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DISASSEMBLING

ASSEMBLING

(2) Disassemble the commutator end of Armature as drawn in 

Fig. 3

.

      Note

: This step is required for the models with electronic control system of 

GA4040C, GA4540C, GA5040C,

                GA6040C, GA4542C, GA5042C, GA6042C

.

Fig. 3

1. Pick up three tabs of

    Self lock 6 with tweezers

    to remove it from Armature.

2. Remove Magnet sleeve, 

    Wave washer 6 and 

    Labyrinth rubber ring 22. 

3. Remove Ball bearing 627DDW with 1R269. 

4. Remove Flat washer 7 and

    Insulation washer. 

Self lock 6

Tabs

Tweezers

Wave washer 6

Magnet sleeve

Labyrinth rubber ring 22

Ball bearing 627DDW

1R269

Flat washer 7

Insulation washer

(1) Assemble small Spiral bevel gear to Armature end by reversing the disassembly procedure. (Refer to 

Fig. 2

(2) Assemble the commutator end of Armature as drawn in 

Fig. 4

.

      Note

: This step is required for the models with electronic control system of 

GA4040C, GA4540C, GA5040C,

                GA6040C, GA4542C, GA5042C, GA6042C

.

Fig. 4

2. Press down Self lock 6 until

    Wave washer 6 gets flat.

3. Magnet sleeve is stabilized

    between Self lock 6 and

    Wave washer 6 by the reaction

    force of Wave washer 6.    

1. Return tabs of Self lock 6 to their

    normal shape before assembling. 

    Then, mount Wave washer 6 to

    the commutator end of Armature.

Note

: Be careful to their directions.

           Refer to the drawings in 

Fig. 4

.

Wave washer 6

Magnet sleeve

Self lock 6

Wave washer 6

Magnet sleeve

Self lock 6

[3] DISASSEMBLY/ASSEMBLY

[3] -2. Armature, Spiral bevel gear [small one] (cont.)

Summary of Contents for GA4042C

Page 1: ...150mm for GA6040C GA6042C Optional accessories Depressed center wheels Rubber pads Dust collecting wheel guards Abrasive discs Wire brushes Wheel covers for wire brushes Diamond wheels Abrasive cut off wheels Wheel covers Sanding lock nut etc Specification Continuous Rating W Voltage V Cycle Hz Input Output 840 Max Output W 110 120 220 230 240 13 12 6 7 6 4 6 1 50 60 50 60 50 60 50 60 50 60 1 400 ...

Page 2: ...S R pliers removing Retaining ring S 9 1R340 Bearing retainer wrench removing Bearing retainer 20 33 from Bearing box 1R350 Ring 60 supporting Gear housing when disassembling Shaft lock mechanism 2 LUBRICATION Fig 1 Item No Description Gear housing C type plate Lubricant Amount Portion to lubricate Coupling Spindle Model No GA4040 GA4540C GA4540 GA5040C GA5040 GA4542C GA4040C GA5042C GA6040 GA6042...

Page 3: ...to the groove on Gear housing cover Rear cover 2 Shift Spiral spring from Carbon brush top 3 Disconnect Carbon brush from commutator by pulling up Note No need to remove in this step Fig 2 Groove on Gear housing cover Gear housing cover Armature Wrench 10 Flat washer 12 Gear housing cover Ball bearing 6001LLB 5 Remove M6 Hex nut to turn it with Wrench 10 counterclockwise Then remove Flat washer 6 ...

Page 4: ... Assemble small Spiral bevel gear to Armature end by reversing the disassembly procedure Refer to Fig 2 2 Assemble the commutator end of Armature as drawn in Fig 4 Note This step is required for the models with electronic control system of GA4040C GA4540C GA5040C GA6040C GA4542C GA5042C GA6042C Fig 4 2 Press down Self lock 6 until Wave washer 6 gets flat 3 Magnet sleeve is stabilized between Self ...

Page 5: ... housing cover Name plate 1 Removing four M4x16 Hex socket head bolts then separate Bearing box section from Gear housing 1 Assemble Gear housing cover together with Armature while facing its notch to the same side as Name plate 2 Assemble Gear housing while facing Spindle to the same side as the notch and Name plate Name plate Gear housing Spindle Bearing box section 2 Remove Ball bearing 696ZZ w...

Page 6: ...9 Spindle 1R050 Spindle Joint sleeve Bearing retainer Bearing box Flat washer 12 Flat washer 12 4 While applying 1R286 to Flat washer 12 through Bearing retainer press it carefully to remove large Spiral bevel gear section including Coupling and Ball bearing 6903ZZ from Bearing box 1R286 large Spiral bevel gear Ball bearing 6903ZZ Coupling Flat washer 12 1R232 Coupling Ball bearing 6903ZZ large Sp...

Page 7: ...etainer 20 33 Bearing retainer 20 33 Felt ring 17 Felt ring 17 Flat washer 21 Assemble by reversing the disassembly procedure Refer to Figs 8 7 and 6 Note Do not re use the removed Joint sleeve New Joint sleeve has to be mounted Refer to the upper right illustration in Fig 7 Apply the following thread locker to the thread of M4x16 Hex socket head bolts if the unscrewed bolts are used ThreeBond 134...

Page 8: ...gly push Switch lever in a direction designated with black arrow 2 Switch lever is disconnected from the locking claw of Switch knob Then remove Switch knob Switch lever Tumbler Switch lever 1R284 Switch knob Switch Switch Switch knob Tumbler of Switch Tumbler of Switch Switch lever Fig 10 Switch knob 2 Fit the hook of Switch knob to the hole of Switch lever Then release Switch lever The hook of S...

Page 9: ...13 Switch block Controller ASSEMBLING Connect Switch block as drawn in Fig D 3 DISASSEMBLING 3 7 Brush Holder DISASSEMBLING Insert Slotted screwdriver into the gap between Switch and Switch block While fitting the tip of the screwdriver to the side groove of Switch remove Switch by levering it up Remove 3x10 Tapping screw Then insert Slotted screwdrivers into the gap between Motor housing and Brus...

Page 10: ...ust Pin cap Pin cap Compression spring 8 1R268 1R350 Fig 14 Fig 15 1 Disassemble Bearing box section from Gear housing Refer to Fig 6 2 Disassemble Shaft lock mechanism as drawn in Figs 14 and 15 Fig 16 Fig 17 1 Be sure to use a new Pin cap for replacement and to remove all the plastic dust on Shoulder pin 6 Fig 16 2 Assemble the Parts for Shaft lock mechanism as drawn in Fig 17 Plastic dust O Rin...

Page 11: ...ath Blue Brown Switch Controller Noise suppressor is installed in Switch block Noise suppressor is not used for some countries Field Brush holder Noise suppressor 7 Black lead wire is used for some countries White lead wire is used for some countries 8 6 1 4 5 2 3 Switch block Switch block Noise suppressor is installed in Switch block Noise suppressor is not used for some countries Black lead wire...

Page 12: ...ore mounting Switch block to Motor housing make sure that these three Connecting terminals of Switch block are not deformed or broken Put Lead wires of Power supply cord into this place designated with gray color 2 Make sure that these connecting terminals of Switch block fit to Brush holders connecting terminals push Switch block to Motor housing until it stops ...

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