Makita Grinder GA4041C User Manual

ECHNICAL INFORMATION

PRODUCT

P 1/ 14

GA4041C/GA4043C, GA4541C/GA4543C,

Model No.

Description

GA5041C/GA5043C

Angle Grinders 100mm (4"), 115mm (4-1/2"),

125mm (5")

CONCEPT AND MAIN APPLICATIONS

1,400W Angle grinder series models; GA4041C/ GA4043C,

GA4541C/ GA4543C and GA5041C/ GA5043C are successor

models of 9560 series models, featuring:

• "Super Joint System II" developed for effective vibration

absorption

Dimensions: mm (")

GA4041C GA4541C

GA4043C GA4543C

GA5041C

GA5043C

Model No.

Length (L)

• Electronic current limiter, speed control and soft start

• Mechanical brake for powerful braking

• Anti-restart function*1

325 (12-3/4)

Width (W) 117 (4-5/8) 130 (5-1/8) 140 (5-1/2)

Height (H) 117 (4-5/8)

121 (4-3/4)

• Re-designed durable gear housing

• Ergonomically best possible barrel grip

*1 Anti-restart function is for models, GA4041C, GA4541C, GA5041C only

Specification

Continuous Rating (W)

Input Output

Voltage (V)

Cycle (Hz)

Max. Output (W)

Current (A)

110

120

127

220

230

240

50/60

1,400

---

840

1,800

2,000

2,100

1,400

6.7

6.4

6.1

Model No.

GA4041C/ GA4043C

100 (4)

GA4541C/ GA4543C

GA5041C/ GA5043C

Diameter

115 (4-1/2)

125 (5)

Wheel size:

mm (")

Hole diameter

Max. thickness

16 (5/8)

22.23 (7/8)

6 (1/4)

No load speed: min.ˉ¹=rpm

Shock absorbing system

Constant speed control

Soft start

2,800 - 11,000

Super Joint System II

Yes

Electronic current limiter

Anti-restart function

GA4041C, GA4541C, GA5041C: Yes/ GA4043C, GA4543C, GA5043C: No

Variable speed control by dial

Yes

Mechanical brake

Protection against electric shock

Double insulation

European countries except UK: 4.0 (13.2), Brazil, Australia: 2.0 (6.6)

Power supply cord: m (ft)

Other countries: 2.5 (8.2)

Weight according to

EPTA-Procedure 01/2003*2: kg (")

2.6 (5.6)

2.7 (5.9)

*2 With Side grip, Wheel cover, Inner flange, Lock nut

Standard equipment

Side grip ...............................................1

Lock nut wrench ..................................1

Depressed center wheel ........................1 (100mm for GA4041C/ GA4043C, 115mm for GA4541C/ GA4543C,

125mm for GA5041C/ GA5043C)

Note: The standard equipment for the tool shown above may vary by country.

Optional accessories

Depressed center wheels

Rubber pads

Wheel covers for wire cup brush sets Abrasive cut off wheels

Wire bevel brush sets Wheel covers

Dust collection wheel guards Wheel covers for wire bevel brush sets Sanding lock nut

Abrasive discs

Diamond wheels

etc.

Wire cup brush sets

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P 2/ 14

Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

Code No.

Description

Use for

1R028 Bearing setting pipe 20-12.2 mounting Gear housing cover to Armature

1R045 Gear extractor (Large)

1R232 Pipe 30

separate Armature from Gear housing cover

removing Coupling and Ball bearing 6903ZZ from large Spiral bevel gear

1R258 V block

supporting Armature and Bearing box

1R268 Spring pin extractor M3

1R269 Bearing extractor

disassembling Shaft lock mechanism

removing Ball bearings 627DDW/ 696ZZ from Armature

removing Switch knob from Switch lever

1R281 Round bar for Arbor 7-50

1R286 Round bar for Arbor 12-50

1R291 Retaining ring S & R pliers

1R340 Bearing retainer wrench

1R350 Ring 60

removing large Spiral bevel gear section from Bearing box

removing Retaining ring S-9

removing Bearing retainer 20-33 from Bearing box

supporting Gear housing when disassembling Shaft lock mechanism

[2] LUBRICATION

Apply Makita grease to the following portions designated with the black triangle and the gray triangle to protect parts

and product from unusual abrasion.

Item No.

Description

Portion to lubricate

Lubricant

Amount

17g

Makita Grease SG No. 0:

Gear housing

Gear room

Makita Grease SG No. 0:

Makita Grease FA No. 2:

Gear housing cover O-ring 27.5 of 6 Gear housing cover

a little

C-type plate

Coupling

Spindle

Outer surface where 58 Coupling contacts

Cylindrical portion where 56 C-type plate contacts

Drum portion where 58 Coupling contacts

a little

Fig. 1

Joint sleeve

Spiral bevel gear (large)

Ball bearing 6903ZZ

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Note in Disassemble (general)

Note: As listed below, the grinders use different spiral bevel gears, and they are not interchangeable.

Referring to this list, therefore, be sure to use correct gears for replacement.

No load

speed: min.ˉ¹

Smaller spiral bevel gear

(on armature shaft)

Larger spiral bevel gear

Model No.

(on spindle)

38 teeth

41 teeth

GA4041 GA4541C

GA4541 GA5041C

GA5041 GA4543C

GA4041C GA5043C

GA4043C

11,000

10 teeth

9 teeth

GA6041

9,000

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P 3/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Armature, Spiral bevel gear [small one]

DISASSEMBLING

(1) Remove Spiral bevel gear (small) from the drive end of Armature as drawn in Fig. 2.

Fig. 2

1. Remove Rear cover by unscrewing

one 4x18 Tapping screw.

2. Shift Spiral spring from 3. Disconnect Carbon brush from

Carbon brush top.

commutator by pulling up.

Note: No need to remove Carbon

brush in this step.

4x18 Tapping screw

Rear cover

4. Unscrew four Tapping screws. Then separate Gear housing cover from Spacer while applying a slotted

screwdriver to the notch on Gear housing cover on belly side.

4x50 Tapping screw

Gear housing cover

Gear housing

Gear housing cover

Armature

Notch on

Gear housing cover

Spacer

5. Remove M6 Hex nut to turn it with Wrench 10

counterclockwise. Then, remove Flat washer 6

and small Spiral bevel gear from Armature.

6. Remove Gear housing cover with 1R045.

Then, remove Compression spring 33 and

Brake shoe holder complete.

Caution: Be careful that the cover and the spring

may jump out from Armature side

M6 Hex nut

due to recoil force by the spring.

Flat washer 6

Gear housing

cover

Spiral bevel

gear (small)

1R045

Compression

spring 33

Brake shoe

holder complete

Wrench 10

Armature

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P 4/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Armature, Spiral bevel gear [small one] (cont.)

DISASSEMBLING

(2) Disassemble the commutator end of Armature as drawn in Fig. 3.

Note: This step is required for the models with electronic control system of GA4041C, GA4043C, GA4541C,

GA4543C, GA5041C, GA5043C.

Fig. 3

2. Remove Magnet sleeve,

Wave washer 6 and

Labyrinth rubber ring 22.

1. Pick up three tabs of

Self lock 6 with tweezers

to remove it from Armature.

Tabs

Self lock 6

Magnet sleeve

Wave washer 6

Tweezers

Labyrinth rubber ring 22

3. Remove Ball bearing 627DDW with 1R269.

1R269

4. Remove Flat washer 7 and

Insulation washer.

Flat washer 7

Insulation washer

Ball bearing 627DDW

ASSEMBLING

(1) Assemble the commutator end of Armature as drawn in Fig. 4.

Note: This step is required for the models with electronic control system of GA4041C, GA4043C, GA4541C,

GA4543C, GA5041C, GA5043C.

Fig. 4

1. Return tabs of Self lock 6 to their

2. Press down Self lock 6 until

Wave washer 6 gets flat.

3. Magnet sleeve is stabilized

between Self lock 6 and

Wave washer 6 by the reaction

force of Wave washer 6.

normal shape before assembling.

Then, mount Wave washer 6 to

the commutator end of Armature.

Note: Be careful of their directions.

Refer to the drawings in Fig. 4.

Self lock 6

Magnet sleeve

Self lock 6

Magnet sleeve

Wave washer 6

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P 5/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Armature, Spiral bevel gear [small one] (cont.)

ASSEMBLING

(2) Assemble the drive end of Armature as drawn in Fig. 5.

Fig. 5

1. Set Brake shoe holder

complete and Compression

spring 33 to Armature.

2. Mount Gear housing cover to

Armature to fit the groove of

the cover to Compression

3. Supporting Armature section

with 2 pcs. of 1R258, press

Gear housing cover to

spring 33 and Armature shaft

through Ball bearing 6001LLB.

Armature section with 1R028.

Compression

spring 33

Ball bearing

6001LLB

Groove of Gear

housing cover

Brake shoe

holder complete

1R028

Compression

spring 33

Armature

1R258

4. Set Spiral bevel gear (small) and Flat washer 6 to Armature shaft.

Then, secure them with M6 Hex nut.

M6 Hex nut

Flat washer 6

Spiral bevel

Wrench 10

gear (small)

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P 6/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Armature, Spiral bevel gear [small one] (cont.)

ASSEMBLING

(3) Assemble Spacer, Armature section and Gear housing to Motor housing as drawn in Fig. 6.

Fig. 6

1. Set Switch knob to “Lock ON” position so that Switch plate is pushed toward Spacer.

Then, mount Spacer while fitting its groove to Switch plate.

And then, return Switch knob to “OFF” position.

Spacer

Switch plate Switch knob

groove

2. Assemble Armature section to Motor housing

while fitting the wings of Brake shoe complete

to the grooves of Spacer.

3. Face the notch to the same side as Name plate

by twisting Gear housing cover.

Gear housing cover

Name plate

Wing of

Brake shoe complete

Groove of Spacer

Spacer

Wing of

Brake shoe complete

Notch on

Gear housing cover

4. Assemble Gear housing while facing Spindle to the same side

as the notch and Name plate.

Spindle

Gear housing

Notch on

Gear housing cover

Name plate

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P 7/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -3. Spiral bevel gear [large one], Ball bearings 696ZZ/ 6201DDW

DISASSEMBLING

Note: The gear and the ball bearings can be replaced without disassembling the motor section.

(1) Remove Ball bearing 696ZZ, Retaining ring S-9, Flat washer 10 and C-type plate from Spindle as drawn in Fig. 7.

Fig. 7

1. Remove four M4x16 Hex socket head bolts, then separate Bearing box section from Gear housing.

M4x16 Hex socket head bolt

Bearing box

section

2. Remove Ball bearing 696ZZ

with 1R269.

3. Remove Retaining ring S-9

with 1R291.

4. Remove Flat washer 10.

Then, remove C-type plate.

1R291

1R269

C-type plate.

Flat washer 10

Ball bearing

696ZZ

Retaining

ring S-9

5. Receive Bearing box with 1R258

and remove Spindle by pressing it

with Arbor press.

6. Joint sleeve can be removed.

Joint sleeve

7. Using 1R291, remove Retaining

ring R-26 from the inside of

Lead flange.

Then, separate Lead flange

from Spindle .

Arbor press

Retaining

ring R-26

1R258

Spindle

Lead flange

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P 8/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -3. Spiral bevel gear [large one], Ball bearings 696ZZ/ 6201DDW (cont.)

DISASSEMBLING

(2) Disassemble large Gear section from Bearing box as drawn in Fig. 8.

Fig. 8

1. Tap Bearing box to shift Flat washer 12

so that the surface is revealed as large as

possible.

2. While applying 1R286 to Flat washer 12 through Bearing

retainer, press it carefully to remove large Spiral bevel gear

section (including Coupling and Ball bearing 6903ZZ)

from Bearing box.

Then, put Bearing box on 1R258.

Flat washer 12

Bearing box

1R286

Ball bearing

6903ZZ

Bearing retainer

Flat washer 12

Coupling

Flat washer 12

1R258

large

Spiral bevel gear

3. Put large Spiral bevel gear section

on 1R258. Then, apply 1R232 to

Coupling of the gear section.

4. Remove Coupling together with Ball bearing 6903ZZ

from large Spiral bevel gear by pressing 1R232 with Arbor

press. And then, disassemble the bearing from Coupling.

Note: Do not re-use the removed Ball bearing 6903ZZ

because it is damaged in the step of removing Spindle.

Arbor press

1R232

large Spiral bevel gear

1R258

Coupling

Ball bearing 6903ZZ

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P 9/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -3. Spiral bevel gear [large one], Ball bearings 696ZZ/ 6201DDW (cont.)

DISASSEMBLING

(3) Disassemble Ball bearing 6201DDW from Bearing box as drawn in Fig. 9.

Fig. 9

1. Clamp Bearing box with Vise. Then, while fitting the claw of 1R340 to the notch of Bearing retainer 20-33,

turn 1R340 clockwise to remove the retainer.

Bearing

retainer 20-33

1R340

Bearing

retainer 20-33

Felt ring 17

2. Take out Felt ring 17 and Flat washer 21

from Lead flange side of Bearing box.

3. Remove Ball bearing 6201DDW with Arbor press.

Arbor press

Felt ring 17

Ball bearing

6201DDW

Flat washer 21

Ball bearing

6201DDW

ASSEMBLING

Assemble by reversing the disassembly procedure. (Refer to Figs. 9, 8 and 7)

Note: • Do not re-use the removed Joint sleeve. New Joint sleeve has to be mounted.

(Refer to the bottom center illustration in Fig. 7)

• Apply the following thread locker to the thread of M4x16 Hex socket head bolts if the unscrewed bolts are used.

* Three Bond 1342

* Loctite 242

(Refer to the upper left illustration in Fig. 7)

• Coupling, large Spiral bevel gear, Ball bearing 6903ZZ have to be assembled tightly that there is any gaps

among them. See the left illustration in Fig. 10.

Fig. 10

Incomplete assembling causes gaps.

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P 10/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -4. Switch Lever

DISASSEMBLING

(1) Remove Rear cover from Motor housing by removing 4x18 Tapping screw. (Fig. 2)

(2) Disassemble Switch lever and Switch knob from the machine as drawn in Fig. 11.

Fig. 11

1. While locking Switch knob

with 1R281, strongly push

Switch lever in a direction

designated with black arrow.

2. Switch lever is disconnected from

the locking claw of Switch knob.

Then, remove Switch knob.

3. Bending Switch lever, pull out

Switch lever from Motor housing.

Switch knob

1R281

Switch lever

ASSEMBLING

(1) Insert Switch lever into Motor housing. And push it until the loop portion comes into sight through Switch knob

assembling hole on Motor housing. Refer to the right and center illustration in Fig. 11.

(2) Assemble Switch knob to Switch lever as drawn in Fig. 12.

Fig. 12

1. Make sure that Compression spring 4 is assembled

to Switch lever in advance.

2. Fitting Switch knob to the loop portion of Switch

lever and the claw portion of Switch plate, hold

Switch knob. And then, 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.)

Switch lever

Switch plate

Switch knob

Compression spring 4

Switch lever

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P 11/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -5. Switch Block

DISASSEMBLING

After removing Switch lever (Refer to Fig. 11), separate Switch block from Motor housing as drawn in Fig. 13.

Fig. 13

Insert Slotted screwdriver into the gap between Switch

block and Motor housing, remove Switch block from

Motor housing by twisting the screwdriver.

Switch block

Controller

Slotted screwdriver

[3] -6. Switch

DISASSEMBLING

After removing Switch lever (Refer to Fig. 11), remove Switch from Switch block as drawn in Fig. 14.

Fig. 14

Insert Slotted screwdriver into the gap between Switch and Switch block.

While fitting the tip of the screwdriver to the side groove of Switch,

remove Switch by prying it off.

Switch

Slotted screwdriver

[3] -7. Brush Holder

DISASSEMBLING

Brush holders can be disassembled as drawn in Fig. 15.

Fig. 15

Remove 3x10 Tapping screw. Then, insert Slotted screwdrivers into the gap between Motor housing

and Brush holder’s plastic portion. And then, disassemble Brush holder by prying them off.

Brush holder

Slotted screwdrivers

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P 12/ 14

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -8. Shaft Lock

DISASSEMBLING

(1) Disassemble Bearing box section as drawn in the upper two illustrations in Fig. 7.

(2) Disassemble Shaft lock mechanism as drawn in Figs. 16 and 17.

Fig. 16

Fig. 17

Release 1R268 from Pin cap carefully

While applying 1R268 to Shoulder pin 6 through the small hole

on Pin cap, tap 1R268 with a hammer.

Now, Shoulder pin 6 comes out from Gear housing complete.

so that Pin cap will not pop out by

Compression spring 8.

1R268

Pin cap

Compression

spring 8

Pin cap

Note: Do not re-use removed Pin cap

because removal one damages

the inside surface of the cap,

producing plastic dust.

1R350

Shoulder pin 6

ASSEMBLING

(1) Be sure to use a new Pin cap for replacement and to remove all the plastic dust on Shoulder pin 6. (Fig. 18)

(2) Assemble the Parts for Shaft lock mechanism as drawn in Fig. 19.

Fig. 18

Fig. 19

1. Insert Shoulder pin 6 through

the hole of Gear housing

complete.

2. Assemble new Pin cap by pressing

it to Shoulder pin 6.

Note: Do not forget to assemble

Compression spring 8.

Plastic dust

Pin cap

Shoulder pin 5

Shoulder

pin 6

Compression

spring 8

O Ring 4

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P 13/ 14

Circuit diagram

GA4041C, GA4043C, GA4541C, GA4543C, GA5041C, GA5043C

Fig. D-1A

with Controller

Color index of lead wires' sheath

Blue

Black lead wire is used

Brown

Switch

for some countries.

Switch block

White lead wire is used

for some countries.

Brush holder

Field

Noise

suppressor

Noise suppressor* is installed

in Switch block.

*Noise suppressor is not used

for some countries.

Controller

GA4041, GA4541, GA5041, GA6041

Fig. D-1B

without Controller

Color index of lead wires' sheath

Brown

Blue

Black lead wire is used

for some countries.

Switch

Switch block

White lead wire is used

for some countries.

Brush holder

Field

Noise

suppressor

Noise suppressor* is installed

in Switch block.

*Noise suppressor is not used

for some countries.

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P 14/ 14

Wiring diagram

Fig. D-2

Wiring of Lead wires of Power supply cord

Put Lead wires of Power supply cord

into this place designated with gray color.

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