T
ECHNICAL INFORMATION
Model No. Description
PRODUCT P 1/ 13
GA4030, GA4530, GA5030 Angle Grinders 100mm (4"), 115mm (4-1/2"), 125mm (5") L
CONCEPT AND MAIN APPLICATIONS 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.
H W Dimensions: mm (") Model No. GA4030 GA4530 GA5030 Length (L) 266 (10-1/2) Width (W) 117 (4-5/8) 128 (5) 138 (5-7/16) Height (H) 95 (3-3/4) 103 (4-1/16)
Specification Voltage (V)
Current (A)
Cycle (Hz)
110 120 220 230 240
6.9 6.0 3.4 3.3 3.2
50/60 50/60 50/60 50/60 50/60
Model No. Diameter Wheel size: 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
Continuous Rating (W) Input Output 720 440 --440 720 440 720 440 720 440
Max. Output (W) 960 960 960 960 960
GA4030 100 (4) 16 (5/8)
GA4530 GA5030 115 (4-1/2) 125 (5) 22.23 (7/8) 11,000 Double insulation Brazil, Australia: 2.0 (6.6), Other countries: 2.5 (8.2) 1.4 (3.1) 1.7
1.8
1.8
* with Wheel cover, Inner flange, Lock nut, Side grip; without Power supply cord
Standard equipment Lock nut wrench 20 ...................... 1 (for GA4030) Lock nut wrench 28 .......................1 (for GA4530/GA5030; USA, Canada, Mexico, Panama) Lock nut wrench 35 ...................... 1 (for GA4530/GA5030; all countries except USA, Canada, Mexico, Panama) Depressed center wheel ................ 1 (100-36 for GA4030, 115-36 for GA4530, 125-36 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
P 2/ 13
Repair
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 [1] NECESSARY REPAIRING TOOLS Code No.
Description
Use for
1R004
Retaining ring S pliers ST-2
Removing / Installing Ring spring 11
1R005
Retaining ring R pliers RT-2N Removing / Installing Retaining ring R-32
1R006 1R031 1R246 1R268 1R269 1R281
Retaining ring R pliers RT-2E Bearing setting pipe 28-20.2 Round bar for arbor 18-100 Spring pin extractor M3 Bearing extractor (small) Round bar for arbor 7-50
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 Switch lever from Switch knob
[2] LUBRICATION Apply the following lubricants to the designated portions to protect parts and product from unusual abrasion. Item No. 18 9
Description
Portion to lubricate
Gear housing
Gear room
O-ring 26
inside
Fig. 1
18
Lubricant Makita grease SG No. 0
Spiral bevel gear 10
Amount 6.9g a little
Makita grease SG No.0
9
M6 Hex nut
[3] DISASSEMBLY/ASSEMBLY [3] -1. Armature, Ball bearing 629DDW, Spiral Bevel Gear 10 DISASSEMBLING (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
P 3/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) DISASSEMBLING (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.
P 4/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) DISASSEMBLING
(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
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.
Retaining ring R-26 After removing Guide plate, remove Retaining ring R-26.
Fig. 9 Labyrinth rubber ring 19
Ball bearing 607LLB
After removing Labyrinth rubber ring 19, remove Ball bearing 607LLB with 1R269.
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 Spiral bevel gear 10 M6 Hex nut
Armature
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.
Ball bearing 629DDW
Strike the edge of Gear housing with a plastic hammer, . So Ball bearing 629DDW is removed together with the Armature.
P 5/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Armature, Ball bearing 629DDW, Spiral bevel gear 10 (cont.) ASSEMBLING Refer to Figs. 11 to 15. Fig. 11
Fig. 12 Gear housing
1R006
protrusion
Retaining ring R-26
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. Fig. 13
Assemble Guide plate to Gear housing while fitting the notch of Guide plate to the protrusion of Gear housing. Fig. 14
Gear housing M6 Hex nut
Guide plate 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 Switch knob
Armature
Pin cap Motor housing
Switch knob Gear Housing 4x22 Tapping screw (4 pcs.)
Facing Pin cap (Spindle lock button) to the opposite side of Switch knob, assemble Gear Housing to Motor housing.
Switch knob
Assemble bearing box section to Gear housing.
P 6/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Spiral Bevel Gear 37, Ball Bearing 6201DDW DISASSEMBLING
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 Spiral bevel gear 37
Retaining ring R-32
Bearing box section
Ball bearing 6201DDW
Labyrinth ring
1R031 1R031 Spindle
Receive Labyrinth ring with 1R031. And remove Spindle from Bearing box section with arbor press.
Fig. 18
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. 19 1R246
1R005 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.
P 7/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Spiral Bevel Gear 37, Ball Bearing 6201DDW (cont.) ASSEMBLING Assemble the parts in Bearing box as illustrated in Figs. 20 to 25. Fig. 20
Fig. 21 Ball bearing 6201DDW
Wrong
1R005 Retaining ring R-32
Flat washer 12
concave side
Correct
Spindle flat side Labyrinth ring
Bearing box
1R031 Install Ball bearing 6201DDW Fit Retaining ring R-32 into and Flat washer 12 to Bearing the groove of Bearing box using 1R005. box. Fig. 22
When setting Labyrinth ring on 1R031, face the flat side upward. Then press fit Spindle to Labyrinth ring.
Fig. 23
Spindle Labyrinth ring
Spiral bevel gear 37
Bearing box
Bearing box
Press fit Spindle to Bearing box that is shown in Fig. 20.
Fig. 24 Ring spring 11
1R031
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. 25 Ring spring 11
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
Ball bearing 696ZZ Press fit Ball bearing 696ZZ to Spindle.
P 8/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -3. Switch mechanism (Switch lever and Switch knob) DISASSEMBLING (1) Remove Rear cover from Motor housing by removing 4x18 Tapping screw. (Fig. 2) (2) Switch lever and Switch knob can be disassembled from the machine as illustrated in Fig. 26. Fig. 26 Switch knob
1R 281 Switch knob Switch lever
Switch Lever
wall of Switch box
1. While locking Switch knob with 1R281, strongly push Switch lever in a direction designated with black arrow.
3. Bend Switch lever to make it free from the wall of Switch box.
2. Switch lever is disconnected from the locking claw of Switch knob. And Switch knob can be removed.
4. Pull out Switch lever from Motor housing.
ASSEMBLING Interlock Switch knob with Switch lever as illustrated in Fig. 27. Fig. 27 1. Make sure that Compression spring 4 is assembled to Switch lever in advance.
Compression spring 4 for pushing back Switch lever to OFF position
hole for hook of Switch lever hole hook
Switch knob Switch knob assembling Switch hole lever 2. Push Switch lever into Motor housing until the hole of Switch lever comes into sight through Switch knob assembling hole on Motor housing. And keep the position.
the top end of Switch lever
the reverse side of Switch knob 3. Fit the hook of Swtich knob to the hole of Switch knob.
4. Release Switch lever. (The hook of Switch knob interlocks with the hole of Switch lever when Switch lever is pushed back to OFF position by Compression spring 4.)
P 9/ 13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -4 Shaft Lock Mechanism DISASSEMBLING (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 Compression spring 8
Pin cap Shoulder Pin 4
1R350
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. 31
Fig. 30
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.
P 10/13
Repair [3] DISASSEMBLY/ASSEMBLY [3] -5 Field DISASSEMBLING (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 Switch. 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.
Circuit
P 11/13 diagram
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. Power supply cord
Field Switch
Black lead wire is used for some countries
Brush holder
Wiring
diagram
Fig. D-2
Wiring to Switch Switch Switch knob Switch lever
Connect the Lead wire of Power supply cord to Switch from the ON-OFF button side.
Switch
ON-OFF Button
Mark on Switch body
Face the wire connecting side to Switch lever.
Lead wire (brown or black)
Power supply cord Lead wire (blue or white)
Wiring
P 12/13 diagram
Fig. D-3
Wiring of Field lead wires Insert Field into Motor housing so that the Field lead wires (red) face the opposite side of Switch knob as illustrated below.
Switch knob side
Field
Field lead wire (red)
Field lead wire (red)
Field lead wire (red)
Switch knob
Pull out Field lead wires (red) from rear opening of the opposite side of Switch lever. Field lead wire (red)
Switch lever Motor housing (viewed from Rear cover side) Fig. D-4
Rear portion of Motor housing (viewed from opposite side of Switch lever) Field lead wires have to be tight in Motor housing. Switch knob Switch lever
* 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.
Switch
P 13/13
Wiring
diagram
Fig. D-5 Rear portion of Motor Housing (viewesd from Switch lever side) Switch lever
Switch knob
* Noise suppressor
Rib
Switch lever Switch
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 .
