Makita GA7060 Manual

ECHNICAL INFORMATION
T
Model No.
Description
March 2016
CONCEPT AND MAIN APPLICATIONS
1 / 25
Specification
Standard equipment
GA7060, GA7060R, GA7061, GA7061R /
GA9060, GA9060R, GA9061, GA9061R
Angle Grinder 180mm (7") /
Angle Grinder 230mm (9")
These models have been developed for heavy duty applications
such as foundry grinding.
The motor is more durable than that of our existing models with
the following improvements:
・Design of anti layer short of Armature (Commutator and its wire
connected portion)
・Low-absorbent motor housing to reduce water absorption
・Adoption of spiral spring type Brush holders yet with a compact body
SJS II (Super joint system II) for GA7061, GA7061R, GA9061 and
GA9061R provides increased machine durability by absorbing
the vibration produced by the wheel grinding or cutting material.
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
Model
450 (17-3/4)
200 (7-7/8)
144 (5-5/8)/
145 (5-3/4)
250 (9-7/8)
L
H
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max Output (W)
110 15 1,65050/60
15 N/A50/60
10 2,20050/60
9.6 2,200
800
800
1,400
1,400
2,200
2,200
3,000
3,00050/60
120
230
240
10.5 2,20050/60 1,400 3,000220
Current (A)
Optional accessories
Anti vibration grip
Toolless lock nut
Dust cover attachment
Toolless wheel cover
W
Max thickness 6.5 (1/4)
Shock absorbing system Yes (SJS II)No
2.5 (8.2), 2.0 (6.6) for Brazil and Australia
Side grip
Lock nut wrench
Note: The standard equipment may vary by country or model variation.
Abrasive discs
Lock nut release socket
Plastic carrying case
*1 Triaxial vector sum. According to EN60745-2-3. *2 With Side grip, Wheel cover, Lock nut, Inner flange
Model No.
Specification
Soft start
Anti-restart function
Protection against electric shock
Power supply cord: m (ft)
Wheel size:
mm (")
Diameter
Hole diameter
6,6008,500
GA7060, GA7060R/
GA7061, GA7061R
GA9060, GA9060R/
GA9061, GA9061R
No/ Yes
No/ Yes
No/ Yes
No/ Yes
Double insulation
180 (7)
22.23 (7/8)
230 (9)
6,6008,500
180 (7) 230 (9)
5.5 (12.1)/
5.6 (12.4)
5.3 (11.7)/
5.4 (11.9)
5.7 (12.6)/
5.7 (12.6)
5.5 (12.1)/
5.5 (12.1)
Weight according to EPTA-
Procedure 01/Ver.2.1*2: kg (lbs)
No load speed: min-ı= rpm
Electronic
control
GA9060/GA9060R GA9061/GA9061RGA7060/GA7060R GA7061/GA7061R
144 (5-5/8)/
145 (5-3/4)
Vibration level*1: m/s2 7.5 6.5 6.57.0
Wheel cover
Flap disc 180 (Grit: 16, 20, 24, 30, 50, 80, 100, 120)
Rubber pad
Wire cup brush
OFFICIAL USE
for ASC & Sales Shop

1INDEX
1INDEX..........................................................................................................................................................................................2
2CAUTION....................................................................................................................................................................................3
3NECESSARY REPAIRING TOOLS...........................................................................................................................................4
4LUBRICANT AND ADHESIVE APPLICATION ......................................................................................................................5
5REPAIR ........................................................................................................................................................................................6
5-1 Armature, Ball bearing 6301DDW/ 6200DDW, Small spiral bevel gear ............................................................................6
5-1-1 Disassembling.............................................................................................................................................................6
5-1-2 Assembling..................................................................................................................................................................8
5-2 Large spiral bevel gear, Ball bearing 608ZZ/ 6905DDW for models GA7060, GA9060, GA7060R, GA9060R...............9
5-2-1 Disassembling.................................................................................................................................................................9
5-2-2 Assembling................................................................................................................................................................... 11
5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB/ 6203DDW, SJS-II components for models GA7061, GA9061,
GA7061R, GA9061R......................................................................................................................................................................12
5-3-1 Disassembling...........................................................................................................................................................12
5-3-2 Assembling................................................................................................................................................................16
5-4 Shaft lock mechanism........................................................................................................................................................19
5-4-1 Disassembling...........................................................................................................................................................19
5-4-2 Assembling................................................................................................................................................................19
5-5 Brush holder cover.............................................................................................................................................................20
5-5-1 Disassembling...........................................................................................................................................................20
5-5-2 Assembling................................................................................................................................................................20
5-6 Assembling of Handle set ..................................................................................................................................................20
5-7 Circuit diagram ..................................................................................................................................................................21
5-8 Wiring diagram ..................................................................................................................................................................22
5-9 Assembling of Carbon brush..............................................................................................................................................25
2 / 25

2CAUTION
Model No.
Gear teeth of
Small spiral bevel gear
on Armature shaft
View and Gear teeth of
Large spiral bevel gear
on Spindle
GA7060, GA7060R
17
55
GA7061, GA7061R
17
55
GA9060, GA9060R
13
54
GA9061, GA9061R
13
54
the grinders use different spiral bevel gears as listed below, and they are not interchangeable.
Be sure to use correct gears for replacement.
3 / 25

3NECESSARY REPAIRING TOOLS
Code No.
Description
Use for
1R003
Retainer ring pliers
removing Ring spring 13
1R005
Retaining ring pliers RT-2N
removing/assembling Retaining ring R-42
1R015-A
Hex head bit H4-150
removing Diffuser
1R029
Bearing setting pipe 23-15.2
press-fitting Large spiral bevel gear
1R030
Bearing setting pipe 25-17.2
press-fitting Spindle, Joint sleeve
1R031
Bearing setting pipe 28-20.2
press-fitting Large spiral bevel gear, Joint sleeve
1R032
Bearing setting plate 8.2
loosening Joint sleeve
1R041
Vise plate
removing/assembling Bearing retainer 26-42*
*The component of Bearing box complete
1R131
Nose 12-15
removing Ball bearing 6301DDW
1R133
Nose 20-25
removing Ball bearing 6905LLB
1R165
Ring spring setting tool B
removing Ball bearing 6203DDW
1R212-A
Tip for Retaining ring pliers
removing Ring spring 13 with 1R003
1R212-B
Plate set (with Screws)
1R245
Round bar for arbor 16-100
Removing Large spiral bevel gear, Ball bearing 6905LLB
1R249
Round bar for arbor 24-100
Removing Ball bearing 6203DDW
1R258
V block
removing Large spiral bevel gear
1R269
Bearing extractor
removing Ball bearings
1R286
Round bar for arbor 12-50
removing Ball bearings
1R291
Retaining ring S and R pliers
removing/ assembling Retaining ring S-10
1R308
Spring pin extractor 4.0
disassembling Shaft lock mechanism
1R350
Ring 60
removing/assembling Bearing retainer 26-42*
*The component of Bearing box complete
1R398
Bearing extractor tightening tool
4 / 25

4LUBRICANTANDADHESIVEAPPLICATION
Lubricant
Amount
Makita grease R No.00
40g
Lubricating oil VG100
a little
Makita grease FA No.2
a little
Gear room (40g)
First, make very thin oil film
on O ring 19 with Lubricating
oil VG100, and then fit the ring
into the groove of Large spiral
bevel gear carefully so as not to
have damage.
After that, apply a little amount of Makita grease
FA No.2 to the upper surface of O ring 19.
Note: Be sure to use both VG100 and Makita grease FANo.2 in
accordance with the instructions shown left, because of
the following reasons.
In case all the lubricant would be Makita grease FA No. 2,
O ring 19 will protrude from the groove of Large spiral bevel gear.
(The groove will be clogged with the grease on O ring 19, and
therefore the space for O ring 19 will not be secured.)
In case all the lubricant would be Lubricating oil VG100,
the oil will spoil the function of “SJS-II”.
(The friction between O ring 19 and Joint sleeve will cause the oil
film shortage.)
Fig.4-1 (All models)
Fig. 4-2
(SJS-II models only: GA7060R, GA7061R, GA9060R, GA9061R)
Apply lubricant and adhesive the designated portions.
Outer circumference of Joint sleeve
Outer circumference of
C type plate 29
Outer circumference of
C type plate 33
Spiral groove
of Spindle
Felt ring 18
(The component of Gear housing complete)
5 / 25

5REPAIR
5-1 Armature, Ball bearing 6301DDW/ 6200DDW, Small spiral bevel gear
5-1-1 Disassembling
Carbon brush
Edge of
Brush holder
Spiral spring (The component of Brush holder
[1] Remove two 4x14 Tapping screws from both sides of machine.
Fig. 5-1-1-1
4x14 Tapping screw
[2] Open Brush holder cover L/R of Motor housing.
Brush holder cover R
Fig. 5-1-1-2
Motor housing
[3] Shift Sprial springs from Carbon brushes
to the edges of Brush holders.
[5] Remove four M6x22 Hex socket
head bolt from Bearing box.
[4] Disconnect Carbon brushes from Commutator
by pulling them upward.
Note: It is not necessarily to remove them from
Brush holders.
Fig. 5-1-1-4
Fig. 5-1-1-3
[6] Remove Bearing box section by tapping
Gear housing complete with a plastic hammer.
Carbon brush
Brush holder
Commutator
Fig. 5-1-1-5
Fig. 5-1-1-6
Bearing box
Bearing box
Plastic hammer
6 / 25

5-1 Armature, Ball bearing 6301DDW/ 6200DDW, Small spiral bevel gear (cont.)
5-1-1 Disassembling (cont.)
Fig. 5-1-1-8
[8] Remove Gear housing complete together with
Armature ass’y.
Fig. 5-1-1-7
Fig. 5-1-1-9
Fig. 5-1-1-10
[9] Fit an offset wrench into M8 Hex nut and place the opposite end
to a workbench as the stopper.
While holding Gear housing complete and the wrench with a hand,
turnArmature ass’y in direction of red arrow to loosen M8 Hex
nut.
Note: Cover Armature ass’y with a waste cloth to prevent
scratch/damage.
[10] Remove the loosened M8 Hex nut, then pull out Small spiral
bevel gear. (Refer to Fig.5-1-1-8.).
Armature ass’y
Gear housing complete
M8 Hex nut (Refer to Fig.5-1-1-8.)
The opposite end of Offset wrench
Waste cloth
Armature ass’y
Worktable
[11] Pull out Armature ass’y.
M8 Hex nut
Small spiral
bevel gear
Gear housing complete
Armature ass’y
Already removed through the step [10] in Fig.5-1-1-9.)
Fig. 5-1-1-11
[7] Remove four 5x30
Tapping screws .
Waste cloth
Armature ass’y
[12] Remove Retaining ring R-42 with 1R005,then remove Flat washer 20.
1R005
Retaining ring R-42
Flat washer 20
Gear housing complete
Retaining ring R-42
Flat washer 20
7 / 25

5-1 Armature, Ball bearing 6301DDW/ 6200DDW, Small spiral bevel gear (cont.)
5-1-1 Disassembling (cont.)
5-1 Armature, Ball bearing 6301DDW/ 6200DDW, Small spiral bevel gear (cont.)
5-1-2 Assembling
Direction of
Makita logo
on Motor housing
Fig.5-1-1-16
Face the indication of Parts No. for Diffuser toward Gear housing complete,
and fit Diffuser into Gear housing complete.
Fig. 5-1-1-15
Fig. 5-1-1-12
[13] Remove Ball bearing 6301DDW with 1R131.
Ball bearing 6301DDW
1R131
[14] Hook the jaws of 1R269 to Ball bearing 6200DW.
While holding the jaws with water pump pliers, remove
the ball bearing.
1R269
Water pump pliers
Ball bearing 6301DDW
[15] Remove Diffuser by passing 1R015 or like through a bent of Gear housing complete then pushing it out to the opposite.
Vent of Gear housing complete
1R131
Diffuser
Diffuser
Asseemble the components by reversing the disassembly procedure.
Also, refer the following points.
Fig. 5-1-1-13
Fig. 5-1-1-14
Indication of Parts
No. for Diffuser
Be careful about the directions of Bearing box ,
Gear housing complete and Motor housing
Gear housing
complete
Projection of
Bearing box
Switch
8 / 25

5-2 Large spiral bevel gear, Ball bearing 608ZZ/ 6905DDW for models GA7060, GA9060, GA7060R, GA9060R
5-2-1 Disassembling
Fig. 5-2-1-5
Fig. 5-2-1-2
Fig. 5-2-1-1
[1] Remove Ball bearing 608ZZ with 1R269.
1R269
Ball bearing 608ZZ
[2] Remove Ring spring 13 with 1R003, 1R212-Aand 1R212-B.
Ring spring 13
1R212-A
1R212-B
1R003
[3] Put 1R032 on the step of Spindle complete.
Tap 1R032 carefully with the ram of anArbor press
until the press-fitting between Spindle complete and
Large spiral bevel gear is loosened.
Note: Avoid the projection of Bearing box
(Refer to Fig. 5-1-1-16 in the previous page.)
Step of Spindle complete
(See the step [3].)
Ram ofArbor press
1R032
Arbor press table
Fig. 5-2-1-3
Fig. 5-2-1-4
[4] Press down Spindle complete with 1R286.
1R286
Spindle complete
Bearing box portion
Large spiral bevel gear
Spindle
complete
[5] Large spiral bevel gear, Bearing box portion
and Spindle complete are removed.
9 / 25

5-2 Large spiral bevel gear, Ball bearing 608ZZ/ 6203DDW for models GA7060, GA9060, GA7060R, GA9060R (cont.)
5-2-1 Disassembling (cont.)
Fig. 5-2-1-7
Fig. 5-2-1-6
[6] Remove three M5x16 Pan head screws, then remove Bearing retainer 50.
M5x16 Pan head screw (3 pcs.)
Bearing retainer 50
1R249
Ball bearing 6203DDW
[7] Remove 6203DDW with 1R249.
Note: When you remove Large spiral bevel gear as shown in
the previous page, Ball bearing 6203DDW has damage.
Therefore, replace the ball bearing with a new one.
10 / 25

5-2 Large spiral bevel gear, Ball bearing 608ZZ/ 6203DDW for models GA7060, GA9060, GA7060R, GA9060R (cont.)
5-2-2 Assembling
Fig. 5-2-2-2
[1] Press-fit Ball bearing 6203DDW
[2] Set Bearing retainer 50 in place by tightening
M5x16 Pan head screws.
M5x16 Pan head
screws (3 pcs.)
Bearing retainer 50
[3] Receive Ball bearing 6203DDW with 1R030,
then press-fit Spindle complete into the ball bearing.
M5x16 Pan head
screws (3 pcs.)
Ball bearing
6203DDW
1R030
[4] Receive Spindle complete with 1R030, then
press-fit the spindle into Large spiral bevel gear.
with 1R029.
1R030
Spindle complete
Large spiral bevel gear
1R029
[5] Fit Ring spring 13 into the groove of
Spindle complete with 1R003 or like.
1R003
Ring spring 13
Groove of Ring spring 13
[6] Receive Spindle complete with 1R030, then
press-fit the spindle into Ball bearing 608ZZ.
Spindle complete
Ball bearing 608ZZ
Fig. 5-2-2-1
Fig. 5-2-2-3
Fig. 5-2-2-1
Fig. 5-2-2-4
Fig. 5-2-2-1
1R030
11 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB/ 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R
5-3-1 Disassembling
Fig. 5-3-1-6
Fig. 5-3-1-3
Fig. 5-3-1-2
Fig. 5-3-1-1
[1] Remove 608ZZ with 1R269.
[2] Remove Retaining ring S-15 with 1R291.
[3] Remove Balancer.
[4] Remove C type plate33.
1R269
Ball bearing 608ZZ
1R291
Retaining ring S-15
[5] Remove C type plate 29.
[6] The components are removed from Spindle.
Fig. 5-3-1-4
Fig. 5-3-1-5
C type plate 29
C type plate 33
Balancer
Retaining ring
S-15
Ball bearing 608ZZ
Step of Spindle complete
(See the step [7] of
the next page.)
12 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-1 Disassembling (cont.)
Fig. 5-3-1-8
Fig. 5-3-1-7
[7] Put 1R032 on the step of Spindle complete.
Tap 1R032 carefully with the ram of an Arbor press until the press-fitting between Spindle complete
and Large spiral bevel gear is loosened.
Ram ofArbor press
1R032
Arbor press table
Note: Avoid the projection of Bearing box.
[8] Press down Spindle complete with 1R286.
1R286
Spindle complete
Joint sleeve
Joint sleeve
Spindle complete
Fig. 5-3-1-9
[9] Remove O-ring 19
with an awl.
O-ring 19
Awl
13 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-1 Disassembling (cont.)
Fig. 5-3-1-11
Fig. 5-3-1-10
[10] Slide Flat washer 17 so that you can
press it down in the next step.
[11] Receive Bearing box complete on two pieces of 1R258, then press down
Flat washer 17 with 1R245 to remove Large spiral bevel gear..
Note: Flat washer 17 is deformed by the step. Therefore, replace it with
a new one.
1R245
1R258
1R258
Large spiral bevel gear
Flat washer 17
Fig. 5-3-1-12
M4x16 Pan head screw (3 pcs.)
[12] Remove three M4x16 Pan head screws and Bearing retainer 59.
Bearing retainer 59
Ball bearing 6905LLB
See step [13] in the next page.
14 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-1 Disassembling (cont.)
Fig. 5-3-1-13
[14] Receive Bearing box complete with two
pieces of 1R350, and hold the bearing box
complete in a vise with two pieces of
1R041 attached.
Turn Bearing retainer 26-42 in direction of
red arrow.
Note: The bearing retainer has thread locking
patch. Therefore, heat it with a heat gun
to loosen the locking.
Fig. 5-3-1-14
1R245
Bearing box
1R041 (2 pcs.)
1R350 (2 pcs.)
Fig. 5-3-1-15
Bearing retainer 26-42.
Felt ring 22
Flat washer 36
[15] Bearing retainer 26-42, Felt ring 22 and Flat washer 36 are
removed.
[16] Press down Ball bearing 6203DDW with 1R249.
Fig. 5-3-1-16
[13] Hook the nails of 1R133 to Ball bearing 6905LLB as shown
below, then press down the nails with 1R245 to remove
the ball bearing.
Note: When you remove Joint sleeve, the ball bearing has damage.
1R245
Nails of 1R133
Ball bearing
6905LLB
1R133
Ball bearing
6203DDW
1R249
15 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-2 Assembling
Fig. 5-3-2-1
Fig. 5-3-2-2
1R245
1R041 (2 pcs.)
1R350 (2 pcs.)
[1] Press-fit Ball bearing 6203DDW
with 1R165.
Spindle complete
1R030
[2] Set Flat washer 26 and Felt ring 22 in place.
Apply Loctite 272 to the thread of Bearing retainer 26-42.
Fig. 5-3-2-3
Fig. 5-3-2-4
1R165
Ball bearing
6203DDW
[4] Receive Ball bearing 6203DDW with 1R350, then press-fit
Spindle complete into Bearing box and the ball bearing.
[3] Receive Bearing box complete with two pieces
of 1R350, and hold the bearing box complete in
a vise with two pieces of 1R041 attached.
Turn Bearing retainer 26-42 in direction of
red arrow.
Bearing box
Bearing box
Ball bearing 6203DDW
Fig. 5-3-2-5
Fig. 5-3-2-6
[5] Do not forget to set Flat washer 17 in place.
1R165
Ball bearing 6905LLB
1R030
[6] Receive Spindle complete with 1R030,
then press-fit Ball bearing 6905LLB
into Bearing box.
Flat washer 17
16 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-2 Assembling (cont.)
Fig. 5-3-2-10
Fig. 5-3-2-8
[6] Set Bearing retainer 59 in place by
tightening Three M4x16 Pan head
screws.
Fig. 5-3-2-7
M4x16 Pan head
screw (3 pcs.)
Bearing retainer 59
[7] Receive Spindle complete with 1R030.
then press-fit the spindle into Large
spiral bevel gear with 1R029.
1R030
1R029
Spindle complete
Joint sleeve
Large spiral bevel
gear
Fig. 5-3-2-9
[8] Set O-ring 19 in place.
Note: According to Fig.4-2 in
page 5, apply the specific
lubricants in advance.
1R030
1R031
[9] Receive Spindle complete with 1R030.
then press-fit the spindle into Joint sleeve with 1R029.
Note: Joint sleeve must be placed
as shown above..
Fig. 5-3-2-11
[11] Set C type plate 33 in place.
[10] Set C type plate 29 in place.
C type plate 29
C type plate 33
Fig. 5-3-2-12
17 / 25

5-3 Large spiral bevel gear, Ball bearing 608ZZ/ 6905LLB / 6203DDW, SJS-II components for models GA7061,
GA9061, GA7061R, GA9061R (cont.)
5-3-2 Assembling (cont.)
Fig. 5-3-2-13
[12] Set Balancer in place.
[14] Receive Spindle complete with
1R030,
then press-fit the spindle complete
into Ball bearing 608ZZ.
[13] Fit Retaining ring S-15 into
the groove of Spindle complete
with 1R291.
Fig. 5-3-2-14
1R030
Ball bearing 608ZZ
Spindle complete
Fig. 5-3-2-15
18 / 25

5-4 Shaft lock mechanism
5-4-1 Disassembling
5-4-2 Assembling
Fig. 5-4-1-1
Shoulder pin 7
Pin cap
Compression spring 8
(between Pin cap and Shoulder
pin 7 in Gear housing complete)
[15] Tap Shoulder pin 7 with 1R308
and a metal hammer to remove
the shoulder pin, Pin cap and
Compression spring 8.
Note: The removal step of the shoulder
pin 8 shaves off the inside of
the pin cap. Therefore, replace
the pin cap with a new one.
1R308
Pin cap
Shoulder pin 7
Remove the shavings of Pin cap from the components.
After that, press-fit a new Pin cap in place.
19 / 25

5-5 Brush holder cover
5-5-1 Disassembling
5-5-2 Assembling
5-6 Assembling of Handle set
Fig. 5-6-1
Fig. 5-5-1-2
Fig. 5-5-1-1
[1] Remove 4x14 Tapping screw from
left/ right side of machine.
[2] Open Brush holder cover R.
(In the same way, open Brush holder cover L.
Remove one of the hinge of
Brush holder cover R.
(In the same way, remove
the other hinge. After that,
remove Brush holder cover L.)
Fig. 5-5-1-3
Assemble by reversing the disassembly procedure.
[1] Tighten two 4x18 Tapping screws to fasten
Handle R to Handle L .
4x18 Tapping screw
4x18 Tapping screw
Gap between Handle R and Handle L
[2] While holding Handle R and Handle L by hands to
disappear the gap, tighten four 5x30 Tapping screws.
5x30 Tapping screws (4 pcs.:
that fastens Handle R and
Handle L to Motor housing)
Fig. 5-6-2
20 / 25