Makita GD0603 Manual

CONCEPT AND MAIN APPLICATIONS
Model GD0603 is the successor of Die grinder 906, inheriting the advantage
such as easy handling and compactness.
The new aesthetic design is incorporated, and the product competitiveness is
enhanced.
PRODUCT
P 1/ 14
October 2015
Model No.
Description Die Grinder
ECHNICAL INFORMATION
T
GD0603
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max Output (W)
120 2 50/60 N/A 150 240
110 2.2 50/60 240 150 240
230-240 1.1 50/60 240 150 240
220 1.2 50/60 240 150 240
Current (A)
Specification
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 289 (11-3/8)
64 (2-1/2)
67 (2-5/8)
Standard equipment
Note: The standard equipment for the tool shown above may vary by country.
Spanner 10 (2 pcs.)
Wheel points
Optional accessories
Wheel points
Collet cone 3.17
Collect cone 3
RockerSwitch type
Max collet size 6mm or 1/4"*
240Continuous rating input: W
Weight according to
EPTA-Procedure 01/2003: kg (lbs) 0.97 (2.1)
Double insulationProtection against electric shock
Brazil, Australia: 2.0 (6.6)
Others: 2.5 (8.2)
Power supply cord: m (ft)
No load speed: minˉ¹= rpm 28,000
Diameter of grip: mm ø65
Circumference of grip: mm 203
Soft grip No
GD0603
Specification Model
LW
H
*3mm / 6mm / 1/4" / 1/8" can be used by changing the collet.
Max wheel diameter 19mm
OFFICIAL USE
for ASC & Sales Shop

1R004 RETAINING RING PLIERS ST-2
RETAINING RING S PLIERS STP-11R004-A
1R026 assembling Ball bearing 608LLB to Spindle section
assembling Ball bearing 698DDW to Spindle
BEARING SETTING PIPE 16-8.2
257562-1 SLEEVE 9
1R027
1R268
1R269 BEARING EXTRACTOR removing Ball bearings from Spindle and Armature
1R274
Code No. Description Use for
[1] NECESSARY REPAIR TOOLS
removing/installing Retaining ring S-8
removing/installing Spring pin 3-12
BEARING SETTING PIPE 18-10.2
SPRING PIN EXTRACTOR M3
TYPE 72 FIELD INSERT JIG supporting Spindle, when removing Spring pin 3-12
Apply Makita grease FA No.2 to the following portions designated with the black triangle to protect parts and product
from unusual abrasion. Fig. 1
[2] LUBRICANT AND ADHESIVE APPLICATION
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
P 2/ 14
Repair
Index
[1] NECESSARY REPAIRING TOOLS
(1)/(31)
Fig. 1
(1)/(31)
Item No. Description
Housing set
Lubricant Amount
approx 1g
Portion to lubricate
MAKITA Grease FA No.2Grooved portion where Spindle rotates
P 2
P 3-6
P 11
P 12-14
[2] LUBRICANT AND ADHESIVE APPLICATION
[3] -1 Spindle, Armature DISASSEMBLING
[3] -1 Spindle, Armature ASSEMBLING
Circuit Diagram
Wiring diagram
P 7-10

P 3/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1 Spindle, Armature
DISASSEMBLING
1. Fix Spindle (11) with wrench 10.
(1) For disassembling Housing set, remove Cap. Fig. 2
2. Unscrew Collet nut 6 (9) by turning Wrench 10 counterclockwise.
3. Remove Collet cone (10).
Fig. 2
(9)
(11)
(9)
(1)
(37)
(29)
(30)
4. Pull off Hanger (37) from Housing set R (1) side.
5. Pull off Cap (30) by unscrewing
two 3x16 Tapping screws (29).
5A. If it is difficult to pull off Cap (30) by hand, insert Slotted
head screwdriver into the gap between Cap (30) and Housing
set (1)/(31) and twist it.
(10)
(30)
Wrench 10
gap between (30) and (1)/(31)

P 4/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
DISASSEMBLING
1. Unscrew four 4x18 Tapping screws (32).
2. Twist Slotted head screwdriver inserted in
the slit of Housing set (1).
(32)
(1)
(31)
(2) Take out Spindle and Armature section. Fig. 3
slit
Slotted head
screwdriver
(1)
(19)
(20)
3. Remove Brush holder (19) together with
Carbon brush (20).
4. Take out Spindle and Armature section.
Fig. 3

(12)
5. Remove Ball bearing 698DDW (16)
with 1R269.
4. Remove Spring pin 13 (12)
by tapping 1R268 with hammer.
1R269
3. Support Spindle (11) with 1R274
while fitting Spring pin 13 (12)
to the hole of 1R274.
P 5/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
DISASSEMBLING
(2) Take out Spindle and Armature section. Fig. 4
1. Pull off Spindle (11) and Armature (21)
from Couping (18).
2. Remove O ring 22 (13) and
Rubber ring 19 (17) from Spindle (11).
Fig. 4
1R274
1R274
(16)
(18) (21)
(11) (17)
(17)
(13) (11)
(11)
1R268

P 6/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
DISASSEMBLING
(3) Remove Ball bearings from Armature. Fig. 5
Fig. 5
A
1R004-A
1R004
(15)
1R269
1. Remove Retaining ring S-8 (15)
with 1R004 and 1R004-A.
2. Remove Ball bearing 608LLB (14)
with 1R269.
(21)
(14)
1R274
1R268
(25)
(14)
4. Remove Spring pin 13 (23)
by tapping 1R268 with hammer.
5. Remove Ball bearing 608LLB (22) / 627LLB (25) with 1R269.
(23)
hole of 1R274
3. Support Spindle (11) with 1R274
while fitting Spring pin 13 (23)
to the hole of 1R274.
(21)
1R269
(22)

P 7/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
ASSEMBLING
(1) Assemble Spindle section. Fig. 6
Fig. 6
2. Press Ball bearing 608LLB with 1R026 / 1R027
and Arbor press until it stops.
3. Assemble Retaining ring S-8 with 1R004 and 1R004-A.
4. Press Ball bearing 698DDW (16) with Arbor press and
Sleeve 9 (257562-1) until it stops.
<Ref.>
Press fit position of Ball bearing 698DDW
1R026
ﾙ
(14)
1. Insert Ball bearing 608LLB (14) with 1R026 and Arbor press
as deep as possible passing over this part.
1R026
(11)
(14)
1R027
1R026
(11)
(14)
(15)
1R004
54.4 - 54.6 mm
9.6 mm
(14) (16)
(14)
(16)
(257562-1)

P 8/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
ASSEMBLING
(2) Assemble Spindle section. Fig. 7
Fig. 7
1R274
(11)
(12)
(12)
1. Align Spindle (11), Spring pin 3-12 (12) and 1R274 as drawn.
2. Assemble Spring pin 3-12 (12) to Spindle (11) by tapping 1R268 until the tip of Spring
pin 3-12 (12) comes out by 2.1~2.4mm from Spindle (11).
3. Make sure that Spindle (11)
with Spring pin 3-12 (12)
can be inserted into
Coupling (18) smoothly.
4. Assemble O ring 22 (13) to Ball
bearing 608DDW (14).
Assemble Rubber ring 19 (17)
to Ball bearing 698DDW (16).
1R268
1R274
(11)
Hole of 1R274
hole of (11)
(18)
2.1 - 2.4 mm
(11) (12)
(17)(13) (14) (16)
(12)

P 9/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
ASSEMBLING
Fig. 9
3. Make sure that Armature (21)
with Spring pin 3-12 (23) can be
inserted into Coupling (18)
smoothly.
(21)
(23)
(18)
(18) (21)
(3) Assemble Armature section. Fig. 8
Fig. 8
(21)
(21)
1R274
1R268
1R274
2.25-2.55 mm
1. Align Armature (21), Spring pin 3-12 (12) and 1R274 as drawn.
2. Assemble Spring pin 3-12 (23) to Armature (21) by tapping 1R268 until the tip of Spring pin 3-12 (23)
comes out by 2.25-2.55mm from Armature (21).
(23)
(23)
(23)
Spindle section

P 10/ 14
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1 Spindle, Armature
ASSEMBLING
(5) Assemble Spindle section and Armature. Fig. 10
Fig. 10
1. Assemble Spindle section and Armature (21) to Housing set L (1) by passing through Field (26).
(1)
2. Assemble Spindle section to Housing set L (1)
while fitting O ring 22 (13) precisely to the
groove of Housing set.
3. Assemble Housing set R (31) while paying
attention to the slippage of O ring 22 (13)
and pinching with Housing set R (31).
(13)
groove
(31)
(26)
(1)
(13)
(21)

P 11/ 14
Fig. D-1
Circuit diagram
Black
White
Orange
Blue
Brown
Purple
Color index of lead wires' sheath
For High voltage area where Noise suppression is required
Field
For Low voltage area where Noise suppression is required
or
For areas where Noise suppression is not required
Field
(4)
(20)
(20)
(3)
(2)
Choke coil
(5)
(20)
(20)
White for some countries
(2)
(2) Noise suppressor
(3) Terminal block
(4) Switch
(5) Power supply cord
(20) Brush holder
(D) Choke coil
(2) Noise suppressor
(3) Terminal block
(4) Switch
(5) Power supply cord
(20) Brush holder
(3)
(4)
(5)
Circuit of Switch
Black
White
Orange
Blue
Brown
Purple
Color index of lead wires' sheath
1 2
Circuit of Switch
1 2
White for some countries
Black for some
countries
Black for some
countries
18 AWG*
*AWG: American Wire Gauge
18 AWG*
18 AWG*
20 AWG*
20 AWG*
18 AWG*
18 AWG*
18 AWG*
18 AWG*
20 AWG*
20 AWG*
18 AWG*
*AWG: American Wire Gauge
Insulated connector M3.5
Insulated connector M3.5
18 AWG*
18 AWG*
Insulated connector M3.5
Insulated connector M3.5
(if used)

(3)
Wiring diagram
P 12/ 14
(26) (4)
(7)
(2)
(19)
(19)
Boss
For easy and exact wiring, put the electrical parts. Fig. D-2
Setting Electrical Parts
(D)
Brush holder (19) has to be so set,
that the connected Field lead wire (purple)
can be guided toward Switch (4) side.
Brush holder (19) has to be so set that the
connected Field lead wire (orange) can be
guided toward Cord clamp (7) side. Put Choke coil (D) between
Brush holder (19) and
Cord clamp (7).
(D)
Put Choke coil (D) between
Brush holder (19) and
Switch (14).
Put Noise suppressor (2)
between Boss and
Cord clamp (7).
Fig. D-2

Wiring diagram
P 13/ 14
(3)
Area A
(26) (4)
(7)
Rib B
(rC)
(rD)
(rF)
(rG)
(rE)
(2)
(19)
Rib A
Boss
Terminal block (3) has to be so put that the Lead
wire (blue) of Power supply cord can be easily
guided out toward Switch (4) side through the
route between Rib E (rE) and Rib G (rG).
These lead wires must be tight
in Area A so as not to make slacks.
(19)
Pass Field lead wires (Purple, Black) under
Brush holders (19).
Pass Field lead wires (Purple, Black) between
Rib A and Rib B.
Put Lead wire (brown) of
Power supply cord between
Rib E (rE) and Rib F (rF).
Put the sag of Field lead wire
(black) and Lead wire (white)
of noise suppressor connected
to Switch, to the left side of
broken line.
Pass the following Lead wires
between Rib E (rE) and Rib G (rG)
if Terminal block (3) is used.
* Lead wires (blue) (brown) of Power
supply cord
* Lead wire (white) of Noise
suppressor connected to Switch (4).
Pass Field lead wires (Orange, White) under
Brush holders (19).
Pass Field lead wires (Orange, White) between
Rib A and Rib B.
Fig. D-3
Put Brush holders (19) as drawn.
Put Choke coils (if used) between
Brush holder and Cord clamp (7).
Choke coil (if used)
Put Choke coils
(if used) between
Brush holder and
Cord clamp.
Put Noise suppressor
(2) (if used) in this
area.
Do not put Lead wires
on Rib G.

Wiring diagram
P 14/ 14
Wiring
In case Closed end connector is used instead of Terminal block
Put Closed end connector between Brush holder (19) and Cord clamp (7).
Do not put Closed end connector on Rib G (rG).
Fig. D-4
Put Lead wire (blue) of Power supply cord and Lead wire (white) of Noise suppressor
that are connected to Switch (4) between Rib E (rE) and Rib G (rG).
(7)
(19)
(19)
(4)
(rG) (rE)