Makita Power Tools Instruction Manual

INSTRUCTION MANUAL
Angle Grinder
GA4030
GA4530
GA5030
DOUBLE
INSULATION
WARNING:
For your personal safety, READ and UNDERSTAND before using.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
ENGLISH
SPECIFICATIONS
Model
GA4030
GA4530
GA5030
Wheel diameter
100mm (4")
115mm (4-1/2")
125mm (5")
No load speed (RPM)
11,000/min
11,000/min
11,000/min
Overall length
266 mm (10-1/2")
266 mm (10-1/2")
266 mm (10-1/2")
Net weight
1.4 kg (3.1 lbs)
1.4 kg (3.1 lbs)
1.4 kg (3.1 lbs)
Spindle thread
M10 x 1.25
5/8"
5/8"
• Due to our continuing programme of research and development, the specifications herein are subject to change without notice.
• Note: Specifications may differ from country to country.
GEA004-2
GENERAL SAFETY RULES
WARNING! Read all instructions. Failure to follow all
instructions listed below may result in electric shock, fire
and/or serious injury. The term "power tool" in all of the
warnings listed below refers to your mains-operated
(corded) power tool or battery-operated (cordless) power
tool.
SAVE THESE INSTRUCTIONS.
The term "power tool" in the warnings refers to your
mains-operated (corded) power tool or battery-operated
(cordless) power tool.
Work area safety
1.
Keep work area clean and well lit. Cluttered and
dark areas invite accidents.
2.
Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or fumes.
3.
Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
Electrical Safety
4.
Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
5.
Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of
electric shock if your body is earthed or grounded.
6.
Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
7.
Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords
increase the risk of electric shock.
8.
When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of
electric shock.
Personal Safety
9.
Stay alert, watch what you are doing and use
common sense when operating a power tool.
Do not use a power tool while you are tired or
under the influence of drugs, alcohol or
medication. A moment of inattention while
operating power tools may result in serious
personal injury.
10. Use safety equipment. Always wear eye
protection. Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will
reduce personal injuries.
11. Avoid accidental starting. Ensure the switch is
in the off-position before plugging in. Carrying
power tools with your finger on the switch or
plugging in power tools that have the switch on
invites accidents.
12. Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
13. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
14. Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing, and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
15. If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
these devices can reduce dust-related hazards.
Power tool use and care
16. Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
17. Do not use the power tool if the switch does
not turn it on and off. Any power tool that cannot
be controlled with the switch is dangerous and
must be repaired.
18. Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
19. Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
20. Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts
and any other condition that may affect the
power tools operation. If damaged, have the
power tool repaired before use. Many accidents
are caused by poorly maintained power tools.
21.
Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
22. Use the power tool, accessories and tool bits
etc. in accordance with these instructions and
in the manner intended for the particular type
of power tool, taking into account the working
conditions and the work to be performed. Use
of the power tool for operations different from
those intended could result in a hazardous
situation.
SERVICE
23. Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
24. Follow instruction for lubricating and
changing accessories.
25. Keep handles dry, clean and free from oil and
grease.
USE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. When using an
extension cord, be sure to use one heavy enough to
carry the current your product will draw. An undersized
cord will cause a drop in line voltage resulting in loss of
power and overheating. Table 1 shows the correct size
to use depending on cord length and nameplate ampere
rating. If in doubt, use the next heavier gage. The
smaller the gage number, the heavier the cord.
Table 1: Minimum gage for cord
Volts
Ampere Rating
Total length of cord in feet
120 V
More Than
Not More Than
0
6
10
12
6
10
12
16
25 ft.
50 ft.
100 ft.
150 ft.
AWG
18
18
16
14
16
16
16
12
16
14
14
12
14
12
Not Recommended
000173
GEB033-1
SPECIFIC SAFETY RULES
DO NOT let comfort or familiarity with product
(gained from repeated use) replace strict adherence
to grinder safety rules. If you use this tool unsafely
or incorrectly, you can suffer serious personal
injury.
1.
Safety Warnings Common for Grinding,
Sanding, Wire Brushing, or Abrasive
Cutting-Off Operations:
2.
This power tool is intended to function as a
grinder, sander, wire brush or cut-off tool.
3.
4.
Read all safety warnings, instructions,
illustrations and specifications provided with
this power tool. Failure to follow all instructions
listed below may result in electric shock, fire
and/or serious injury.
Operations such as polishing are not
recommended to be performed with this power
tool. Operations for which the power tool was not
designed may create a hazard and cause
personal injury.
Do not use accessories which are not
specifically designed and recommended by
the tool manufacturer. Just because the
5.
6.
7.
8.
9.
10.
11.
accessory can be attached to your power tool, it
does not assure safe operation.
The rated speed of the accessory must be at
least equal to the maximum speed marked on
the power tool. Accessories running faster than
their rated speed can break and fly apart.
The outside diameter and the thickness of
your accessory must be within the capacity
rating of your power tool. Incorrectly sized
accessories cannot be adequately guarded or
controlled.
The arbour size of wheels, flanges, backing
pads or any other accessory must properly fit
the spindle of the power tool. Accessories with
arbour holes that do not match the mounting
hardware of the power tool will run out of balance,
vibrate excessively and may cause loss of control.
Do not use a damaged accessory. Before each
use inspect the accessory such as abrasive
wheels for chips and cracks, backing pad for
cracks, tear or excess wear, wire brush for
loose or cracked wires. If power tool or
accessory is dropped, inspect for damage or
install an undamaged accessory. After
inspecting and installing an accessory,
position yourself and bystanders away from
the plane of the rotating accessory and run the
power tool at maximum no-load speed for one
minute. Damaged accessories will normally
break apart during this test time.
Wear
personal
protective
equipment.
Depending on application, use face shield,
safety goggles or safety glasses. As
appropriate, wear dust mask, hearing
protectors, gloves and workshop apron
capable of stopping small abrasive or
workpiece fragments. The eye protection must
be capable of stopping flying debris generated by
various operations . The dust mask or respirator
must be capable of filtrating particles generated
by your operation. Prolonged exposure to high
intensity noise may cause hearing loss.
Keep bystanders a safe distance away from
work area. Anyone entering the work area
must wear personal protective equipment.
Fragments of workpiece or of a broken accessory
may fly away and cause injury beyond immediate
area of operation.
Hold power tool by insulated gripping
surfaces only, when performing an operation
where the cutting accessory may contact
hidden wiring or its own cord. Cutting
accessory contacting a "live" wire may make
exposed metal parts of the power tool "live" and
shock the operator.
12.
13.
14.
15.
16.
17.
18.
Position the cord clear of the spinning
accessory. If you lose control, the cord may be
cut or snagged and your hand or arm may be
pulled into the spinning accessory.
Never lay the power tool down until the
accessory has come to a complete stop. The
spinning accessory may grab the surface and pull
the power tool out of your control.
Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
accessory could snag your clothing, pulling the
accessory into your body.
Regularly clean the power tool’s air vents. The
motor’s fan will draw the dust inside the housing
and excessive accumulation of powdered metal
may cause electrical hazards.
Do not operate the power tool near flammable
materials. Sparks could ignite these materials.
Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution or shock.
Kickback and Related Warnings
Kickback is a sudden reaction to a pinched or
snagged rotating wheel, backing pad, brush or
any other accessory. Pinching or snagging causes
rapid stalling of the rotating accessory which in
turn causes the uncontrolled power tool to be
forced in the direction opposite of the accessory’s
rotation at the point of the binding.
For example, if an abrasive wheel is snagged or
pinched by the workpiece, the edge of the wheel
that is entering into the pinch point can dig into the
surface of the material causing the wheel to climb
out or kick out. The wheel may either jump toward
or away from the operator, depending on direction
of the wheel’s movement at the point of pinching.
Abrasive wheels may also break under these
conditions.
Kickback is the result of power tool misuse and/or
incorrect operating procedures or conditions and
can be avoided by taking proper precautions as
given below.
a) Maintain a firm grip on the power tool and
position your body and arm to allow you to
resist kickback forces. Always use auxiliary
handle, if provided, for maximum control over
kickback or torque reaction during start-up. The
operator can control torque reactions or kickback
forces, if proper precautions are taken.
b) Never place your hand near the rotating
accessory. Accessory may kickback over your
hand.
c) Do not position your body in the area where
power tool will move if kickback occurs.
Kickback will propel the tool in direction opposite to
the wheel’s movement at the point of snagging.
d) Use special care when working corners,
sharp edges etc. Avoid bouncing and snagging
the accessory. Corners, sharp edges or bouncing
have a tendency to snag the rotating accessory
and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade
or toothed saw blade. Such blades create
frequent kickback and loss of control
19. Safety Warnings Specific for Grinding and
Abrasive Cutting-Off Operations:
a) Use only wheel types that are recommended
for your power tool and the specific guard
designed for the selected wheel. Wheels for
which the power tool was not designed cannot be
adequately guarded and are unsafe.
b) The guard must be securely attached to the
power tool and positioned for maximum safety,
so the least amount of wheel is exposed
towards the operator. The guard helps to protect
operator from broken wheel fragments and
accidental contact with wheel.
c) Wheels must be used only for recommended
applications. For example: do not grind with
the side of cut-off wheel. Abrasive cut-off wheels
are intended for peripheral grinding, side forces
applied to these wheels may cause them to
shatter.
d) Always use undamaged wheel flanges that
are of correct size and shape for your selected
wheel. Proper wheel flanges support the wheel
thus reducing the possibility of wheel breakage.
Flanges for cut-off wheels may be different from
grinding wheel flanges.
e) Do not use worn down wheels from larger
power tools. Wheel intended for larger power tool
is not suitable for the higher speed of a smaller tool
and may burst.
20. Additional Safety Warnings Specific for
Abrasive Cutting-Off Operations:
a) Do not “jam” the cut-off wheel or apply
excessive pressure. Do not attempt to make an
excessive depth of cut. Overstressing the wheel
increases the loading and susceptibility to twisting
or binding of the wheel in the cut and the possibility
of kickback or wheel breakage.
b) Do not position your body in line with and
behind the rotating wheel. When the wheel, at
the point of operation, is moving away from your
body, the possible kickback may propel the
spinning wheel and the power tool directly at you.
c) When wheel is binding or when interrupting a
cut for any reason, switch off the power tool
and hold the power tool motionless until the
wheel comes to a complete stop. Never attempt
21.
22.
23.
24.
25.
26.
27.
28.
to remove the cut-off wheel from the cut while
the wheel is in motion otherwise kickback may
occur. Investigate and take corrective action to
eliminate the cause of wheel binding
d) Do not restart the cutting operation in the
workpiece. Let the wheel reach full speed and
carefully reenter the cut. The wheel may bind,
walk up or kickback if the power tool is restarted in
the workpiece.
e) Support panels or any oversized workpiece
to minimize the risk of wheel pinching and
kickback. Large workpieces tend to sag under
their own weight. Supports must be placed under
the workpiece near the line of cut and near the
edge of the workpiece on both sides of the wheel.
f) Use extra caution when making a “pocket
cut” into existing walls or other blind areas.
The protruding wheel may cut gas or water pipes,
electrical wiring or objects that can cause kickback.
Safety Warnings Specific for Sanding
Operations:
a) Do not use excessively oversized sanding
disc
paper.
Follow
manufacturers
recommendations, when selecting sanding
paper. Larger sanding paper extending beyond the
sanding pad presents a laceration hazard and may
cause snagging, tearing of the disc or kickback.
Safety Warnings Specific for Wire Brushing
Operations:
a) Be aware that wire bristles are thrown by the
brush even during ordinary operation. Do not
overstress the wires by applying excessive
load to the brush. The wire bristles can easily
penetrate light clothing and/or skin.
b) If the use of a guard is recommended for wire
brushing, do not allow interference of the wire
wheel or brush with the guard. Wire wheel or
brush may expand in diameter due to work load
and centrifugal forces.
When using depressed centre grinding wheels,
be sure to use only fiberglass-reinforced
wheels.
Be careful not to damage the spindle, the
flange (especially the installing surface) or the
lock nut. Damage to these parts could result in
wheel breakage.
Make sure the wheel is not contacting the
workpiece before the switch is turned on.
Before using the tool on an actual workpiece,
let it run for a while. Watch for vibration or
wobbling that could indicate poor installation
or a poorly balanced wheel.
Use the specified surface of the wheel to
perform the grinding.
Watch out for flying sparks. Hold the tool so
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
that sparks fly away from you and other
persons or flammable materials.
Do not leave the tool running. Operate the tool
only when hand-held.
Do not touch the workpiece immediately after
operation; it may be extremely hot and could
burn your skin.
Always be sure that the tool is switched off
and unplugged or that the battery cartridge is
removed before carrying out any work on the
tool.
Observe the instructions of the manufacturer
for correct mounting and use of wheels.
Handle and store wheels with care.
Do not use separate reducing bushings or
adaptors to adapt large hole abrasive wheels.
Use only flanges specified for this tool.
For tools intended to be fitted with threaded
hole wheel, ensure that the thread in the wheel
is long enough to accept the spindle length.
Check that the workpiece is properly
supported.
Watch out for flying sparks. Hold the tool so
that sparks fly away from you and other
persons or flammable materials.
Pay attention that the wheel continues to
rotate after the tool is switched off.
If working place is extremely hot and humid, or
badly polluted by conductive dust, use a
short-circuit breaker (30 mA) to assure
operator safety.
Do not use the tool on any materials
containing asbestos.
Do not use water or grinding lubricant.
Ensure that ventilation openings are kept clear
when working in dusty conditions. If it should
become necessary to clear dust, first
disconnect the tool from the mains supply
( use non metallic objects ) and avoid
damaging internal parts.
When use cut-off wheel, always work with the
dust collecting wheel guard required by
domestic regulation.
Cutting discs must not be subjected to any
lateral pressure.
USD201-2
Symbols
The followings show the symbols used for tool.
・ volts
・
amperes
・
hertz
・
alternating current
・
no load speed
・
Class II Construction
・
revolutions or reciprocation per minute
FUNCTIONAL DESCRIPTION
•
CAUTION:
Always be sure that the tool is switched off and
unplugged before adjusting or checking function on
the tool.
Shaft lock
1. Shaft lock
1
009422
CAUTION:
Never actuate the shaft lock when the spindle is
moving. The tool may be damaged.
Press the shaft lock to prevent spindle rotation when
installing or removing accessories.
•
Switch action
1. Switch lever
WARNING:
MISUSE or failure to follow the safety rules stated in
this instruction manual may cause serious personal
injury.
1
SAVE THESE INSTRUCTIONS.
009423
CAUTION:
Before plugging in the tool, always check to see
that the slide switch actuates properly and returns
to the "OFF" position when the rear of the slide
switch is depressed.
•
Switch can be locked in "ON" position for ease of
operator comfort during extended use. Apply
caution when locking tool in "ON" position and
maintain firm grasp on tool.
To start the tool, slide the switch lever toward the "I
(ON)" position. For continuous operation, press the front
of the switch lever to lock it.
To stop the tool, press the rear of the switch lever, then
slide it toward the "O (OFF)" position.
•
cut-off wheel or diamond wheel, the wheel guard
must be fitted on the tool so that the closed side of
the guard always points toward the operator.
Mount the wheel guard with the protrusion on the wheel
guard band aligned with the notch on the bearing box.
Then rotate the wheel guard to such an angle that it can
protect the operator according to work. Be sure to
tighten the screw securely.
To remove wheel guard, follow the installation procedure
in reverse.
Installing or removing depressed center
grinding wheel/Multi-disc
1
2
3
4
ASSEMBLY
•
CAUTION:
Always be sure that the tool is switched off and
unplugged before carrying out any work on the
tool.
1. Lock nut
2. Depressed
center grinding
wheel/Multi-disc
3. Ring
4. Inner flange
009426
Installing side grip (handle)
WARNING:
Always use supplied guard when depressed center
grinding wheel/Multi-disc is on tool. Wheel can
shatter during use and guard helps to reduce
chances of personal injury.
Mount the inner flange onto the spindle. Fit the
wheel/disc on the inner flange and screw the lock nut
onto the spindle.
To tighten the lock nut, press the shaft lock firmly so that
the spindle cannot revolve, then use the lock nut wrench
and securely tighten clockwise.
•
009424
CAUTION:
Always be sure that the side grip is installed
securely before operation.
Screw the side grip securely on the position of the tool
as shown in the figure.
•
1
1. Lock nut wrench
2. Shaft lock
Installing or removing wheel guard
1
2
1. Wheel guard
2. Screw
3. Bearing box
2
009427
To remove the wheel, follow the installation procedure in
reverse.
3
009425
•
CAUTION:
When using a depressed center grinding
wheel/Multi-disc, flex wheel, wire wheel brush,
WARNING:
Only actuate the shaft lock when the spindle is not
moving.
Installing or removing flex wheel (optional
accessory)
1
2
3
4
1. Lock nut
2. Flex wheel
3. Plastic pad
4. Inner flange
•
•
•
009434
WARNING:
Always use supplied guard when flex wheel is on
tool. Wheel can shatter during use and guard helps
to reduce chances of personal injury.
Follow instructions for depressed center grinding
wheel/Multi-disc but also use plastic pad over wheel.
See order of assembly on accessories page in this
manual.
•
NEVER bang or hit grinding disc or wheel onto
work.
Avoid bouncing and snagging the wheel, especially
when working corners, sharp edges etc. This can
cause loss of control and kickback.
NEVER use tool with wood cutting blades and
other saw blades. Such blades when used on a
grinder frequently kick and cause loss of control
leading to personal injury.
•
CAUTION:
After operation, always switch off the tool and wait
until the wheel has come to a complete stop before
putting the tool down.
Grinding and sanding operation
Installing or removing abrasive disc (optional
accessory)
A
B
009429
1
2
1. Lock nut
2. Abrasive disc
3. Rubber pad
3
009435
NOTE:
•
Use sander accessories specified in this manual.
These must be purchased separately.
Mount the rubber pad onto the spindle. Fit the disc on
the rubber pad and screw the lock nut onto the spindle.
To tighten the lock nut, press the shaft lock firmly so that
the spindle cannot revolve, then use the lock nut wrench
and securely tighten clockwise.
To remove the disc, follow the installation procedure in
reverse.
ALWAYS hold the tool firmly with one hand on housing
and the other on the side handle. Turn the tool on and
then apply the wheel or disc to the workpiece.
In general, keep the edge of the wheel or disc at an
angle of about 15 degrees to the workpiece surface.
During the break-in period with a new wheel, do not work
the grinder in the B direction or it will cut into the
workpiece. Once the edge of the wheel has been
rounded off by use, the wheel may be worked in both A
and B direction.
Operation with wire cup brush (optional
accessory)
1. Wire cup brush
1
OPERATION
009436
•
•
WARNING:
It should never be necessary to force the tool. The
weight of the tool applies adequate pressure.
Forcing and excessive pressure could cause
dangerous wheel breakage.
ALWAYS replace wheel if tool is dropped while
grinding.
•
CAUTION:
Check operation of brush by running tool with no
load, insuring that no one is in front of or in line with
brush.
Do not use brush that is damaged, or which is out
of balance. Use of damaged brush could increase
potential for injury from contact with broken brush
wires.
Unplug tool and place it upside down allowing easy
access to spindle. Remove any accessories on spindle.
Thread wire cup brush onto spindle and tighten with
supplied wrench. When using brush, avoid applying too
much pressure which causes over bending of wires,
leading to premature breakage.
•
MAINTENANCE
•
CAUTION:
Always be sure that the tool is switched off and
unplugged before attempting to perform inspection
or maintenance.
1. Exhaust vent
2. Inhalation vent
1
Operation with wire wheel brush (optional
accessory)
1
2
1. Wire wheel
brush
009428
009437
•
•
•
CAUTION:
Check operation of wire wheel brush by running
tool with no load, insuring that no one is in front of
or in line with the wire wheel brush.
Do not use wire wheel brush that is damaged, or
which is out of balance. Use of damaged wire
wheel brush could increase potential for injury from
contact with broken wires.
ALWAYS use guard with wire wheel brushes,
assuring diameter of wheel fits inside guard. Wheel
can shatter during use and guard helps to reduce
chances of personal injury.
Unplug tool and place it upside down allowing easy
access to spindle. Remove any accessories on spindle.
Thread wire wheel brush onto spindle and tighten with
the wrenches.
When using wire wheel brush, avoid applying too much
pressure which causes over bending of wires, leading to
premature breakage.
The tool and its air vents have to be kept clean.
Regularly clean the tool's air vents or whenever the
vents start to become obstructed.
To maintain product SAFETY and RELIABILITY, repairs,
carbon brush inspection and replacement, any other
maintenance or adjustment should be performed by
Makita Authorized or Factory Service Centers, always
using Makita replacement parts.
ACCESSORIES
CAUTION:
These
accessories
or
attachments
are
recommended for use with your Makita tool
specified in this manual. The use of any other
accessories or attachments might present a risk of
injury to persons. Only use accessory or
attachment for its stated purpose.
•
Your tool is supplied with a guard for use with a
depressed center grinding wheel, multi-disc, flex
wheel and wire wheel brush. If you decide to use
your Makita grinder with approved accessories
which you purchase from your Makita distributor or
factory service center, be sure to obtain and use all
necessary fasteners and guards as recommended
in this manual. Your failure to do so could result in
personal injury to you and others.
If you need any assistance for more details regarding
these accessories, ask your local Makita Service Center.
•
1
2
2
8
2
3
3
9
11
4
6
10
5
7
12
5
GA4030
1
Wheel gurad
Inner flange 35
Inner flange 45
Inner flange 45
Depressed center grinding wheel/Multi-disc
4
5
Lock nut 10-35
Lock nut 5/8-45
Lock nut 5/8-45
6
Plastic pad
N/A
N/A
7
Flex wheel
N/A
N/A
8
Rubber pad 76
Rubber pad 100
Rubber pad 115
Sanding lock nut 10-30
Sanding lock nut 5/8-48
Abrasive disc
9
10
12
-
Sanding lock nut 5/8-48
Wire wheel brush
11
009438
GA5030
Grip 36
2
3
GA4530
Wire cup brush
Lock nut wrench 20
Lock nut wrench 28
Lock nut wrench 28