Makita DGA404 Manual

The subject models are cordless angle grinders powered by 18V Li-ion battery,

and equipped with highly enhanced Brushless DC motor compared to the current

models DGA402/ DGA452.

A built-in controller changes the cutting speed automatically according to load condition,

enabling users to obtain high speed rotation on light duty application/ high torque on

heavy duty application.

Models No.

Description

PRODUCT

TECHNICAL INFORMATION

CONCEPT AND MAIN APPLICATIONS

Specification

Standard equipment

Optional accessories

P 1/ 14

Dimensions: mm (")

DGA404

All

Width (W) DGA454

Length (L)*1 362 (14-1/4)

117 (4-5/8)

130 (5-1/8)

DGA504

DGA404

Height (H)

140 (5-1/2)

DGA454,

DGA504 145 (5-3/4)

Note: The standard equipment may vary by country or model variation.

DGA404, DGA454, DGA504

18V Cordless Angle Grinders L

Specification Model DGA404

Weight according to

EPTA-Procedure 01/2003: kg(lbs)*22.5 (5.5) 2.5 (5.6)2.4 (5.3)

Battery

1.5, 2.0, 3.0, 4.0, 5.0Capacity: Ah

Voltage: V

Li-ionCell

Energy capacity: W 27, 36, 54, 72, 90

Charging time (approx.): min. 15, 18, 22, 36, 45 with DC18RC

Wheel size: mm (") Hole diameter

6 (1/4)Max. thickness

Diameter 100 (4)

16 (5/8) 22.23 (7/8)

8,500

Yes

No load speed: min.ֿ ¹= rpm

Slide

Switch type

Electronic

control

Overload warning lamp

Electronic current limiter

Soft start

Anti-restart function

Battery fuel gauge

Soft grip

*2 With 3.0Ah battery

*1 With BL1830/ BL1840/ BL1850

Note: BL1815 is not compatible.

DGA504DGA454

115 (4-1/2) 125 (5)

Lock nut wrench ............................................ 1

Side grip ......................................................... 1

Depressed center grinding wheel ................... 1 (100mm for DGA404, 115mm for DGA454, 125mm for DGA504)

Battery cover .................................................. 1 (except -Z- model)

Plastic carrying case ....................................... 1 (except -Z- model)

Charger DC18RC ........................................... 1 (except -Z- model)

Li-ion battery BL1830 or BL1840 ................. 2 (except -Z- model)

Depressed center wheels

Rubber pads

Abrasive discs

Wire brushes

Diamond wheels

Abrasive cut off wheels

Toolless wheel covers

Sanding lock nuts

Fast charger DC18RC

Fast charger DC18SD

Charger DC24SC

Automotive charger DC18SE

Four port multi charger DC18SF

Li-ion battery BL1815N

Li-ion battery BL1820

Li-ion battery BL1830

Li-ion battery BL1840

Li-ion battery BL1850

OFFICIAL USE

for ASC & Sales Shop

Repair

P 2/ 14

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

[2] LUBRICATION

Code No. Description Use for

1R045 Gear extractor (large) removing Rotor

1R027 Bearing setting pipe ø18-ø10.2 pressfitting Rotor

1R029 Bearing setting pipe ø23-ø15.2 pressfitting Spiral bevel gear 37

1R004 Retaining ring pliers ST-2 removing/ assembling Ring spring 11

1R034 Bearing setting plate ø12.2

1R258 V block removing Spiral bevel gear 37

1R291 Retaining ring S and R pliers removing Retaining ring R-32

Round bar for arbor ø12-50 removing Ball bearing 629LLB1R286

Round bar for arbor ø6-50 removing Spiral bevel gear 371R280

Bearing extractor (small) removing Ball bearing 607LLB/ 696ZZ1R269

Spring pin extractor M3 disassembling Shaft lock mechanism1R268

Item No. Description Lubricant Amount

a little

Portion to lubricate

O ring 26

Spiral bevel gear 10

Apply the following grease to protect parts and product from unusual abrasion. (Fig. 1)

Gear teeth in the gear room of Gear housing

Inner periphery that appears from Gear housing cover

Fig. 1

Makita

grease

SG. No.0

Gear housing cover

Gear housing

DISASSEMBLING

Repair

P 3/ 14

(1) Remove Gear housing cover with Rotor section from Motor housing. (Figs. 2, 3 and 4)

(2) Disassemble Rotor section. (Fig. 5)

Remove four 4x30 Tapping screws.

Fig. 2

4x30 Tapping

screw (4 pcs.)

4x30 Tapping screw (4 pcs.)

Gear housing

Bearing box

Bearing boxGear housing cover

Fig. 5

Fig. 3

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Rotor, Ball bearing 629LLB/ 607LLB, Spiral bevel gear 10

Remove the assembled part of Gear housing and Bearing box

from Gear housing cover.

While holding Rotor by a gloved

hand, turn M6 Hex nut counter-

clockwise with a Wrench 10.

Wrench 10

M6 Hex nut

Rotor

Gear housing cover

Spiral bevel gear 10

M6 Hex nut

Fig. 4

Thin slotted screwdriver

(First, turn it carefully to enlarge the gap

between Gear housing cover and Motor housing,

then pry off Gear housing cover with Rotor section.)

Groove to insert a thin slotted screwdriver

Insert a thin slotted screwdriver into the groove of Gear housing cover, and

remove Gear housing cover from Motor housing.

Gear housing cover

Motor housing

DISASSEMBLING

Repair

P 4/ 14

Fig. 6

Fig. 7

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Rotor, Ball bearing 629LLB/ 607LLB, Spiral bevel gear 10 (cont.)

Hook the jaws of 1R045 with Gear housing cover, then push out Rotor.

Remove Ball bearing 607LLB* from Rotor with 1R269.

* The component of Rotor

Press down Ball bearing 629LLB

with 1R286.

1R045

Rotor

Gear housing cover

Gear

housing cover

(3) Disassemlble Gear housing cover and Rotor section. (Figs. 6 and 7)

1R286

Arbor

press

Ball bearing

629LLB

Ball bearing 607LLB

1R269

Rotor

When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 8

because Rotor is a strong magnet, failure to follow this instruction could result in:

• Finger injury caused by pinching between Rotors pulling each other.

• Magnetic loss of Rotors or damage on the magnet portion of Rotor.

(Fig. 9)

Fig. 8 Fig. 9

* Magnetic loss of Rotors

* Damage on the magnet

portion of Rotor

Right Wrong

A proper distance

between Rotors

Caution for Handling of Rotor

ASSEMBLING

Repair

P 5/ 14

Fig. 10

Fig. 11

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Rotor, Ball bearing 629LLB/ 607LLB, Spiral bevel gear 10 (cont.)

When you assemble Rotor with Gear housing cover to Motor housing,

the magnetic force of Rotor toward Stator returns Gear housing cover

back to the original position.

Therefore, be careful not to pinch your fingers between Motor housing

and Gear housing cover.

Face the groove of Gear housing cover and Spindle toward the opposite

of Switch knob.

Fig. 12

Assemble by reversing the disassembly procedure.

Note: Be careful about the points shown in Figs. 10, 11 and 12.

Gear housing

cover

Motor housing

Switch knob

Groove of Gear housing cover Spindle

Receive the inner race of Ball bearing 629LLB in Gear housing cover with 1R027,

and pressfit the shaft of Rotor into the hole of Ball bearing 629LLB.

Arbor press

Rotor

1R027

Gear housing

cover

Gear housing

cover

O ring 26

with Grrease SG No. 0

on the inner periphery

Ball bearing 629LLB

1R027

Hole of Ball bearing 629LLB

DISASSEMBLING

Repair

P 6/ 14

Note: The subject parts can be removed without disassembling Motor section.

Disassemble Bearing box section as drawn in Fig. 13 to Fig. 19.

Fig. 13

Fig. 15

Fig. 17

Fig. 19

Fig. 18

Fig. 14

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Spiral bevel gear 37, Ball bearing 696ZZ and Ball bearing 6201DDW

Remove four M4x14

Pan head screws and

Bearing box from

Gear housing.

Remove Ball bearing

696ZZ with 1R269.

While opening Ring spring 11 with 1R004, pry and

remove it from Spindle with a slotted screwdriver.

Pry up Open

1R004

Slotted

screwdriver

Fig. 16

Arbor press

Spindle

Spiral bevel

gear 37

1R258

Bearing box

Press down Spindle with 1R280.

Remove Retaining ring R-32 from

Bearing box with 1R291

Bearing box section can be disassembled. Be careful about each position and the direction of Labyrinth ring

Note: When Spindle is removed from Spiral bevel gear 37, Ball bearing 6201DDW has a damage during the removal

process. Therefore, replace Ball bearing 6201DDW with a new one.

Spindle Labyrinth ring

M4x14 Pan head

screw (4 pcs.)

Bearing box Ball bearing

6201DDW

O ring 45 Ball bearing 696ZZFlat washer 12

Ring spring 11

Spiral bevel gear 37Retaining ring

R-32

Arbor press

1R280

Spindle

1R258

Spiral bevel

gear 37

Bearing box

Receive Bearing box on 1R258.

Provide an impact to Spindle carefully with Arbor press so that Arbor press

does not touch Spiral bevel gear 37

and Spindle sinks slightly.

1R291 Retaining ring R-32

Ball bearing

6201DDW

Bearing box

Turn Bearing box upside down.

Receive Bearing box on U groove of Arbor

press table as shown right, and press down

Flat washer 12 and Ball bearing 6201DDW

with 1R027

Flat washer 12/ Ball bearing 6201DDW

U groove of Arbor press table

1R027

Arbor press

Bearing box

Ring

spring 11

Gear housing

Bearing box

Ball bearing

696ZZ

M4x14 Pan head

screw (4 pcs.)

ASSEMBLING

Repair

P 7/ 14

DISASSEMBLING

ASSEMBLING

Assemble by reversing the disassembly procedure.

Note: When Spindle is pressfit into Spiral bevel gear 37:

1. insert the thread of Spindle into the hole of 1R034 to

receive the stepped portion of Spindle on 1R034.

2. put 1R029 on the area around the center hole of

Spiral bevel gear 37 and then press it down.

See Fig. 20.

(1) According to Fig. 13 in the previous page, remove Bearing box from Motor housing.

(2) Disassemble Shaft lock section as drawn in Figs. 21 and 22.

Fig. 20

Fig. 21

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Spiral bevel gear 37, Ball bearing 696ZZ and Ball bearing 6201DDW (cont.)

[3]-3. Shaft lock section

1R029

Bearing

box

Spiral bevel

gear 37

Spindle

1R034

Arbor press

Apply 1R268 to Shoulder pin 4 through the small hole

on Pin cap and tap 1R268 with a metal hammer.

Shoulder pin 4 is removed from Gear housing.

Release 1R268 from Pin cap carefully so that Pin cap is

not slung by Compression spring 8.

Shoulder pin 4

Gear housing

Note: Remove some plastic

dust on this area before

reassembling.

Pin cap

Note: Do not re-use removed Pin cap because removal one

damages the inside surface of the cap.

Compression

spring 8

O ring 5

Small hole on Pin cap

1R268

Fig. 22

Assemble by reversing the disassembly procedure.

Repair

P 8/ 14

Refer to Figs. 23 and 24.

Fig. 23

Fig. 24

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Assembling of Stator complete

Fit four projections on Housing set into four the mating cavity in Stator complete.

Mating cavity on the left side and the right side (Two each)

Projection in Housing on the left side and the right side (Two each)

Stator complete

Be sure to align the center line of Bearing room with the terminal of Stator complete.

Terminal of Stator complete

Bearing room (to fit Ball

bearing 607LLB of Rotor

complete) on Housing set

Repair

P 9/ 14

Refer to the following and next pages. (Figs. 25, 26, 27, and 28)

Fig. 25 Fig. 26

Insert the hook of Switch knob into

the square hole of Switch lever

Protrude the bar of Lever from

the triangle hole of Switch lever.

Turn the bar of Lever counterclockwise to place

the long bar end and the short bar end onto

the depressions on the triangle corners of Switch lever.

[3] DISASSEMBLY/ASSEMBLY

[3]-5. Assembling of Switch knob and Switch lever

Switch lever Switch knob The ends of Torsion spring 2

must be placed on

these positions.

Fig. 27

Set Torsion spring 2 in place of Lever, and then

pass Pin 2 through the holes of Lever.

Lever

Pin 2

Torsion spring 2

Upper view

Long bar end of Lever

The curve of Lever must be faced

toward the center of the triangle hole.

Long bar end of Lever

Depressions on the triangle

corners of Switch lever

Short bar end of Lever

Repair

P 10/ 14

[3] DISASSEMBLY/ASSEMBLY

[3]-5. Assembling of Switch knob and Switch lever (cont.)

Fig. 28

Insert one end of Pin 2 into the hole of Housing L.

and put the one end of Torsion spring 2 on the rib

of Housing L. (See below for the detail.)

The other end of Pin 2 should be inserted into

the hole of Housing R.

Place the top projection on the reverse side of Switch knob

into the groove of Housing L. (See below for the detail.)

Inside view of Housing L (before assembling)

Groove

RibHole

Inside view of Housing L (after assembling)

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