Makita LXDG01 1 Series Manual

PRODUCT
P 1/10
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
BGD800 (LXDG01)*1, BGD801
Cordless Die Grinder
Specification
Standard equipment
Optional accessories
Collet cones (3mm, 6mm, 8mm, 1/8", 1/4")
Side grip
Wheel points
Battery BL1830
Fast charger DC18RA
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Note: The standard equipment shown above may vary by country.
Wrench 13 ............................................... 2
Collect cone 6mm or 1/4" ....................... 1
Collect cone 8mm ................................... 1 (for India)
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
118 (4-5/8)
82 (3-1/4)
402 (15-3/4) 307 (12-1/8)
BGD800 BGD801
BGD800
BGD801
Note: These models are not compatible with 1.3Ah Li-ion battery BL1815.
*2: The tools for India additionally includes 8mm collet cone.
*3: 1/4" is the Max. collet capacity in inch for North American countries.
(Collet cone of inch size corresponding to 8mm is not available for these models.)
*4: with battery, collet cone and collet nut
Battery
Cell
Voltage: V
Capacity: Ah
Supplied with the tool
Option
Li-ion
18
3.0
Weight according to
EPTA-Procedure 01/2003*4: kg (lbs) 2.0 (4.4) 1.7 (3.8)
No load speed: min-1=rpm 25,000
Collet size: mm (") 3, 6, 8 (1/8, 1/4)
6*2(1/4)
Max collet capacity: mm (") 8 (1/4)*3
Max wheel diameter: mm (")
Max output: W 350
38 (1-1/2)
Specification Model BGD800 BGD801
22 with DC18RACharging time (approx.): min.
*1 Model number for North and Central American countries
L
H
W
These new products are available in the following variations.
BGD800 (LXDG01)*1
Model No. Type Quantity Charger Plastic
carrying case
Battery
cover
Battery
BL1830 DC18RA Yes
BGD800Z
(LXDG01Z)*1
2 1
--- --- ------ ---
BGD800RFE
(LXDG01)*1
BGD801
All models also include the accessories listed below in "Standard equipment".
Model No. Type Quantity Charger Plastic
carrying case
Battery
cover
Battery
BL1830
---
DC18RA Yes
BGD801Z
2 1
--- ------ ---
BGD801RFE
Models BGD800 (LXDG01)*1 and BGD801 are Cordless die grinders
powered by 18V/3.0A Li-ion battery BL1830, featuring the same
easy-to-grip slim motor housing as used for Model BGA402 Cordless
angle grinder.
BGD800 is a long-nose die grinder using the mechanical section of
Model GD601 while BGD801 is a short-nose type using that of
Model GD602.
TECHNICAL INFORMATION

Flat washer 22
P 2/ 10
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATION
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Coupling, Spindle
Fig. 1
Code No. Description Use for
1R279 Round bar for arbor 5-50 removing Armature
1R291 Retaining ring S and R pliers removing Retaining rings S-9 and S-12
Hex socket bit 17 fixing Coupling when removing it from Spindle
Wrench 13 removing Spindle from Coupling
1R350 Ring 60 holding Bearing box complete when removing Armature
1R382 Armature positioning jig positioning Armature at the precise position when mounting it to
Bearing box complete
Item No.
Apply lubricant as instructed in the table below.
Description Lubricant Amount (g)Portion to lubricate
DISASSEMBLING
Ball bearing 6001LLB
Spindle
5 Felt Ring 17 Apply sufficient lubricant to protect from dust. “VG100”
Fig. 2
1. Remove Insulation cover from Barrel,
then remove four 4x30 Tapping screws
that fasten Barrel section to Housing.
2. Separate Barrel section
from Housing.
Note:
Be careful not to lose
Flat washer 22 in this step.
(1) Remove Collet cone and Collet sleeve from Spindle.
(2) Remove Insulation cover from Barrel section. Separate Barrel section from Housing,
then disassemble Barrel section using vise. (Fig.2)
Insulation cover
Barrel section
4x30 Tapping screw
(4 pcs)
Barrel section
Housing
3. Fix Barrel section in vise securely,
then remove Bearing retainer from
Barrel complete by turning Barrel
complete counterclockwise.
BGD0800 (LXDG01)
Felt ring
Flat washer 18
Bearing
retainer
Barrel
complete
Housing

P 3/ 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Coupling, Spindle
Fig. 3
Fig. 4
Fig. 5
DISASSEMBLING
ASSEMBLING
4. Turn Spindle counterclockwise with Wrench 13 while holding Coupling
with Hex box bit 17.
6. Drive the removed Coupling in Spindle again
about 2 pitches for utilizing it as a removing tool.
7. Push Coupling by hand towards the front end of
Barrel complete, and remove Spindle together with
Ball bearing 6001LLB and Retaining ring S-12;
in this step, Ball bearing 629LLB remains in
Barrel complete.
(2) Remove Coupling from Spindle, then separate Spindle from Barrel complete. (Figs. 3,4)
(3) Remove Retaining ring S-12 and Ball bearing 6001LLB from Spindle. (Fig. 5)
Coupling
Hex socket
bit 17
Spindle
Wrench 13
Spindle
Do the reverse of the disassembling steps.
8. Remove Ball bearing 629LLB from the rear end of
Barrel complete.
Coupling
5. The Coupling disconnected from
Spindle remains in Hex box bit 17.
Ball bearing
6001LLB
Ball bearing
6001LLB
Retaining
ring S-12
BGD0800 (LXDG01)
Retaining
ring S-12
Ball bearing
6291LLB
[front end]
[rear end]
Spindle
Retaining ring
S-12
Barrel complete
Drive Coupling
about 2 pitches
in Spindle again.
Ball bearing
6001LLB
Ball bearing
629LLB
[front end]
[rear end]

P 4/ 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Armature
Fig. 6
Fig. 7
DISASSEMBLING
2. Disassemble Armature section by pulling out.
3. Remove Armature from Gear housing cover
by applying 1R279 to the Armature shaft,
then pressing it with arbor press.
1. Remove Carbon brushes and Spacer.
(1) Remove Barrel section. (Fig. 2)
(2) Disassemble Armature. (Fig. 6)
(3) Separate Armature from Gear housing cover. (Fig. 7)
Armature
Gear housing cover
Flat washer 22
Carbon brush
Spacer
4. Remove Coupling together with Ball bearing 629LLB
from Gear housing cover, then separate Coupling from
Ball bearing 629LLB by removing Retaining ring S-9.
Coupling
Ball bearing
629LLB
Retaining
ring S-9
BGD0800 (LXDG01)
1R291
Coupling
Ball bearing
629LLB
Turn over.
1R279
1R350
Armature
Coupling
Gear housing cover
Flat washer 22
will remain here
if it does not
fall off from
Gear housing cover
when separating
Barrel section in
the step of Fig 2.

P 5/ 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Armature
ASSEMBLING
(1) Assemble Coupling to Ball bearing 629LLB by fitting Retaining ring S-9. (Fig. 7)
(2) Assemble Armature to Gear housing cover. (Fig. 8)
1. Assemble Ball bearing 629LLB
with Coupling to Gear housing
cover, then mount them on 1R382.
2. Press Armature carefully
into Coupling on 1R382
with arbor press until stopped.
Note: Press Armature into
Coupling hole as slowly turning it
so that it is set precisely at a right
angle to Coupling.
Spacer
1R382 Coupling
Coupling
Fig. 8
Fig. 9
Flat washer 22
3. Mount Spacer to Coupling. 4. Mount Flat washer 22.
5. Assemble Armature to Housing.
Coupling
square depression
Switch lever
Barrel complete
Housing
BGD0800 (LXDG01)
6. Assemble Barrel section to Housing with the square depression side
set aligned with the Switch lever side.
1R382
Coupling
Ball bearing
629LLB
Gear housing cover

P 6/ 10
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATION
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature
Fig. 1
Code No. Description Use for
1R005 Retaining ring pliers RT-2N removing Retaining ring R-32
1R279 Round bar for arbor 5-50 removing Armature
1R291 Retaining ring S and R pliers removing Retaining ring S-15
1R350 Ring 60 holding Bearing box complete when removing Armature
1R383 Armature positioning jig positioning Armature at the precise position when mounting it to
Bearing box complete
Item No.
Apply lubricant as instructed in the table below.
Description Lubricant Amount (g)Portion to lubricate
DISASSEMBLING
---
Felt Ring 18
(a component part of
Bearing box complete)
Apply sufficient lubricant to protect from dust. “VG100”
Fig. 2
BGD0801
(1) Remove Collet cone and Collet sleeve from Spindle.
(2) Remove Insulation cover from Bearing box complete,
then separate Bearing box complete from Housing. (Fig.2)
1.Remove Insulation cover from Bearing box complete,
then remove Carbon brush.
2. Remove Bearing box complete together with
Armature from Housing.
4x22 Tapping screw (4 pcs)
Insulation cover
Bearing box complete Armature
Bearing box
complete
Housing
Ball Bearing 6002LLB
Bearing box complete
Felt Ring 18

P 7/ 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature
Fig. 3
DISASSEMBLING
(3) Separate Armature from Bearing box complete. (Fig. 3)
BGD0801
Fig. 4
ASSEMBLING
1. Insert 1R383 into Spindle hole,
then put Armature shaft on Spindle hole.
2. Assemble Armature to Bearing box complete
by pressing into Spindle hole with arbor press
until stopped.
Assemble Armature to Gear housing cover by using Armature positioning jig 1R383. (Fig. 4)
Note: 1R383 must be used for fixing Armature spindle at right depth.
Spindle
1R383 Spindle
1R383
Armature
3. Assemble Bearing box complete and Armature to Housing
with square depression side set aligned Switch side.
Bearing box
complete
Bearing box
complete
Bearing box
complete
Note: Press Armature into
Spindle hole as slowly turning it
so that it is set precisely at a right
angle to Bearing box complete.
3. Remove Armature from
Gear housing cover
by applying 1R279 to
the Armature shaft
through Spindle hole,
then pressing it
with arbor press.
Spindle
Bearing box
complete
1R279
Armature
1R350
Spindle
Armature
Housing
square depression
Switch lever

P 8/ 10
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Spindle and Bearing Box Complete
Fig. 5
DISASSEMBLING
(1) Remove Collet cone and Collet sleeve from Spindle and separate Bearing box complete from Housing. (Fig. 2)
(2) Separate Armature from Bearing box complete. (Fig.3)
(3) Disassemble Bearing box complete. (Fig. 5)
BGD0801
ASSEMBLING
Spindle
1R291
1. Remove Retaining ring S-15. 2. Remove Spindle
from Bearing box.
4. Remove Ball bearing
6002LLB from
Bearing box complete.
3. Remove Retaining
ring R-32 from
Bearing box complete.
Retaining
ring S-15 Retaining
ring R-32
1R005
Ball Bearing
6002LLB
Do the reverse of the disassembling steps. (Figs. 5 and 4)

Circuit diagram
Wiring diagram
P 9/ 10
Fig. D-1
Fig. D-2
Fig. D-3
Color index of lead wires' sheath
Switch button
Black
Red
LED Circuit
End bell
complete
Switch
Controller
Terminal
Connector
Switch knob
Lead wire holder
of Endbell complete
Endbell complete
Insulating terminal
Insulating terminal
BGD0800 (LXDG01)/ BGD0801
Fix Endbell complete in place as below.
Wiring to Switch
Connect Insulating terminals as below.
Housing (L)

Wiring diagram
P 10/10
Fig. D-4
BGD0800 (LXDG01)/ BGD0801
Yoke unit
Wiring in Housing (L)
Endbell completeHousing (L)Controller
Switch
LED light
circuit
Terminal
Flag connector
Terminal
Flag connectors must be connected
to Terminal as below.
Lead wires from Controller to Terminal
must be routed under Controller.
Do not route them over the ribs around
Controller and Terminal.
Lead wire of
LED light circuit
Lead wire holder
Lead wires from LED Light circuit
must be routed in the area surrounded
by the dotted line.