Page 1
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.
Page 2
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)
Page 3
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
Page 4
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
Page 5
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
Page 6
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.
P 6/ 14
Spacer
2. Assemble Armature section to Motor housing
while fitting the wings of Brake shoe complete
to the grooves of Spacer.
Wing of
Brake shoe complete
Wing of
Brake shoe complete
Switch plate Switch knob
groove
Groove of Spacer
3. Face the notch to the same side as Name plate
by twisting Gear housing cover.
Gear housing cover
Name plate
Spacer
Notch on
Gear housing cover
4. Assemble Gear housing while facing Spindle to the same side
as the notch and Name plate.
Spindle
Notch on
Gear housing cover
Name plate
Gear housing
Page 7
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.
1R269
Ball bearing
696ZZ
5. Receive Bearing box with 1R258
and remove Spindle by pressing it
with Arbor press.
Arbor press
3. Remove Retaining ring S-9
with 1R291.
1R291
Retaining
ring S-9
6. Joint sleeve can be removed.
Joint sleeve
4. Remove Flat washer 10.
Then, remove C-type plate.
C-type plate.
Flat washer 10
7. Using 1R291, remove Retaining
ring R-26 from the inside of
Lead flange.
Then, separate Lead flange
from Spindle .
1R258
1R258
1R258 1R258
Spindle
Retaining
ring R-26
Spindle
Lead flange
Page 8
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
P 8/ 14
1. Tap Bearing box to shift Flat washer 12
so that the surface is revealed as large as
possible.
Then, put Bearing box on 1R258.
Bearing box
Bearing retainer
3. Put large Spiral bevel gear section
on 1R258. Then, apply 1R232 to
Coupling of the gear section.
Flat washer 12
Flat washer 12
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.
1R286
Ball bearing
6903ZZ
Coupling
1R258
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.
large
Spiral bevel gear
Flat washer 12
large Spiral bevel gear
1R232
1R232
1R2581R258 1R2581R258
Coupling
Ball bearing 6903ZZ
Arbor press
Page 9
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
1R340
retainer 20-33
P 9/ 14
Bearing
retainer 20-33
2. Take out Felt ring 17 and Flat washer 21
from Lead flange side of Bearing box.
Felt ring 17
Flat washer 21
Ball bearing
6201DDW
Felt ring 17
3. Remove Ball bearing 6201DDW with Arbor press.
Arbor press
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.
Page 10
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
P 10/ 14
1. While locking Switch knob
with 1R281, strongly push
Switch lever in a direction
designated with black arrow.
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. Switch lever is disconnected from
the locking claw of Switch knob.
Then, remove Switch knob.
Switch knob
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
3. Bending Switch lever, pull out
Switch lever from Motor housing.
Switch lever
Switch knob
Compression spring 4
Switch lever
Page 11
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.
Slotted screwdriver
[3] -6. Switch
DISASSEMBLING
Switch block
Controller
P 11/ 14
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
Page 12
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
P 12/ 14
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.
1R268
Pin cap
Pin cap
1R350
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.
Shoulder pin 6
Release 1R268 from Pin cap carefully
so that Pin cap will not pop out by
Compression spring 8.
Pin cap
Compression
spring 8
Note: Do not re-use removed Pin cap
because removal one damages
the inside surface of the cap,
producing plastic dust.
Fig. 18 Fig. 19
1. Insert Shoulder pin 6 through
the hole of Gear housing
complete.
Plastic dust
Shoulder pin 5
O Ring 4
Shoulder
pin 6
2. Assemble new Pin cap by pressing
it to Shoulder pin 6.
Note: Do not forget to assemble
Compression spring 8.
Pin cap
Compression
spring 8
Page 13
Circuit diagram
GA4041C, GA4043C, GA4541C, GA4543C, GA5041C, GA5043C
Fig. D-1A
with Controller
Color index of lead wires' sheath
Blue
Brown
P 13/ 14
Black lead wire is used
for some countries.
White lead wire is used
for some countries.
Noise suppressor* is installed
in Switch block.
*Noise suppressor is not used
for some countries.
GA4041, GA4541, GA5041, GA6041
Fig. D-1B
Switch
1
2
Switch block
Noise
suppressor
3
Controller
6
Field
7
45
8
Brush holder
Blue Brown
Black lead wire is used
for some countries.
White lead wire is used
for some countries.
Noise suppressor* is installed
in Switch block.
*Noise suppressor is not used
for some countries.
without Controller
Color index of lead wires' sheath
Switch
1
Switch block
Noise
suppressor
2
3
6
Field
4
8
Brush holder
57
Page 14
Wiring diagram
Fig. D-2
P 14/ 14
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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