 12 screws are pivoted; pos.24;
• The cover of pos. 23 is removed with the shaft;
• The circlip 15 is removed and the shaft ring pos. 17;
• The shaft is pressed out( knocked out) from the lid into which the bearing is posed. Bearing Type 6021DD;
• The driven gear pos. 33 is removed from the shaft by simply tapping the shaft;
• The key is released in pos.25

In order to reach the bearing pos.21, it is necessary to unscrew the 2 screws M4 × 10 pos.19 securing the bearing cover pos. The Bulgarian Hitachi G13SR3 uses three types of bearings: 628 - mounted on the spindle of the gearbox, 626 - mounted on the rotor on the side of the drive gear, 6201 - mounted on the rotor on the collector side.

How to remove the drive gear from the rotor shaft of Bulgakov Hitachi with the disk 125

To remove the pinion gear pos.33, it is necessary to clamp the rotor pos.8.The gear is fixed with the M6 ​​nut pos.4.Using a car key, unscrew the nut by turning it counter-clockwise. Having removed a gear wheel, take a rotor from the case of a reducer.

Replacement of bevel gears in Bulgarians Hitachi

In the Bulgars of Hitachi the failed conical gears are changed in pairs. To the replacement of gears leads wear of the teeth, licking, the destruction of several teeth.

The design of the Hitachi G23SCY grinder reducer with a disk up to 230

The reducer of bullets with a disc up to 230 mm is much more powerful. The design of the reducer 230 uses a clutch pos. 24 and a damper pos.23.This design acts as a clutch, preventing impact when the working disk is bitten or crashed. Clutch allows you to smoothly start the Bulgarian.

How to remove the driven gear from the reducer shaft of the Hitachi grinder with the dial up to 230

To dismantle the reduction gear gears with a disk up to 230, it is necessary to resort to making sure that no restoration work is possible.

The dismantling of the driven gear assembly does not differ from the similar disassembly of the grinder assembly with a disc up to 125 mm. The only difference, in the Bulgarian 230 gear 20, is pressed onto the shaft pos.29.It is better to remove the gear from the shaft with the help of the press, but also the handy tools will do. For example, a vice. The shaft is installed in the bearing pos.27.Type of bearing 6302DD.

The Bulgarian Hitachi G23SCY uses three types of bearings: 6302DD - mounted on the spindle of the gearbox, 6301DD - mounted on the rotor on the side of the drive gear, 6000VV - mounted on the rotor on the collector side.

Rules for greasing gearboxes for Bulgarians Hitachi

For the quality of lubrication in the gearbox, you can determine the percentage of wear of bevel gears. The darker the grease, the more traces of metal chips in it, the greater the probability of an increased percentage of gear wear. The percentage of wear of the reduction gear gears is easily determined by the contact spot.

Use a special flushing liquid to remove the old grease. To thoroughly remove all old grease, it is recommended to heat the gearbox housing with a hairdryer before turning the grease into liquid.

The new grease is applied in the gear housing in an amount that is less than half the body volume. To lubricate gearboxes, manufacturers produce their own lubricant. But Russian manufacturers have learned to make lubricants that are not inferior in quality to foreign ones, but whose price is much lower.

Conclusion:

reliability of Bulgarians from Hitachi is provided by technological and organizational measures;

Bulgarians Hitachi difficult to forge;

in Bulgarians Hitachi implemented the basic principle, the best value for money;

prolong the work of the Bulgarian can be timely change of carbon brushes, replacement of lubricants, gentle operating modes.

Video repair Bulgars Hitachi

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