Makita GA5011 Manual

Model No.
Description
PRODUCT
CONCEPT AND MAIN APPLICATIONS
P 1/11
Specification
Standard equipment
Note: The standard equipment for the tool shown above may differ from country to country.
GA5011/GA6011, GA5021/GA6021
Angle Grinders 125mm (5") /150mm (6")
These four models have been developed as sister models
of GA5010/GA6010 and GA5020/GA6020, featuring
Large type switch trigger.
Models GA5021/GA6021 feature Super Joint System (SJS).
Lock nut wrench 35 .............. 1 pc
Lock nut wrench 28 .............. 1 pc
Depressed center wheel ......... 1 pc (125-36 for GA5011 and GA5021, 150-36 for GA6011 and GA6021)
Side grip ................................ 1 pc
Model No.
No load speed: min.-1 = rpm
Diameter
Hole diameter
Wheel size:
mm (")
Protection against electric shock
Power supply cord: m (ft)
Net weight: kg (lbs)
GA5011 GA5021 GA6011 GA6021
125 (5) 150 (6)
Australia: 2.0 (6.6), Other countries: 2.5 (8.2)
2.2 (4.8) 2.3 (5.1) 2.3 (5.1)2.2 (4.8)
11,000 10,000
Double insulation
22.23 (7/8)
Super Joint System (SJS) No Yes
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
Model No. GA5011 GA6011
384 (15-1/8)
139 (5-1/2) 172 (6-3/4)
113 (4-7/16)
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
Model No. GA5021 GA6021
384 (15-1/8)
139 (5-1/2) 172 (6-3/4)
120 (4-3/4)
L
H
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
120
110 10 1,050
---
700 1,60050/60
5.0 1,050 700 1,70050/60
4.8 1,050 700 1,70050/60
4.6 1,050 700 1,70050/60
11 900 1,60050/60
220
230
240
Current (A)
Optional accessories
Anti-vibration grip, Dust cover attachment, Loop handle, Toolless wheel cover
GA5011, GA5021: Accessories for 125mm angle grinder
GA6011, GA6021: Accessories for 150mm angle grinder
Electric brake No Yes
(North America only)
No Yes
No Yes
(North America only)
W
TECHNICAL INFORMATION

P 2 / 11
Note: Some parts numbers and descriptions differ from model to model. Refer to the following list and replace the
descriptions in this technical information. (for example, Small spiral bevel gear means Spiral bevel gear 13 or Spiral
bevel gear 11.)
[1] NECESSARY REPAIRING TOOLS
CAUTION: Unplug the machine, and remove the wheel, the wheel cover, the inner and the outer
flange from the machine for safety before repair/ maintenance in accordance with
the instruction manual!
Repair
DescriptionCode No.
Retaining Ring S Pliers ST-21R004
Use for
Removing Ring spring on Spindle
Holding Armature when removing Small spiral bevel gear from Armature
Holding Bearing box when removing Large spiral bevel gear from Spindle
Assembling Large spiral bevel gear
Retaining Ring R Pliers RT-2N1R005 Removing Retaining ring R-30 from Gear housing.
Bearing Setting Pipe 25-17.2
1R030
1R036 Bearing Setting Plate 17.2
Armature Holder 41.5 Set for Vise
1R039
1R258 V Block (1set: 2pcs)
1R268 Spring Pin Extractor 3 Removing Shoulder pin 5
1R269 Bearing extractor (small) Removing Ball bearing 696ZZ
1R350 Ring 60 Holding Gear housing when disassembling Shaft lock mechanism
Wrench 11 Removing / assembling M7 Hex nut from / to Armature shaft
[2] LUBRICATION
Lubricate the parts below in order to protect parts and product from unusual abrasion.
Put approx. 15g of Makita grease SG No.0 in the gear room of Gear housing.
Apply Makita Grease SG No.0 to the portions designated with the mark of . (Fig. 1)
Fig. 1
Large spiral bevel gear
Outer periphery
Lock spring 16 (GA5021 and GA6021 only)39
Surface that contacts Large spiral bevel gear
Spindle
GA5011 GA6011
without SJS-Super Joint System
GA5021 GA6021
with SJS-Super Joint System
Model No.
Description
Ball bearing in Bearing box
Spindle
Bearing box
Small spiral bevel gear
Large spiral bevel gear
49
Item No. Description Portion to lubricate
39
49
13
34A
11
35A
13
34B
11
35B
6202DDW
Longer than that of
GA5011 and GA6011
6002DDW
Ring spring on Spindle 11 (Inner diameter: 10.5mm) 7 (Inner diameter: 6.5mm)
Longer than that of
GA5011 and GA6011

P 3 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Small Spiral Bevel Gear, Armature, Ball bearing 6000DDW
Repair
DISASSEMBLY
Holding Armature with 1R039
and Vise, remove M7 Hex nut
by turning Wrench 11 counter-
clockwise.
Separate Gear housing with Armature
from motor housing by unscrewing
5x25 Tapping screws.
After removing Carbon brush,
unscrew M5x18 Pan head screws.
Striking the illustrated position,
disassemble Bearing box section.
Gear housing
(1) Take the disassemble step as illustrated in Fig. 2 to 7.
Carbon brush
Motor
housing
Armature
5x25 Tapping
screws: 4 pcs.
M5x18 Pan head
screws: 4 pcs.
Fig. 2 Fig. 3 Fig. 4
Fig. 5 Fig. 6
Fig. 7
Gear housing
M7 Hex nut
Wrench 11 1R039
Holding Gear housing while facing its bearing box
installation side upward, pull off Armature.
Small spiral bevel gear is left in Gear housing.
Armature
Small spiral bevel gear
Cloth that is wrapping Small
spiral bevel gear
If impossible to pull off Armature by hand as illustrated in Fig. 6,
spray Small spiral bevel gear with Lubricant.
Wrapping Small spiral bevel gear with cloth, remove it with
Water pump pliers while twisting.
Armature is separated from Gear housing.
Water pump
pliers
Small spiral
bevel gear
Bearing box
section

P 4 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Small Spiral Bevel Gear, Armature, Ball bearing 6000DDW
Repair
DISASSEMBLY
ASSEMBLY
Armature
Inserting Armature into Gear housing, mount Small
spiral bevel gear on Armature shaft, and secure
Small spiral bevel gear with M7 Hex nut.
Strike Gear housing with plastic hammer.
Ball bearing 6000DDW is removed together with
Armature.
M7 Hex nut
Ball baring
6000DDW
Small spiral
bevel gear
Fig. 9A Fig. 9B
(1) Assemble Ball bearing 6000DDW into Gear housing. Refer to Fig. 9.
(2) After assembling Flat washer 22, secure the Ball bearing 6000DDW and Flat washer 22 with Retaining ring R-30.
Refer to Fig. 8.
(3) Insert Armature into Gear housing. Refer to Fig. 6. And assembling Small spiral bevel gear to Armature shaft,
secure it with M7 Hex nut. Refer to Fig. 5.
(4) And then, do the reverse of the disassembling steps. Refer to Figs. 2 to 4.
Fig. 8 Fig. 9
Tap Gear housing on table.
Ball bearing 6000DDW comes out from Gear housing.
If Ball bearing 6000DDW can not be removed, go ahead
to Figs. 9A and 9B.
Disassemble Retaining
ring R-30 with 1R005.
And then, remove Flat
washer 22.
Ball bearing
6000DDW
1R005
Flat
washer 22
Retaining ring R-30
(2) Disassemble Ball bearing as illustrated in Figs. 8 to 9 / 9A / 9B.

P 5 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -3A. Large Spiral Bevel Gear, Spindle, Ball bearing 6202DDW
(GA5011, GA6011 without SJS)
Repair
DISASSEMBLY
Disassemble Bearing box section
as illustrated in Fig. 3.
Remove Ball bearing 696ZZ
as illustrated above.
1R269
Fig. 10
Fig. 12
Note: If Ring spring 11 is deformed in this step, replace the deformed one
by the new one.
Note: Ball bearing 6202DDW is damaged when
removing Spindle with Arbor press in the step
of Fig. 12.
Therefore, do not reuse it when assembling.
Fig. 13
Fig. 11
1R005
1R258
Ring spring 11
Slotted screwdriver
Opening the notch of Ring spring 11 with 1R005, lift up its opposite side
with slotted screwdriver. Ring spring 11 can be removed.
Remove Spindle by pressing with Arbor press.
Ball Bearing
696ZZ
1R258
1R258 1R258
1R246
After removing Bearing retainer 39, disassemble
Ball bearing 6202DDW with 1R246 and Arbor press.
Flat washer 15
Ball bearing 6202DDW
Hold the disassembled Bearing
box section at the three bulges
with 1R258 for easy disassembling.
Bulge
Spindle with Labyrinth ring
Bearing
box
Bearing
retainer
39
Large spiral bevel gear
M3x6 Pan
head screw: 3 pcs.
(1) Separate Bearing box section, as illustrated in Figs. 2 and 3.
(2) Disassemble Bearing box section as illustrated in Figs. 10, 11, 12 and 13.

P 6 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -3A. Large Spiral Bevel Gear, Spindle, Ball bearing 6202DDW
(GA5011, GA6011 without SJS)
Repair
ASSEMBLY
Use new Ball bearing
6202DDW.
Bearing retainer 39
Bearing Box
Bearing box section is assembled as illustrated in Figs. 14 and 15.
And assemble it to Gear housing. Refer to Figs. 2 and 3.
Flat
washer 15
1R036
Spindle
Large spiral
bevel gear
Ball bearing
6202DDW
Ball bearing
696DDW
Assemble Spindle to
Bearing box, by pressing
with Arbor press.
After securing the large Spiral bevel gear with Ring spring 11,
assemble Ball bearing 696ZZ to Spindle.
Set Bearing box onto 1R036 for inserting
Spindle into the center hole of 1R036.
And putting 1R030 onto Large spiral bevel
gear, assemble Large spiral bevel gear to Spindle
by pressing with Arbor press.
Ring spring 11
Fig. 14
Fig. 15
1R030
Note: New Ring spring 11 has to be used,
if it is deformed in the Step of Fig. 12.

1R258 1R258
P 7/ 11
[3] DISASSEMBLY/ASSEMBLY
[3] -3B. Large Spiral Bevel Gear, SJS system, Ball bearing 6002DDW
(GA5021, GA6021 with SJS)
Repair
DISASSEMBLY
Disassemble Bearing box section
as illustrated in Fig. 3.
Remove Ball bearing 696ZZ as
illustrated above.
1R005
Ring spring 7
Slotted
screwdriver Lock
washer
Flat washer 8
Ball bearing
696ZZ
Opening the notch of Ring spring 7 with 1R005, lift up its opposite side
with Slotted screwdriver. Ring spring 7 can be removed.
Flat washer 8 and Lock washer are removed from Spindle.
Note: Ring spring 7 tends to be deformed when removing and mounting.
However, it can be reused by adjusting to Spindle with Pliers.
Fig. 16 Fig. 17
Fig. 18
Fig. 19
Bearing retainer 39
M3x6 Pan
head Screw: 3 pcs.
Tap Bearing box on the table.
Large spiral bevel gear with Lock sleeve comes out
from Bearing box.
Large spiral
bevel gear
Lock sleeve Lock spring
Pull off Lock sleeve while
turning it counterclockwise.
Remove Bearing retainer 39
by unscrewing M3x6 Pan head
screws.
Pull off Lock spring
while turning it
counterclockwise.
Lock spring
Lock sleeve
Water pump pliers Water pump pliers
Spindle
Hold Bearing box section at its three bulges
with 1R258.
And remove Spindle with Arbor press.
1R269
(1) Separate Bearing box section, as illustrated in Figs. 2 and 3.
(2) Disassemble SJS system and Ball bearing 6002DDW as illustrated in Figs. 16 to 20 / 20A.

P 8 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -3B. Large Spiral Bevel Gear, Spindle, Ball bearing 6002DDW
(GA5021, GA6021 with SJS)
Repair
DISASSEMBLY
1R246
If Ball bearing 6002DDW can not be
removed in the way illustrated in Fig. 20,
disassemble with Arbor press.
Flat
washer 15
Ball bearing
6002DDW
Fig. 20A
Flat washer 15
Ball bearing
6002DDW
Tap Bearing box on the table.
Ball bearing 6002DDW comes out from Bearing box.
Fig. 20
Fig. 21
Bearing retainer 39
Assemble Flat washer 15, Ball bearing 6002DDW and Bearing
retainer 39 to Bearing box. And secure them with M3x6
Pan head screws.
And them, assemble Spindle with Arbor press.
Flat washer 15
Ball bearing
6002DDW
Spindle
ASSEMBLY
(1) Assemble Ball bearing 6002DW and Spindle to Bearing box as illustrated in Fig. 21.
(2) Assemble SJS components to Large Spiral bevel gear as illustrated in Figs. 22 and 23.
Fig. 23
Assembly of SJS components
Fig. 22
Assembly of SJS components
Set Lock spring into rib of
Large spiral bevel gear.
And strike Lock spring while
turning Large spiral bevel
gear clockwise.
Lock spring can be assembled
to the inside of rib.
Strike Lock sleeve
while turning Large
spiral bevel gear
counterclockwise.
Lock sleeve can be
assembled.

P 9 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -3B. Large Spiral Bevel Gear, Spindle, Ball bearing 6002DDW
(GA5021, GA6021 with SJS)
Repair
ASSEMBLY
Fig. 24
(3) Assemble Large spiral gear with SJS components to Spindle as illustrated in Fig. 24.
1R036
Set Bearing box onto 1R036 while
inserting Spindle into the center hole
of 1R036.
And putting 1R030 onto Large
spiral bevel gear, assemble Large
spiral bevel gear to Spindle by
pressing with Arbor press.
1R030
After mounting Lock washer and Flat washer 8,
secure them with Ring spring 7.
And then, assemble Ball bearing 696ZZ with
Arbor press.
Ball bearing 696ZZ
Ring spring 7
Flat washer 8
Lock washer

P 10 / 11
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Shaft Lock Mechanism
Repair
DISASSEMBLY
ASSEMBLY
Applying 1R268 to Shoulder pin 5 through the small hole
on Pin cap, strike 1R268 with plastic hammer.
Shoulder pin 5 comes out from Gear housing complete.
Release 1R268 from Pin cap carefully
so that Pin cap is slung by Compression
spring 8.
Shoulder pin 5
Pin cap
Impossible to reuse Pin cap, because
removal of Shoulder pin 4 damages the
inside surface of Pin cap, producing
plastic dust.
Pin cap
Pin cap
Compression
spring 8
1R268
1R350
Fig. 27 Fig. 28
(1) Be sure to use new Pin cap for replacement and remove all the plastic dust on Shoulder pin 5. (Fig. 27)
(2) Assemble the components for Shaft lock mechanism as illustrated in Fig. 28.
Plastic dust
O ring 7
Shoulder pin 5
Shoulder
pin 5
Assemble Pin cap by pressing it
to Shoulder pin 7.
Insert Shoulder pin 7
through the hole of Gear
housing complete. Pin cap
Do not forget to assemble
Compression spring 8.
Compression spring 8
Fig. 25 Fig. 26
(1) Remove Bearing box from Gear housing. And remove Carbon brush from Motor housing. (Fig. 2 and 3)
(2) Separate Gear housing from Motor housing. (Fig. 4)
(3) Remove Armature from Gear housing. (Figs. 5, 6 and 7)
(4) Shaft lock mechanism can be disassembled as illustrated in Figs. 25 and 26.

Circuit diagram
Wiring diagram
P 11 / 11
White
Color index of lead wires' sheath
Black
Fig. D-1
Fig. D-2 Fig. D-3
Fig. D-4
Lead Wire A: Blue for some countries, instead of white
Lead Wire B: Brown for some Countries, instead of black
Power supply
cord
Switch
Field
Noise suppressor
A
B
Switch
Insulated terminal
Lead wire holder
Fix Field lead wire (black) and that of (white) with
Lead wire holder, while tightening them in this area.
Noise suppressor
Do not use these
Lead wire holders.
Handle set (L)
Handle set (L)
Fix Field lead wire (white), and
Connecting lead wire (white)
between Switch and Noise
suppressor with these Lead wire
holders before assembling Switch.
Noise suppressor's
lead wire (white)
Connect Field lead wire (black) and Noise Suppressor's Lead
wire (white) to Switch terminal No.4 as illustrated above.
Switch
Makita logo
Pull out Field lead wires from the
opening of Makita logo side.
Field lead wire (black)
Wiring around Switch
Wiring of Motor housingWiring in Handle Set (L)
Noise suppressor is not used for
some countries.
Switch