Read through carefully and understand these instructions before use.

Disc Grinder

G 10SD2 • G 12S2 • G 13SD

Handling instructions

G13SD

001Cover_G10SD2_ChS 13.5.16, 8:35 AM1

1

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3

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15°~30°

A B

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9

6mm

88

17mm

4

001Table_G10SD2_ChS 13.5.16, 8:37 AM1

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1 Wrench2 Wheel nut3 Depressed center wheel4 Wheel washer5 Wheel guard6 Spindle7 Push button8 Wear limit9 No. of carbon brush0 SpringA Carbon brushB Brush holder

Symbols WARNING

The following show symbolsused for the machine. Be surethat you understand theirmeaning before use.

To reduce the risk of injury,user must read instructionmanual.

Always wear eye protection.

001Table_G10SD2_ChS 13.5.16, 8:37 AM2

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8

GENERAL POWER TOOL SAFETY WARNINGS

WARNINGRead all safety warnings and all instructions.Failure to follow the warnings and instructions may resultin electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.The term “power tool” in the warnings refers to yourmains-operated (corded) power tool or battery-operated(cordless) power tool.1) Work area safety

a) Keep work area clean and well lit.Cluttered or dark areas invite accidents.

b) Do not operate power tools in explosiveatmospheres, such as in the presence offlammable liquids, gases or dust.Power tools create sparks which may ignite thedust or fumes.

c) Keep children and bystanders away whileoperating a power tool.Distractions can cause you to lose control.

2) Electrical safetya) Power tool plugs must match the outlet.

Never modify the plug in any way.Do not use any adapter plugs with earthed(grounded) power tools.Unmodified plugs and matching outlets willreduce risk of electric shock.

b) Avoid body contact with earthed or groundedsurfaces, such as pipes, radiators, ranges andrefrigerators.There is an increased risk of electric shock ifyour body is earthed or grounded.

c) Do not expose power tools to rain or wetconditions.Water entering a power tool will increase therisk of electric shock.

d) Do not abuse the cord. Never use the cord forcarrying, pulling or unplugging the power tool.Keep cord away from heat, oil, sharp edges ormoving parts.Damaged or entangled cords increase the riskof electric shock.

e) When operating a power tool outdoors, use anextension cord suitable for outdoor use.Use of a cord suitable for outdoor use reducesthe risk of electric shock.

f) If operating a power tool in a damp locationis unavoidable, use a residual current device(RCD) protected supply.Use of an RCD reduces the risk of electric shock.

3) Personal safetya) Stay alert, watch what you are doing and use

common sense when operating a power tool.Do not use a power tool while you are tired orunder the influence of drugs, alcohol or medication.A moment of inattention while operating powertools may result in serious personal injury.

b) Use personal protective equipment. Always weareye protection.Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protectionused for appropriate conditions will reducepersonal injuries.

c) Prevent unintentional starting. Ensure the switchis in the off-position before connecting to powersource and/or battery pack, picking up orcarrying the tool.

Carrying power tools with your finger on theswitch or energising power tools that have theswitch on invites accidents.

d) Remove any adjusting key or wrench beforeturning the power tool on.A wrench or a key left attached to a rotating partof the power tool may result in personal injury.

e) Do not overreach. Keep proper footing andbalance at all times.This enables better control of the power tool inunexpected situations.

f) Dress properly. Do not wear loose clothing orjewellery. Keep your hair, clothing and glovesaway from moving parts.Loose clothes, jewellery or long hair can becaught in moving parts.

g) If devices are provided for the connection ofdust extraction and collection facilities, ensurethese are connected and properly used.Use of dust collection can reduce dust relatedhazards.

4) Power tool use and carea) Do not force the power tool. Use the correct

power tool for your application.The correct power tool will do the job better andsafer at the rate for which it was designed.

b) Do not use the power tool if the switch doesnot turn it on and off.Any power tool that cannot be controlled withthe switch is dangerous and must be repaired.

c) Disconnect the plug from the power sourceand/or the battery pack from the power toolbefore making any adjustments, changingaccessories, or storing power tools.Such preventive safety measures reduce the riskof starting the power tool accidentally.

d) Store idle power tools out of the reach of childrenand do not allow persons unfamiliar with thepower tool or these instructions to operate thepower tool.Power tools are dangerous in the hands ofuntrained users.

e) Maintain power tools. Check for misalignmentor binding of moving parts, breakage of partsand any other condition that may affect thepower tool's operation.If damaged, have the power tool repaired beforeuse.Many accidents are caused by poorly maintainedpower tools.

f) Keep cutting tools sharp and clean.Properly maintained cutting tools with sharpcutting edges are less likely to bind and areeasier to control.

g) Use the power tool, accessories and tool bitsetc. in accordance with these instructions, takinginto account the working conditions and thework to be performed.Use of the power tool for operations different fromthose intended could result in a hazardous situation.

5) Servicea) Have your power tool serviced by a qualified

repair person using only identical replacementparts.This will ensure that the safety of the power toolis maintained.

PRECAUTIONKeep children and infirm persons away.When not in use, tools should be stored out of reach ofchildren and infirm persons.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM8

9

SAFETY WARNINGS COMMON FORGRINDING OPERATIONS

a) This power tool is intended to function as a grinder.Read all safety warnings, instructions, illustrationsand specifications provided with this power tool.Failure to follow all instructions listed below mayresult in electric shock, fire and/or serious injury.

b) Operations such as sanding, wire brushing orpolishing or cutting-off are not recommended tobe performed with this power tool.Operations for which the power tool was notdesigned may create a hazard and cause personalinjury.

c) Do not use accessories which are not specificallydesigned and recommended by the toolmanufacturer.Just because the accessory can be attached to yourpower tool, it does not assure safe operation.

d) The rated speed of the accessory must be at leastequal to the maximum speed marked on the powertool.Accessories running faster than their rated speedcan break and fly apart.

e) The outside diameter and the thickness of youraccessory must be within the capacity rating ofyour power tool.Incorrectly sized accessories cannot be adequatelyguarded or controlled.

f) The arbour size of wheels, flanges, backing padsor any other accessory must properly fit the spindleof the power tool.Accessories with arbour holes that do not matchthe mounting hardware of the power tool will runout of balance, vibrate excessively and may causeloss of control.

g) Do not use a damaged accessory. Before each useinspect the accessory such as abrasive wheels forchips and cracks, backing pad for cracks, tear orexcess wear, wire brush for loose or cracked wires.If power tool or accessory is dropped, inspect fordamage or install an undamaged accessory. Afterinspecting and installing an accessory, positionyourself and bystanders away from the plane ofthe rotating accessory and run the power tool atmaximum no-load speed for one minute.Damaged accessories will normally break apartduring this test time.

h) Wear personal protective equipment. Depending onapplication, use face shield, safety goggles or safetyglasses. As appropriate, wear dust mask, hearingprotectors, gloves and workshop apron capable ofstopping small abrasive or workpiece fragments.The eye protection must be capable of stoppingflying debris generated by various operations. Thedust mask or respirator must be capable of filtratingparticles generated by your operation. Prolongedexposure to high intensity noise may cause hearingloss.

i) Keep bystanders a safe distance away from workarea. Anyone entering the work area must wearpersonal protective equipment.Fragments of workpiece or of a broken accessorymay fly away and cause injury beyond immediatearea of operation.

j) Hold power tool by insulated gripping surfacesonly, when performing an operation where thecutting accessory may contact hidden wiring or itsown cord.Cutting accessory contacting a”live” wire may makeexposed metal parts of the power tool “live” andshock the operator.

k) Position the cord clear of the spinning accessory.If you lose control, the cord may be cut or snaggedand your hand or arm may be pulled into thespinning accessory.

l) Never lay the power tool down until the accessoryhas come to a complete stop.The spinning accessory may grab the surface andpull the power tool out of your control.

m) Do not run the power tool while carrying it at yourside.Accidental contact with the spinning accessory couldsnag your clothing, pulling the accessory into yourbody.

n) Regularly clean the power tool’s air vents.The motor’s fan will draw the dust inside the housingand excessive accumulation of powdered metal maycause electrical hazards.

o) Do not operate the power tool near flammablematerials.Sparks could ignite these materials.

p) Do not use accessories that require liquid coolants.Using water or other liquid coolants may result inelectrocution or shock.

KICKBACK AND RELATED WARNINGS

Kickback is a sudden reaction to a pinched or snaggedrotating wheel, backing pad or any other accessory. Pinchingor snagging causes rapid stalling of the rotating accessorywhich in turn causes the uncontrolled power tool to beforced in the direction opposite of the accessory’s rotation atthe point of the binding.For example, if an abrasive wheel is snagged or pinched bythe workpiece, the edge of the wheel that is entering into thepinch point can dig into the surface of the material causingthe wheel to climb out or kick out. The wheel may eitherjump toward or away from the operator, depending ondirection of the wheel’s movement at the point of pinching.Abrasive wheels may also break under these conditions.Kickback is the result of power tool misuse and/or incorrectoperating procedures or conditions and can be avoidedby taking proper precautions as given below.

a) Maintain a firm grip on the power tool and positionyour body and arm to allow you to resist kickbackforces. Always use auxiliary handle, if provided, formaximum control over kickback or torque reactionduring start-up.The operator can control torque reactions or kickbackforces, if proper precautions are taken.

b) Never place your hand near the rotating accessory.Accessory may kickback over your hand.

c) Do not position your body in the area where powertool will move if kickback occurs.Kickback will propel the tool in direction oppositeto the wheel’s movement at the point of snagging.

d) Use special care when working corners, sharp edgesetc. Avoid bouncing and snagging the accessory.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM9

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Corners, sharp edges or bouncing have a tendencyto snag the rotating accessory and cause loss ofcontrol or kickback.

e) Do not attach a saw chain woodcarving blade ortoothed saw blade.Such blades create frequent kickback and loss ofcontrol.

SAFETY WARNINGS SPECIFIC FORGRINDING OPERATIONS

a) Use only wheel types that are recommended foryour power tool and the specific guard designedfor the selected wheel.Wheels for which the power tool was not designedcannot be adequately guarded and are unsafe.

b) The guard must be securely attached to the powertool and positioned for maximum safety, so theleast amount of wheel is exposed towards theoperator.The guard helps to protect operator from brokenwheel fragments and accidental contact with wheel.

c) Wheels must be used only for recommendedapplications. For example: do not grind with theside of cut-off wheel.

Abrasive cut-off wheels are intended for peripheralgrinding, side forces applied to these wheels maycause them to shatter.

d) Always use undamaged wheel flanges that are ofcorrect size and shape for your selected wheel.Proper wheel flanges support the wheel thusreducing the possibility of wheel breakage. Flangesfor cut-off wheels may be different from grindingwheel flanges.

e) Do not use worn down wheels from larger powertools.Wheel intended for larger power tool is not suitablefor the higher speed of a smaller tool and mayburst.

PRECAUTIONS ON USING DISC GRINDER

1. Never operate these power tools without WheelGuards.

2. Use only depressed center wheels rated at 80m/s(72m/s only for 100 mm disc grinders) or more.

3. Always hold the body handle and side handle ofthe power tool firmly. Otherwise the counterforceproduced may result in inaccurate and evendangerous operation.

SPECIFICATIONS

*Be sure to check the nameplate on product as it is subject to change by areas.

Model G10SD2 G12S2 G13SD

Voltage (by areas)* (110 V, 115 V, 220 V, 230 V, 240 V)

Power Input* 800 W

No-load speed 11000 / min 10000 / min

Outer dia. × hole dia. 100 × 16 mm 115 × 22.23 mm 125 × 22.23 mmWheel

Peripheral speed 72 m/s 80 m/s

Weight (Only main body) 1.6 kg

STANDARD ACCESSORIES

(1) Depressed center wheel .......................................... 1(2) Wrench ........................................................................ 1(3) Side handle ................................................................ 1Standard accessories are subject to change withoutnotice.

APPLICATIONS

� Removal of casting fin and finishing of various typesof steel, bronze and aluminum materials and castings.

� Grinding of welded sections or sections cut bymeans of a cutting torch.

� Grinding of synthetic resins, slate, brick, marble,etc.

PRIOR TO OPERATION

1. Power sourceEnsure that the power source to be utilized conformsto the power requirements specified on the productnameplate.

2. Power switchEnsure that the power switch is in the OFF position.If the plug is connected to a receptacle while thepower switch is in the ON position, the power toolwill start operating immediately, which could causea serious accident.

3. Extension cordWhen the work area is removed from the powersource, use an extension cord of sufficient thicknessand rated capacity. The extension cord should bekept as short as practicable.

4. Fitting and adjusting the wheel guardThe wheel guard is a protective device to preventinjury should the depressed center wheel shatterduring operation. Ensure that the guard is properlyfitted and fastened before commencing grindingoperation.By slightly loosening the setting screw, the wheelguard can be turned and set at any desired anglefor maximum operational effectiveness. Ensure thatthe setting screw is thoroughly tightened afteradjusting the wheel guard.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM10

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5. Ensure that the depressed center wheel to be utilizedis the correct type and free of cracks or surfacedefects. Also ensure that the depressed center wheelis properly mounted and the wheel nut is securelytightened, Refer to the section on “ASSEMBLINGAND DISASSEMBLING THE DEPRESSED CENTERWHEEL”.

6. Conducting a trial runEnsure that the abrasive products is correctlymounted and tightened before use and run the toolat no-load for 30 seconds in a safe position, stopimmediately if there is considerable vibration or ifother defects are detected.If this condition occurs, check the machine todetermine the cause.

7. Confirm the push buttonConfirm that the push button is disengaged bypushing push button two or three times beforeswitching the power tool on (See Fig. 2).

8. Fixing the side handleScrew the side handle into the gear cover.

PRACTICAL GRINDER APPLICATION

1. PressureTo prolong the life of the machine and ensure afirst class finish, it is important that the machineshould not be overloaded by applying too muchpressure. In most applications, the weight of themachine alone is sufficient for effective grinding.Too much pressure will result in reduced rotationalspeed, inferior surface finish, and overloading whichcould reduce the life of the machine.

2. Grinding angleDo not apply the entire surface of the depressedcenter wheel to the material to be ground. Asshown in Fig. 1, the machine should be held at anangle of 15° – 30° so that the external edge of thedepressed center wheel contacts the material at anoptimum angle.

3. To prevent a new depressed center wheel fromdigging into the workpiece, initial grinding shouldbe performed by drawing the grinder across theworkpiece toward the operator (Fig. 1 direction B).Once the leading edge of the depressed centerwheel is properly abraded, grinding may beconducted in either direction.

4. Precautions immediately after finishing operationThe wheel continues to rotate after the tool isswitched off.After switching off the machine, do not put it downuntil the depressed center wheel has come to acomplete stop. Apart from avoiding seriousaccidents, this precaution will reduce the amountof dust and swarf sucked into the machine.

CAUTIONS� Check that the work piece is properly supported.� Ensure that ventilation openings are kept clear when

working in dusty conditions.If it should become necessary to clear dust, firstdisconnect the tool from the mains supply (use non-metallic objects) and avoid damaging internal parts.

� Ensure that sparks resulting from use do not createa hazard e.g. do not hit persons, or ignite flammablesubstances.

� Always use eye and ear protection.Other personal protective equipment such as dustmask, gloves, helmet and apron should be wornwhen necessary.If in doubt, wear the protective equipment.

� When the machine is not use, the power sourceshould be disconnected.

ASSEMBLING AND DISASSEMBLING THEDEPRESSED CENTER WHEEL (Fig. 2)

CAUTION Be sure to switch OFF and disconnect theattachment plug from the receptacle to avoida serious accident.

1. Assembling (Fig. 2)(1) Turn the disc grinder upsidedown so that the spindle

is facing upward.(2) Align the across flats of the wheel washer with the

notched part of the spindle, then attach them.(3) Fit the protuberance of the depressed center wheel

onto the wheel washer.(4) Screw the wheel nut onto the spindle.(5) While pushing the push button with one hand, lock

the spindle by turning the depressed center wheelslowly with the other hand.Tighten the wheel nut by using the supplied wrenchas shown in Fig. 2.

2. DisassemblingFollow the above procedures in reverse.

CAUTIONS� Comfirm that the depressed center wheel is mounted

firmly.� Confirm that the push button is disengaged by

pushing push button two or three times beforeswitching the power tool on.

MAINTENANCE AND INSPECTION

1. Inspecting the depressed center wheelEnsure that the depressed center wheel is free ofcracks and surface defects.

2. Inspecting the mounting screwsRegularly inspect all mounting screws and ensurethat they are properly tightened. Should any of thescrews be loose, retighten them immediately. Failureto do so could result in serious hazard.

3. Inspecting the carbon brush (Fig. 3)The motor employs carbon brushes which areconsumable parts. Since an exclusively worn carbonbrush can result in motor trouble, replace the carbonbrush with a new one having the same carbonbrush No. shown in the figure when it becomesworn to or near the “wear limit”. In addition, alwayskeep carbon brushes clean and ensure that theyslide freely within the brush holders.

4. Replacing a carbon brush (Fig. 4)

(1) Loosen the D4 tapping screw retaining the tail cover

and remove the tail cover.(2) Use the auxiliary hexagonal wrench or small

screwdriver to pull up the edge of the spring thatis holding down the carbon brush. Remove theedge of the spring toward the outside of the brushholder.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM11

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(3) Remove the end of the pig-tail on the carbon brushfrom the terminal section of brush holder and thenremove the carbon brush from the brush holder.

(1) Insert the end of the pig-tail of the carbon brush

in the terminal section of brush holder.(2) Insert the carbon brush in the brush holder.(3) Use the auxiliary hexagonal wrench or small

screwdriver to return the edge of the spring to thehead of the carbon brush.

(4) Mount the tail cover and tighten the D4 tappingscrew.

5. Maintenance of the motorThe motor unit winding is the very “heart” of thepower tool. Exercise due care to ensure the windingdoes not become damaged and/or wet with oil orwater.

6. Service parts listA : Item No.B : Code No.C : No. UsedD : Remarks

CAUTIONRepair, modification and inspection of Hitachi PowerTools must be carried out by a Hitachi AuthorizedService Center.This Parts List will be helpful if presented with thetool to the Hitachi Authorized Service Center whenrequesting repair or other maintenance.In the operation and maintenance of power tools,the safety regulations and standards prescribed ineach country must be observed.

MODIFICATIONSHitachi Power Tools are constantly being improvedand modified to incorporate the latest technologicaladvancements.Accordingly, some parts (i.e. code numbers and/ordesign) may be changed without prior notice.

NOTEDue to HITACHI’s continuing program of research anddevelopment, the specifications herein are subject tochange without prior notice.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM12

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02Eng_G10SD2_ChS 13.5.16, 8:41 AM18

311Code No. C99091223 MPrinted in Malaysia

Hitachi Koki Co., Ltd.

02Eng_G10SD2_ChS 13.5.16, 8:41 AM19