TECHNICAL INFORMATION

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Allan McCormick
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1 TECHNICAL INFORMATION Model No. Description CONCEPT AND MAIN APPLICATIONS Specification GA4030, GA4530, GA5030 Angle Grinders 100mm (4"), 115mm (4-1/2"), 125mm (5") GA4030/ GA4530/ GA5030 are small diameter Angle grinders with ergonomically best possible barrel grip. Regardless of whether the user grips motor housing or rear cover, the extra-ergonomic barrel grip fits any user s palm and fingers perfectly, and provides easy and comfortable handling while minimizing hand fatigue and pain. Each model is also available with Plastic carrying case as GA4030K/ GA4530K/ GA5030K. GA5030 is also available with Aluminum case as GA5030KSP. Model No. Length (L) Width (W) Height (H) H W L Dimensions: mm (") GA4030 GA (10-1/2) 117 (4-5/8) 128 (5) 95 (3-3/4) PRODUCT P 1/ 13 GA (5-7/16) 103 (4-1/16) Voltage (V) Current (A) Cycle (Hz) 50/60 50/60 50/60 50/60 50/60 Continuous Rating (W) Input Output Max. Output (W) Model No. Wheel size: Diameter mm (") Hole diameter No load speed: min.-1 = rpm Protection against electric shock Power supply cord: m (ft) Net weight: kg (lbs) Weight according EPTA-Procedure 01/2003*: kg GA4030 GA4530 GA (4) 115 (4-1/2) 125 (5) 16 (5/8) (7/8) 11,000 Double insulation Brazil, Australia: 2.0 (6.6), Other countries: 2.5 (8.2) 1.4 (3.1) * with Wheel cover, Inner flange, Lock nut, Side grip; without Power supply cord Standard equipment Lock nut wrench (for GA4030) Lock nut wrench (for GA4530/GA5030; USA, Canada, Mexico, Panama) Lock nut wrench (for GA4530/GA5030; all countries except USA, Canada, Mexico, Panama) Depressed center wheel... 1 ( for GA4030, for GA4530, for GA5030) Side grip (standard soft grip)... 1 (Anti-vibration grip instead if required) Wheel cover (standard type)... 1 (Toolless wheel cover instead if required) Plastic carrying case... 1 (for GA4030K, GA4530K, GA5030K) Aluminum case... 1 (for GA5030KSP) Note: The standard equipment for the tool shown above may differ by country. Optional accessories Wheel guards Cut-off wheels Abrasive discs Rubber pad (for abrasive disc) Sanding lock nuts Wire cup brushes Wire bevel brush (for GA4030 only) Wheel brush (for GA5030 only) Anti-vibration grip

2 [1] NECESSARY REPAIRING TOOLS [2] LUBRICATION P 2/ 13 CAUTION: Unplug the tool and remove the following parts for safety before repair/ maintenance in accordance with the instruction manual! Depressed center wheel, Inner flange, Lock nut, Wheel cover Code No. 1R004 1R005 1R006 1R031 1R246 1R268 1R269 1R281 Description Retaining ring S pliers ST-2 Retaining ring R pliers RT-2N Retaining ring R pliers RT-2E Bearing setting pipe Round bar for arbor Spring pin extractor M3 Bearing extractor (small) Round bar for arbor 7-50 Use for Removing / Installing Ring spring 11 Removing / Installing Retaining ring R-32 Removing / Installing Retaining ring R-26 Removing Spindle from Spiral bevel gear 37 Removing Ball bearing 6201DDW when difficult to remove by hand Disassembling Shaft lock mechanism Removing Ball bearing 696ZZ from Spindle Removing from Apply the following lubricants to the designated portions to protect parts and product from unusual abrasion. Item No. Description 18 Gear housing 9 O-ring 26 Fig. 1 Portion to lubricate Gear room inside Spiral bevel gear Lubricant Amount Makita grease SG No g a little Makita grease SG No.0 M6 Hex nut [3] -1. Armature, Ball bearing 629DDW, Spiral Bevel Gear 10 (1) Remove Rear cover by loosening 4x18 Tapping screw. (2) Move Carbon brushes away from Armature s commutator to prevent scratching. Fig. 2 Shift Spiral spring from Carbon brush top. Move Carbon brush away from commutator by pulling it up. No need to remove. Brush holder Rear cover 4x18 Tapping screw

3 [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) P 3/ 13 (3) Remove Armature together with Gear housing from Motor housing as illustrated in Figs. 3,and 4. (4) Remove Armature from Gear housing as illustrated in Figs. 5 and 6. Fig. 3 M4x14 Pan head screw (4 pcs.) Bearing box Remove M4x14 Pan head screw (4pcs.) with which Bearing box is fastened to Gear housing. Gear housing Fig. 4 After removing 4x22 Tapping screws (4pcs.), separate Gear housing together with Armature as illustrated below. Armature Motor housing 4x22 Tapping screw (4 pcs.) Gear housing Fig. 5 Fig. 6 Pull off Armature while supporting Spiral bevel gear 10 by hand so as not to drop off from Gear housing. M6 Hex nut Armature Spiral bevel gear 10 Turn M6 Hex nut counterclockwise with a wrench to remove it. Note: If difficult to remove Armature due to galling and seizing of Spiral bevel gear 10 in Gear housing: 1. Spray the lubricant between Spiral bevel gear 10 and Armature shaft. 2. Cover Spiral bevel 10 with a cloth, and hold Spiral bevel gear 10 over the cloth with water pump pliers. 3. Remove Spiral bevel gear 10 by turning the water pump pliers counterclockwise.

4 [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) P 4/ 13 (5) Take out Ball bearing 629DDW as illustrated in Figs. 7 and 8. Remove Ball bearing 607LLB from Armature as illustrated in Fig. 9. Fig. 7 Fig. 8 Ball bearing 629DDW 1R006 Guide plate Retaining ring R-26 After removing Guide plate, remove Retaining ring R-26. Strike Gear housing against a worktable. Ball bearing 629DDW can be removed from Gear housing. Note: Put something soft on a worktable to avoid the damage on Gear housing in this step. Fig. 9 Labyrinth rubber ring 19 Ball bearing 607LLB 1R269 After removing Labyrinth rubber ring 19, remove Ball bearing 607LLB with 1R269. Insulation Washer Note: If difficult to remove the Ball bearing 629DDW in the way illustrated in Fig. 8, remove the Ball bearing as illustrated in Fig. 10. Fig. 10 M6 Hex nut Spiral bevel gear 10 Armature Ball bearing 629DDW 1. Insert Armature into Gear housing. 2. Assemble Spiral bevel gear 10 to the Armature in Gear housing. 3. Fasten Spiral bevel gear 10 with M6 Hex nut. Strike the edge of Gear housing with a plastic hammer,. So Ball bearing 629DDW is removed together with the Armature.

5 [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) P 5/ 13 ASSEMBLING Refer to Figs. 11 to 15. Fig. 11 Fig. 12 Retaining ring R-26 1R006 protrusion Gear housing notch Guide plate Ball bearing 629DDW Gear housing Assemble Ball bearing 629DDW to Gear housing. Then, mount Retaining ring R-26 to secure the Ball bearing. Assemble Guide plate to Gear housing while fitting the notch of Guide plate to the protrusion of Gear housing. Fig. 13 Fig. 14 Gear housing Guide plate M6 Hex nut Armature Spiral bevel gear 10 Insert Armature into Gear housing, and assemble Spiral bevel gear 10 to Armature in Gear housing. Tighten M6 Hex nut with a wrench by turning clockwise to secure the Spiral bevel gear 10. Fig. 15 Pin cap (Spindle lock button) on the opposite side of Armature Motor housing Pin cap Gear Housing 4x22 Tapping screw (4 pcs.) Facing Pin cap (Spindle lock button) to the opposite side of, assemble Gear Housing to Motor housing. Assemble bearing box section to Gear housing.

6 [3] -2. Spiral Bevel Gear 37, Ball Bearing 6201DDW P 6/ 13 The parts in Bearing box can be removed illustrated in Figs. 16 to 19. There is no need to disassemble Motor section. Fig. 16 Gear housing Remove Bearing box from Gear housing. Remove Bearing 696ZZ from Spindle with 1R269. Ring Spring 11 1R269 1R004 Bearing box M4x14 Pan head screw (4 pcs.) Ball bearing 696ZZ While spreading the cut portion of Ring spring 11 with 1R004, shift the Ring spring 11 from the groove on Spindle. Fig. 17 Bearing box section 1R031 Retaining ring R-32 Spiral bevel gear 37 Ball bearing 6201DDW Labyrinth ring Spindle Receive Labyrinth ring with 1R031. And remove Spindle from Bearing box section with arbor press. 1R031 The tolerance between Spiral bevel gear 37 and Spindle is so small that it is difficult to remove Spindle without damage to Ball bearing 6201DDW. Therefore, Ball bearing 6201DDW has to be always replaced with the new one. Fig. 18 Fig. 19 1R005 1R246 Retaining ring R-32 Flat washer 12 Ball bearing 6201DDW Remove Retaining ring R-32 with 1R005. Strike Bearing box section against a worktable. Ball bearing 6201DDW can be removed. If difficult to remove Ball bearing 6201DDW in the way illustrated left, use arbor press.

7 [3] -2. Spiral Bevel Gear 37, Ball Bearing 6201DDW (cont.) P 7/ 13 ASSEMBLING Assemble the parts in Bearing box as illustrated in Figs. 20 to 25. Fig. 20 Fig. 21 Ball bearing 6201DDW 1R005 Wrong Correct Flat washer 12 Retaining ring R-32 concave side Spindle flat side Bearing box Labyrinth ring 1R031 Install Ball bearing 6201DDW and Flat washer 12 to Bearing box. Fit Retaining ring R-32 into the groove of Bearing box using 1R005. When setting Labyrinth ring on 1R031, face the flat side upward. Then press fit Spindle to Labyrinth ring. Fig. 22 Fig. 23 Spindle Labyrinth ring Spiral bevel gear 37 1R031 Bearing box Bearing box Press fit Spindle to Bearing box that is shown in Fig. 20. Face the teeth of Spiral bevel gear 37 upward and put 1R031 on Spiral bevel gear 37 as illustrated above. Press fit Spiral bevel gear 37 to Bearing box gently. Fig. 24 Fig. 25 Ring spring 11 Ring spring 11 Ball bearing 696ZZ Put Ring spring 11 into the groove of Spindle. As the cut ends of Ring spring 11 remains spread yet, press the sides of Ring spring 11 with pliers so as to fit them completely. Ball bearing 696ZZ Press fit Ball bearing 696ZZ to Spindle.

8 [3] -3. mechanism ( and ) P 8/ 13 (1) Remove Rear cover from Motor housing by removing 4x18 Tapping screw. (Fig. 2) (2) and can be disassembled from the machine as illustrated in Fig. 26. Fig. 26 1R 281 Lever 1. While locking with 1R281, strongly push in a direction designated with black arrow. 2. is disconnected from the locking claw of. And can be removed. wall of box 3. Bend to make it free from the wall of box. 4. Pull out from Motor housing. ASSEMBLING Interlock with as illustrated in Fig. 27. Fig Make sure that Compression spring 4 is assembled to lever in advance. Compression spring 4 for pushing back to OFF position hole for hook of hook hole the top end of assembling hole lever 2. Push into Motor housing until the hole of comes into sight through assembling hole on Motor housing. And keep the position. the reverse side of 3. Fit the hook of Swtich knob to the hole of. 4. Release. (The hook of interlocks with the hole of when is pushed back to OFF position by Compression spring 4.)

9 [3] -4 Shaft Lock Mechanism P 9/ 13 (1) Disconnect Carbon brush from Armature s commutator as illustrated in Fig. 2. (2) Disassemble Bearing box section from Gear housing as illustrated in Fig. 3. (3) Separate Gear housing together with Armature from Motor housing as illustrated in Fig. 4. (4) Disassemble Armature from Gear housing as illustrated in Figs. 5 and 6. (5) Shaft lock mechanism can be disassembled in the order of Figs. 28 and 29. Fig. 28 Fig. 29 1R268 Pin cap Note: Do not removed Pin cap because removal of Shoulder pin 4 damages the inside surface of Pin cap, producing plastic dust. Therefore, be sure to use a new Pin cap for replacement and remove all the plastic dust on Should pin 4. Pin cap Pin cap Compression spring 8 1R350 Shoulder Pin 4 O ring 5 Applying 1R268 to Shoulder pin 4 through the small hole on Pin cap, strike 1R268 with Hammer. Now, Shoulder pin 4 comes out from Gear housing. Release 1R268 from Pin cap carefully so that Pin cap is not slung by Compression spring 8. ASSEMBLING (1) Remove all the plastic dust on Shoulder pin 4. (Fig. 30) (2) Assemble the parts for Shaft lock mechanism as illustrated in Fig. 31. Note: Do not use the removed Pin cap. (See Fig. 29) Fig. 30 Fig. 31 Insert Shoulder pin 4 through the hole of Gear housing complete. Install Pin cap by pressing it to Shoulder pin 4. Pin cap plastic dust Shoulder pin 4 O ring 5 Shoulder pin 4 Compression spring 8 Do not forget to set Compression spring 8 in place.

10 [3] -5 Field P 10/13 (1) After removing Rear cover, disconnect Carbon brush from Armature s commutator as illustrated in Fig. 2. (2) Disassemble Bearing box section from Gear housing as illustrated in Fig. 3. (3) Separate Gear housing together with Armature from Motor housing as illustrated in Fig. 4. (4) Disassemble Armature from Gear housing as illustrated in Figs. 5 and 6. (5) Disconnect Filed lead wires from brush holders and. Refer to Circuit Diagram, Fig. D-1. (6) Now Field can be disassembled as illustrated in Fig. 32. Fig. 32 Remove Baffle plate. Do not strike Motor housing. Otherwise, the edge of Motor housing may be damaged/ broken. 4x70 Tapping Screw (2 pcs.) Baffle Plate Provisionally assemble Gear housing to Motor housing. And strike the Gear housing with plastic hammer until the press fit of Field to Motor housing becomes loose. Drive four 4x22 Tapping screws to Motor housing. And strike the heads of the screws with plastic hammer until Field is removed.

11 Circuit diagram P 11/13 Fig. D-1 Black White Red Color index of lead wires' sheath Blue Brown Brush holder Noise suppressor White lead wire is used for some countries. Field Power supply cord Brush holder Black lead wire is used for some countries Wiring diagram Fig. D-2 Wiring to Connect the Lead wire of Power supply cord to from the ON-OFF button side. Lead wire (brown or black) Mark on body ON-OFF Button Face the wire connecting side to. Lead wire (blue or white) Power supply cord

12 Wiring diagram Fig. D-3 P 12/13 Wiring of Field lead wires Insert Field into Motor housing so that the Field lead wires (red) face the opposite side of as illustrated below. knob side Field Field lead wire (red) Field lead wire (red) Field lead wire (red) Pull out Field lead wires (red) from rear opening of the opposite side of. Motor housing (viewed from Rear cover side) Field lead wire (red) Fig. D-4 Rear portion of Motor housing (viewed from opposite side of ) Field lead wires have to be tight in Motor housing. * Noise suppressor rib Power supply cord Cord clamp Put the extra portion of Lead wire of Power supply cord in this place. rib * Noise suppressor is not used for some countries.

13 P 13/13 Wiring diagram Fig. D-5 Rear portion of Motor Housing (viewesd from side) * Noise suppressor Rib Field lead wire (black) Field Lead Wire (black) has to be tight in Motor housing. * Noise suppressor is not used for some countries. Fig. D-6 Wiring for Pigtail of Carbon brush Carbon brush Pigtail rib Pigtail of Carbon brush has to be put in the inside of rib as illustrated above.

TECHNICAL INFORMATION

TECHNICAL INFORMATION Model No. Description GA5020C/GA6020C, GA5021C/GA6021C Angle Grinders 125mm (5") /150mm (6") L PRODUCT P 1/10 CONCEPT AND MAIN APPLICATIONS These four models have been developed as