Makita GA5020Y Use and Care Manual
Contents
1. e Tr a k ta 008074 E DOUBLE INSULATION nd UNDERSTAND before using OR FUTURE REFERENCE ENGLISH SPECIFICATIONS GA5020C GA6020C Model GA5020 GA5021 GA5021C GA6020 GA6021 GA6021C Depressed center wheel diameter 125 mm 125 mm 125 mm 150 mm 150 mm 150 mm Spindle thread M14 M14 M14 M14 M14 M14 No 1089 Se Rated 44000 min 11 000 min 10 000 min 10 000 min 10 000 min 9 000 min Overall length 356 mm 384 mm 390 mm 356 mm 384 mm 390 mm Net weight 2 7kg 2 7kg 2 9 kg 3 0 kg 2 8 kg 3 0 kg Safety class En Due to our continuing programme of research and development the specifications herein are subject to change without notice Specifications may differ from country to country Weight according to EPTA Procedure 01 2003 END202 6 Symbols The following show the symbols used for the equipment Be sure that you understand their meaning before use Read instruction manual al DOUBLE INSULATION Wear safety glasses Only for EU countries Do not dispose of electric equipment together with household waste material In observance of European Directive 2002 96 EC on waste electric and electronic equipment and its implementation in accordance with national law electric equipment that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility ENE048 1 Intended use The tool is in2. 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 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
3. a saw chain woodcarving blade or toothed saw blade Such blades create frequent kickback and loss of control 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 Additional Safety Warnings Specific for Abrasive Cutting Off Operations a Do not jam the cut off wheel or apply excessive pressure
4. tool with lock off button To prevent the switch trigger from being accidentally pulled a lock off button is provided To start the tool depress the lock off button and pull the switch trigger Release the switch trigger to stop For tool with typeB switch trigger 1 Lock lever 2 Switch trigger For tool with the lock on switch To start the tool simply pull the switch trigger A Release the switch trigger to stop For continuous operation pull the switch trigger A and then push in the lock lever B To stop the tool from the locked position pull the switch trigger A fully then release it For tool with the lock off switch To prevent the switch trigger from accidentally pulled a lock lever is provided To start the tool push in the lock lever B and then pull the switch trigger A Release the switch trigger to stop For tool with the lock on and lock off switch To prevent the switch trigger from accidentally pulled a lock lever is provided To start the tool push in the lock lever B and then pull the switch trigger A Release the switch trigger to stop For continuous operation push in the lock lever B pull the switch trigger and then push the lock lever further in B To stop the tool from the locked position pull the switch trigger A fully then release it Electronic function Constant speed control For models GA5020C GA5021C GA6020C GA6021C Possible to get fine finish because the rotating
5. ccessory 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
6. ct adherence to grinder safety rules If you use this tool unsafely or incorrectly you can suffer serious personal injury Safety Warnings Common for Grinding Sanding Wire Brushing or Abrasive Cutting Off Operations 1 This power tool is intended to function as a grinder sander wire brush or cut off tool 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 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 mount
7. ct 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 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 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 If operating a power tool in a damp location is unavoidable use a ground fault circuit interrupter GFCI protected supply Use of an GFCI reduces the risk of electric shock Personal safety 10 11 12 13 14 15 16 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 Use personal protective equipment Always wear eye protection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries Prevent unintentional starting Ensure t
8. e Accessory ACAUTION Always be sure that the loop handle is installed securely before operation 1 Protrusion of loop handle 2 Matching hole in gear housing Always install the loop handle on the tool before operation Hold the tool s switch handle and the loop handle firmly with both hands during operation Install the loop handle so that its protrusion will fit into the matching hole in the gear housing Install the bolts and tighten them with the hex wrench The loop handle can be installed in two different directions as shown in the figures whichever is convenient for your work 1 Loop handle 2 Hex wrench 3 Bolt 1 Loop handle 2 Hex wrench 3 Bolt Installing or removing wheel guard ACAUTION When using a depressed center grinding wheel Multi disc wire wheel brush or cut off wheel the wheel guard must be fitted on the tool so that the closed side of the guard always points toward the operator For tool with locking screw type wheel guard 1 Wheel guard 2 Screw 3 Bearing box 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 around 180 degrees counterclockwise Be sure to tighten the screw securely To remove wheel guard follow the installation procedure in reverse For tool with clamp lever type wheel guard 1 Bearing box 2 Wheel guard 3 Screw 4 Lever 1 Screw Loosen
9. e grinding 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 sawblades Such blades when used on a grinder frequently kick and cause loss of control leading to personal injury ACAUTION 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 ALWAYS hold the tool firmly with one hand on rear handle 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 MAINTENANCE ACAUTION Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance 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 1 Exhaust vent 2 Inhalation vent Replacing carbon brushes Makita grinder with approved accessories which you purchase
10. from your Makita distributor or 1 Limit mark 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 Wheel guard Wheel cover Inner flange Depressed center wheels Lock nut For depressed center wheel Remove and check the carbon brushes regularly Rubber pad Replace when they wear down to the limit mark Keep Abrasive discs the carbon brushes clean and free to slip in the holders Lock nut For abrasive disc Both carbon brushes should be replaced at the same Lock nut wrench time Use only identical carbon brushes Wire cup brush Use a screwdriver to remove the brush holder caps Side grip Take out the worn carbon brushes insert the new ones Loop handle and secure the brush holder caps Dust cover 1 Brush holder cap 2 Screwdriver After replacing brushes plug in the tool and break in brushes by running tool with no load for about 10 minutes Then check the tool while running and electric brake operation when releasing the switch trigger If electric brake is not working well ask your local Makita service center for repair For models GA5020 GA6020 To maintain product SAFETY and RELIABILITY repairs any other maintenance or adjustment should be performed b
11. g 22 Watch out for flying sparks Hold the tool so that sparks fly away from you and other persons or flammable materials 23 Do not leave the tool running Operate the tool only when hand held 24 Do not touch the workpiece immediately after operation it may be extremely hot and could burn your skin 25 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 26 Observe the instructions of the manufacturer for correct mounting and use of wheels Handle and store wheels with care 27 Do not use separate reducing bushings or adaptors to adapt large hole abrasive wheels 28 Use only flanges specified for this tool 29 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 30 Check that the workpiece is properly supported 31 Pay attention that the wheel continues to rotate after the tool is switched off 32 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 33 Do not use the tool containing asbestos 34 Do not use water or grinding lubricant 35 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 avo
12. he switch is in the off position before connecting to power source and or battery pack picking up or carrying the tool Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents 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 Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations 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 If devices are provided for the connection of dust extraction and collection facilities ensure these are connected and properly used Use of dust collection can reduce dust related hazards Power tool use and care 17 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 20 21 22 23 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 Disconnect the plug from the power source and or the battery pack from the power tool before making any adjustments changing accesso
13. id damaging internal parts 36 When use cut off wheel always work with the dust collecting wheel guard required by domestic regulation 37 Cutting discs must not be subjected to any lateral pressure on any materials ZA WARNING MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury SAVE THESE INSTRUCTIONS FUNCTIONAL DESCRIPTION ACAUTION Always be sure that the tool is switched off and unplugged before adjusting or checking function on the tool Shaft lock 1 Shaft lock ACAUTION 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 ACAUTION Before plugging in the tool always check to see that the switch trigger actuates properly and returns to the OFF position when released For tool with type A switch trigger 1 Lock button Lock off button 2 Switch trigger typeA For tool without lock button and lock off button To start the tool simply pull the switch trigger Release the switch trigger to stop For tool with lock button To start the tool simply pull the switch trigger Release the switch trigger to stop For continuous operation pull the switch trigger and then push in the lock button To stop the tool from the locked position pull the switch trigger fully then release it For
14. ing 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 10 Hold power tool by insulated gripping surfaces o
15. nly 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 11 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 12 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 13 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 14 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 15 Do not operate the power tool near flammable materials Sparks could ignite these materials 16 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 a
16. objects that can cause kickback Safety Warnings Specific for Sanding Operations Safety Warnings Specific for 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 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 Additional safety warnings 17 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 20 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 21 Use the specified surface of the wheel to perform the grindin
17. ries or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally 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 Maintain power tools Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the power tool s operation If damaged have the power tool repaired before use Many accidents are caused by poorly maintained power tools Keep cutting tools sharp and clean Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control Use the power tool accessories and tool bits etc in accordance with these instructions 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 24 25 26 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 Follow instruction for changing accessories Keep handles dry clean and free from oil and grease lubricating and GEB033 2 SPECIFIC SAFETY RULES DO NOT let comfort or familiarity with product gained from repeated use replace stri
18. speed is kept constantly even under the loaded condition Additionally when the load on the tool exceeds admissible levels power to the motor is reduced to protect the motor from overheating When the load returns to admissible levels the tool will operate as normal Soft start feature Soft start because of suppressed starting shock Indication lamp 1 Indication lamp The indication lamp lights up green when the tool is plugged If the indication lamp does not light up the mains cord or the controller may be defective The indication lamp is lit but the tool does not start even if the tool is switched on the carbon brushes may be worn out or the controller the motor or the ON OFF switch may be defective Unintentional restart proof Even locking lever keeping the switch trigger depressed Lock on position does not allow the tool to restart even when the tool is plugged At this time the indication lamp flickers red and shows the unintentional restart proof device is on function To cancel the unintentional restart proof pull the switch trigger fully then release it ASSEMBLY ACAUTION Always be sure that the tool is switched off and unplugged before carrying out any work on the tool Installing side grip handle ACAUTION 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 Installing loop handl
19. tended for grinding sanding and cutting of metal and stone materials without the use of water ENF002 1 Power supply The tool should be connected only to a power supply of the same voltage as indicated on the nameplate and can only be operated on single phase AC supply They are double insulated in accordance with European Standard and can therefore also be used from sockets without earth wire GEA005 2 General Power Tool Safety Warnings WARNING Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference 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 or 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 conta
20. the lever on the wheel guard after loosening the screw 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 around to the position shown in the figure Tighten the lever to fasten the wheel guard If the lever is too tight or too loose to fasten the wheel guard loosen or tighten the screw to adjust the tightening of the wheel guard band To remove wheel guard follow the installation procedure in reverse Installing or removing depressed center grinding wheel Multi disc accessory 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 1 Lock nut 2 Depressed center grinding wheel Multi disc 3 Inner flange 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 1 Lock nut wrench 2 Shaft lock To remove the wheel follow the installation procedure in reverse OPERATION AWARNING lt 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 whil
21. y Makita Authorized Service Centers always using Makita replacement parts ACCESSORIES ACAUTION 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 and wire wheel brush A cut off wheel can also be used with an optional guard If you decide to use your 11 Makita Corporation 88471005
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