Makita GA4543C, GA4541C, GA5041C, GA4041C, GA4043C User Manual
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T
ECHNICAL INFORMATION
Model No.
GA4041C/GA4043C, GA4541C/GA4543C,
GA5041C/GA5043C
Description
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
• Electronic current limiter, speed control and soft start
• Mechanical brake for powerful braking
• Anti-restart function*1
• Re-designed durable gear housing
• Ergonomically best possible barrel grip
1 Anti-restart function is for models, GA4041C, GA4541C, GA5041C only
*
Specification
Voltage (V) Cycle (Hz)
110
120
127 12
220
230
240
Current (A)
13
12
6.7
6.4
6.1
50/60
50/60
50/60
50/60
50/60
50/60
H
W
Dimensions: mm (")
Model No.
Length (L)
Width (W)
Height (H)
Continuous Rating (W)
Input Output
1,400
--1,400
1,400
1,400
1,400
GA4041C
GA4043C
117 (4-5/8)
117 (4-5/8)
840
840
840
840
840
840
PRODUCT
P 1/ 14
L
GA4541C
GA4543C
325 (12-3/4)
130 (5-1/8) 140 (5-1/2)
Max. Output (W)
GA5041C
GA5043C
121 (4-3/4)
1,800
2,000
2,000
2,100
2,100
2,100
Model No.
Wheel size:
mm (")
No load speed: min.
Shock absorbing system
Constant speed control
Soft start
Electronic current limiter
control
Anti-restart function
Electronic
Variable speed control by dial
Mechanical brake
Protection against electric shock
Power supply cord: m (ft)
Weight according to
EPTA-Procedure 01/2003*2: kg (")
*2 With Side grip, Wheel cover, Inner flange, Lock nut
Diameter
Hole diameter
Max. thickness 6 (1/4)
ˉ¹=rpm
GA4041C/ GA4043C
100 (4) 115 (4-1/2)
GA4041C, GA4541C, GA5041C: Yes/ GA4043C, GA4543C, GA5043C: No
European countries except UK: 4.0 (13.2), Brazil, Australia: 2.0 (6.6)
2.6 (5.6) 2.7 (5.9)2.7 (5.9)
GA4541C/ GA4543C
22.23 (7/8)16 (5/8)
2,800 - 11,000
Super Joint System II
Yes
Yes
Yes
Yes
Yes
Double insulation
Other countries: 2.5 (8.2)
GA5041C/ GA5043C
125 (5)
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
Dust collection wheel guards
Abrasive discs
Wire cup brush sets
Wheel covers for wire cup brush sets
Wire bevel brush sets
Wheel covers for wire bevel brush sets
Diamond wheels
Dust collecting wheel guards
Abrasive cut off wheels
Wheel covers
Sanding lock nut
etc.
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) separate Armature from Gear housing cover
1R232 Pipe 30 removing Coupling and Ball bearing 6903ZZ from large Spiral bevel gear
1R258 V block supporting Armature and Bearing box
1R268 Spring pin extractor M3 disassembling Shaft lock mechanism
1R269 Bearing extractor removing Ball bearings 627DDW/ 696ZZ from Armature
1R281 Round bar for Arbor 7-50 removing Switch knob from Switch lever
1R286 Round bar for Arbor 12-50 removing large Spiral bevel gear section from Bearing box
1R291 Retaining ring S & R pliers removing Retaining ring S-9
1R340 Bearing retainer wrench removing Bearing retainer 20-33 from Bearing box
1R350 Ring 60 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
Gear housing
1
Gear housing cover
6
C-type plate a little56 Outer surface where 58 Coupling contacts
Coupling
58
Spindle
70
Fig. 1
Ball bearing 6903ZZ
Gear room 17g
O-ring 27.5 of 6 Gear housing cover
Cylindrical portion where 56 C-type plate contacts
Drum portion where 58 Coupling contacts
Joint sleeve
56
58
Spiral bevel gear (large)
70
Makita Grease SG No. 0:
Makita Grease SG No. 0:
Makita Grease FA No. 2:
Makita Grease FA No. 2:
Makita Grease FA No. 2:
Lubricant AmountPortion to lubricate
a little
a little
a little
6
1
[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.
Model No.
GA4041 GA4541C
GA4541 GA5041C
GA5041 GA4543C
GA4041C GA5043C
GA4043C
GA6041
No load
speed: min.ˉ¹
11,000
9,000
Smaller spiral bevel gear
(on armature shaft)
Larger spiral bevel gear
10 teeth 38 teeth
9 teeth 41 teeth
(on spindle)
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
P 3/ 14
1. Remove Rear cover by unscrewing
one 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.
Gear housing cover
Gear housing
4x50 Tapping screw
2. Shift Spiral spring from
Carbon brush top.
4x18 Tapping screw
3. Disconnect Carbon brush from
commutator by pulling up.
Note: No need to remove Carbon
brush in this step.
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.
M6 Hex nut
Flat washer 6
Spiral bevel
gear (small)
Wrench 10
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
due to recoil force by the spring.
Gear housing
1R045
cover
Compression
spring 33
Brake shoe
holder complete
Armature
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
1. Pick up three tabs of
Self lock 6 with tweezers
to remove it from Armature.
3. Remove Ball bearing 627DDW with 1R269. 4. Remove Flat washer 7 and
1R269
Ball bearing 627DDW
ASSEMBLING
Tabs
Self lock 6
Tweezers
2. Remove Magnet sleeve,
Wave washer 6 and
Labyrinth rubber ring 22.
Magnet sleeve
Wave washer 6
Labyrinth rubber ring 22
Insulation washer.
Flat washer 7
Insulation washer
(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
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
Wave washer 6
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.
Self lock 6
Magnet sleeve
Wave washer 6
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
P 5/ 14
1. Set Brake shoe holder
complete and Compression
spring 33 to Armature.
Compression
spring 33
Brake shoe
holder complete
Armature
4. Set Spiral bevel gear (small) and Flat washer 6 to Armature shaft.
Then, secure them with M6 Hex nut.
2. Mount Gear housing cover to
Armature to fit the groove of
the cover to Compression
spring 33 and Armature shaft
through Ball bearing 6001LLB.
Ball bearing
6001LLB
Groove of Gear
housing cover
Compression
spring 33
3. Supporting Armature section
with 2 pcs. of 1R258, press
Gear housing cover to
Armature section with 1R028.
1R028
1R258
Flat washer 6
Spiral bevel
gear (small)
M6 Hex nut
Wrench 10
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