makita DGA405 Cordless Angle Grinder Instruction Manual

DGA405
DGA455
DGA505

DGA405 Cordless Angle Grinder

Explanation of general view

1. Button| 14. Depressed center wheel| 27. Abrasive cut-off wheel/diamond wheel
---|---|---
2. Red indicator| 15. Inner flange| 28. Wheel guard for abrasive cut-off wheel/diamond wheel
3. Battery cartridge| 16. Lock nut wrench| 29. Abrasive cut-off wheel
4. Lock-off lever| 17. Ezynut| 30. Diamond wheel
5. Switch lever| 18. Abrasive wheel| 31. Thickness: Less than 4 mm (5/32”)
6. Battery indicator| 19. Spindle| 32. Thickness: 4 mm (5/32”) or more
7. Mode indicator| 20. Arrow| 33. Wire cup brush
8. Shaft lock| 21. Notch| 34. Wire wheel brush
9. Wheel guard| 22. Flex wheel| 35. Exhaust vent
10. Bearing box| 23. Plastic pad| 36. Inhalation vent
11. Screw| 24. Sanding lock nut| 37. Dust cover
12. Lever| 25. Abrasive disc|
13. Lock nut| 26. Rubber pad|

SPECIFICATIONS

• Due to our continuing program of research and development, the specifications herein are subject to change without notice.
• Specifications and battery cartridge may differ from country to country.
• Weight, with battery cartridge, according to EPTA-Procedure 01/2003

Intended use
The tool is intended for grinding, sanding and cutting of metal and stone materials without the use of water.

General Power Tool Safety
Warnings
GEA010-1
WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
CORDLESS GRINDER SAFETY
WARNINGS
GEB059-3
Safety Warnings Common for Grinding, Sanding, Wire Brushing, or Abrasive Cutting-Off Operations:

1. This power tool is intended to function as a grinder, sander, wire brush or cut-off tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
   Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

2. Operations such as polishing are not recommended to be performed with this power tool. Operations for which the power tool was not designed may create a hazard and cause personal injury.

3. Do not use accessories which are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.

4. The rated speed of the accessory must be at least  equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.

5. The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.

6. Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbour hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

7. Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is  dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away  from the plane of the rotating accessory and runthe power tool at maximum no- load speed for one minute. Damaged accessories will normally break apart during this test time.

8. Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or  workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure  to high intensity noise may cause hearing loss.

9. Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of  workpiece or of a broken accessory may fly away and cause injury beyond immediate  area of operation.

10. Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and  could give the operator an electric shock.

11. Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.

12. Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.

13. Regularly clean the power tool’s air vents. The motor’s fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

14. Do not operate the power tool near flammable materials. Sparks could ignite these materials.

15. Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

Kickback and Related Warnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be  forced in the direction opposite of the accessory’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may
either jump toward or away from the operator, depending on direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator  can control torque reactions or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
c) Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have  a tendency to snag the rotating accessory and causeloss of control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive Cutting-Off Operations:
a) Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel. Wheels for which  the power tool was not designed cannot be adequately guarded and are unsafe.
b) The grinding surface of centre depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.
c) The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. The guard helps to protect the operator from broken wheel fragments, accidental contact with wheel and sparks that could ignite clothing.
d) Wheels must be used only for recommended applications. For example: do not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
e) Always use undamaged wheel flanges that are of correct size and shape for your selected wheel.
Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.
f) Do not use worn down wheels from larger power tools. Wheel intended for larger power tool is not suitable for the higher speed of a smaller tool and may burst.

SAVE THESE INSTRUCTIONS.
WARNING:
DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

IMPORTANT SAFETY INSTRUCTIONS

FOR BATTERY CARTRIDGE

1. Before using battery cartridge, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.

2. Do not disassemble battery cartridge.

3. If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns and even an explosion.

4. If electrolyte gets into your eyes, rinse them out with clear water and seek medical attention right away. It may result in loss of your eyesight.

5. Do not short the battery cartridge:
   (1) Do not touch the terminals with any conductive material.
   (2) Avoid storing battery cartridge in a container with other metal objects such as nails, coins, etc.
   (3) Do not expose battery cartridge to water or rain.
   A battery short can cause a large current flow, overheating, possible burns and even a breakdown.

6. Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50°C (122°F).

7. Do not incinerate the battery cartridge even if it is severely damaged or is completely worn out. The battery cartridge can explode in a fire.

8. Be careful not to drop or strike battery.

9. Do not use a damaged battery.

10. Follow your local regulations relating to disposal of battery.

SAVE THESE INSTRUCTIONS.
Tips for maintaining maximum battery life

1. Charge the battery cartridge before completely discharged.
   Always stop tool operation and charge the battery cartridge when you notice less tool power.

2. Never recharge a fully charged battery cartridge.
   Overcharging shortens the battery service life.

3. Charge the battery cartridge with room temperature at 10°C – 40°C (50°F – 104°F). Let a hot battery cartridge cool down before charging it.

4. Charge the battery cartridge once in every six months if you do not use it for a long period of time.

FUNCTIONAL DESCRIPTION

CAUTION:

• Always be sure that the tool is switched off and the battery cartridge is removed before adjusting or checking function on the tool.
  Installing or removing battery cartridge (Fig. 1)
  CAUTION:

• Always switch off the tool before installing or removing of the battery cartridge.

• Hold the tool and the battery cartridge firmly when installing or removing battery cartridge. Failure to hold the tool and the battery cartridge firmly may cause them to slip off your hands and result in damage to the tool and battery  cartridge and a personal injury.
  To remove the battery cartridge, slide it from the tool while sliding the button on the front of the cartridge.
  To install the battery cartridge, align the tongue on the battery cartridge with the groove in the housing and slip it into place. Insert it all the way until it locks in place with a little click. If you can see the red indicator on the upper
  side of the button, it is not locked completely.

CAUTION:

• Always install the battery cartridge fully until the red indicator cannot be seen. If not, it may accidentally fall out of the tool, causing injury to you or someone around you.
• Do not install the battery cartridge forcibly. If the cartridge does not slide in easily, it is not being inserted correctly.

Switch action
CAUTION:

• Before installing the battery cartridge into the tool, always check to see that the switch lever actuates properly and returns to the “OFF” position when released.
• Do not pull the switch lever hard without pulling the lock-off lever. This can cause switch breakage.
  To prevent the switch lever from being accidentally pulled, a lock-off lever is provided. To start the tool, pull the lockoff lever toward the operator and then pull the switch lever. Release  the switch lever to stop. (Fig. 2)

Accidental re-start preventive function
Even if installing the battery cartridge while pulling the switch lever, the tool does not start.
To start the tool, first release the switch lever. Then pull the lock-off lever and then pull the switch lever.
Indicating remaining battery capacity (Fig. 3)
When you turn the tool on, the battery indicator shows the remaining battery capacity.
The remaining battery capacity is shown as the following table.

Automatic speed change function (Fig. 4)

This tool has “high speed mode” and “high torque mode”.
It automatically changes operation mode depending on the work load. When mode indicator lights up during operation, the tool is in high torque mode.

Tool/battery protection system
The tool is equipped with a tool/battery protection system.
This system automatically cuts off power to the motor to extend tool and battery life.
The tool will automatically stop during operation if the tool or battery is placed under one of the following conditions.
In some conditions, the indicator lights up.
Overload protection
When the tool is operated in a manner that causes it to draw an abnormally high current, the tool automatically stops without any indications. In this situation, turn the tool off and stop the application that caused the tool to become  overloaded. Then turn the tool on to restart.
Overheat protection for tool
When the tool is overheated, the tool stops automatically and the battery indicator shows following state. In this
situation, let the tool cool before turning the tool on again.

Releasing protection lock
When the protection system works repeatedly, the tool is locked and the battery indicator shows the following state.

In this situation, the tool does not start even if turning the tool off and on. To release the protection lock, remove the battery, set it to the battery charger and wait until the charging finishes.

Shaft lock
CAUTION:

• Never actuate the shaft lock when the spindle is moving. The tool may be damaged.
  Press the shaft lock to prevent spindle rotation when installing or removing accessories. (Fig. 5)

ASSEMBLY

CAUTION:

• Always be sure that the tool is switched off and the battery cartridge is removed before carrying out any work on the tool.

Installing side grip (handle)
CAUTION:

• Always be sure that the side grip is installed securely before operation.
  Screw the side grip securely on the position of the tool as shown in the figure. (Fig. 6)

Installing or removing wheel guard (For depressed center wheel, flap disc/abrasive cut-off wheel, diamond wheel)
WARNING:

• When using a depressed center grinding wheel/flap disc, flex wheel, wire wheel brush, cut-off wheel or diamond wheel, the wheel guard must be fitted on the tool so that the closed side of the guard always points toward the operator.
• When using an abrasive cut-off/diamond wheel, be sure to use only the special wheel guard designed for use with cut-off wheels. (In some European countries, when using a diamond wheel, the ordinary guard can be used. Follow  the regulations in your country.) For tool with clamp lever type wheel guard  Loosen the lever on the wheel guard after loosening the screw. Mount the wheel guard with the protrusion on the wheel guard band aligned with the notch  on the bearing box. Then rotate the wheel guard to such an angle that it can protect the operator according to work. (Fig. 7)
  Tighten the lever to fasten the wheel guard. If the lever is too tight or too loose to fasten the wheel guard, loosen or tighten the screw to adjust the tightening of the wheel guard band. (Fig. 8)
  To remove wheel guard, follow the installation procedure in reverse.

Installing or removing depressed center wheel or flap disc (optional accessory)
WARNING:

• When using a depressed center wheel or flap disc, the wheel guard must be fitted on the tool so that the closed side of the guard always points toward the operator.
• Only actuate the shaft lock when the spindle is not moving.

Mount the inner flange onto the spindle.
Make sure to fit the dented part of the inner flange onto the straight part at the bottom of the spindle.
Fit the wheel/disc on the inner flange and screw the lock nut onto the spindle. (Fig. 10)
To tighten the lock nut, press the shaft lock firmly so that the spindle cannot revolve, then use the lock nut wrench and securely tighten clockwise. (Fig. 11)
To remove the wheel, follow the installation procedure in reverse.

OPERATION

WARNING:

• It should never be necessary to force the tool. The weight of the tool applies adequate pressure. Forcing and excessive pressure could cause dangerous wheel breakage.
• ALWAYS replace wheel if tool is dropped while rinding.
• NEVER bang or hit grinding disc or wheel onto work.
• Avoid bouncing and snagging the wheel, especially when working corners, sharp edges etc. This can cause loss of control and kickback.
• NEVER use tool with wood cutting blades and other sawblades. Such blades when used on a grinder  frequently kick and cause loss of control leading topersonal injury.

CAUTION:

• Never switch on the tool when it is in contact with the workpiece, it may cause an injury to operator.
• Always wear safety goggles or a face shield during operation.
• After operation, always switch off the tool and wait until the wheel has come to a complete stop before putting the tool down.

Grinding and sanding operation (Fig. 18)
ALWAYS hold the tool firmly with one hand on housing and the other on the side handle. Turn the tool on and then apply the wheel or disc to the workpiece.
In general, keep the edge of the wheel or disc at an angle of about 15 degrees to the workpiece surface.
During the break-in period with a new wheel, do not work the grinder in the B direction or it will cut into the workpiece. Once the edge of the wheel has been rounded off by use, the wheel may be worked in both A and B  direction.
Operation with abrasive cut-off/diamond wheel (optional accessory) (Fig. 19)
Remove the battery cartridge from the tool and place it upside down allowing easy access to spindle. Mount the inner flange and abrasive cut-off/diamond wheel onto the spindle. Tighten the lock nut securely with supplied wrench. The  direction for mounting the lock nut and the inner flange varies by wheel thickness.
Refer to the table below. (Fig. 20)

WARNING:

• When using an abrasive cut-off/diamond wheel, be sure to use only the special wheel guard designed for use with cut-off wheels. (In some European countries, when using a diamond wheel, the ordinary guard can be used. Follow  the regulations in your country.)

• NEVER use cut-off wheel for side grinding.

• Do not “jam” the wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility  of kickback, wheel breakage and overheating of the motor may occur.

• Do not start the cutting operation in the workpiece. Let the wheel reach full speed and carefully enter into the cut moving the tool forward over the workpiece surface.
  The wheel may bind, walk up or kickback if the power tool is started in the workpiece.

• During cutting operations, never change the angle of the wheel. Placing side pressure on the cut-off wheel (as in grinding) will cause the wheel to crack and break, causing serious personal injury.

• A diamond wheel shall be operated perpendicular to the material being cut.

MAINTENANCE

CAUTION:

• Always be sure that the tool is switched off and the battery cartridge is removed before attempting to perform inspection or maintenance.
• Never use gasoline, benzine, thinner, alcohol or the like. Discoloration, deformation or cracks may result.
  The tool and its air vents have to be kept clean. Regularly clean the tool’s air vents or whenever the vents start to become obstructed. (Fig. 23)
  Remove the dust cover from inhalation vent and clean it for smooth air circulation. (Fig. 24)

NOTE:

• Clean out the dust cover when it is clogged with dust or foreign matters. Continuing operation with a clogged dust cover may damage the tool.
  To maintain product SAFETY and RELIABILITY, repairs, any other maintenance or adjustment should be performed by Makita Authorized Service Centers, always using Makita replacement parts.

OPTIONAL ACCESSORIES

CAUTION:

• These accessories or attachments are recommended for use with your Makita tool specified in this manual.
  The use of any other accessories or attachments might present a risk of injury to persons. Only use accessory or attachment for its stated purpose.
  If you need any assistance for more details regarding these accessories, ask your local Makita Service Center.

• Makita genuine battery and charger

| 100 mm (4″) model| | 115 mm (4-1/2″) model| | 125 mm (5″) model
---|---|---|---|---|---
1| | Grip 36|
2| | Wheel guard (for grinding wheel)|
3| Inner flange 30| | Inner flange 42
Super flange 47 1| | Inner flange 42
Super flange 47 1
4| | Depressed center wheel/Flap disc|
5| Lock nut 10-30| | Lock nut 14-45
Ezy nut 2| | Lock nut 14-45
Ezy nut 2
6| Plastic pad| | Plastic pad| | Plastic pad
7| Flex wheel| | Flex wheel| | Flex wheel
8| Rubber pad 76| | Rubber pad 100| | Rubber pad 115
9| | Abrasive disc|
10| Sanding lock nut 10-30| | Sanding lock nut 14-48| | Sanding lock nut 14-48
11| | Wire wheel brush|
12| | Wire cup brush|
13| | Wheel guard (for cut-off wheel) *3|
14| | Abrasive cut-off wheel/Diamond wheel|
—| Lock nut wrench 20| | I Lock nut wrench 35| | Lock nut wrench 35

Note:

1. Super flange needs only 1/3 of efforts to undo lock nut, compared with conventional type.
2. Do not use Super flange and Ezynut together.
3. In some European countries, when using a diamond wheel, the ordinary guard can be used instead of the special guard covering the both side of the wheel. Follow the regulations in your country.

NOTE:

• Some items in the list may be included in the tool package as standard accessories. They may differ from country to country.

Noise
ENG905-1
The typical A-weighted noise level determined according
to EN60745:
Model DGA405, DGA455
Sound pressure level (LpA): 80 dB (A)
Uncertainty (K): 3 dB (A)
The noise level under working may exceed 80 dB (A).

Model DGA505
Sound pressure level (LpA): 79 dB (A)
Uncertainty (K): 3 dB (A)
The noise level under working may exceed 80 dB (A).

Vibration
ENG900-1
The vibration total value (tri-axial vector sum) determined according to EN60745:
Model DGA405
Work mode: surface grinding
Vibration emission (ah,AG): 4.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2
Model DGA455
Work mode: surface grinding with normal side grip
Vibration emission (ah,AG): 5.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: surface grinding with anti vibration side grip
Vibration emission (ah,AG): 5.0 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2
Model DGA505
Work mode: surface grinding with normal side grip Vibration emission (ah,AG): 6.0 m/s2
Uncertainty (K): 1.5 m/s2
Work mode : surface grinding with anti vibration side grip
Vibration emission (ah,AG): 5.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2

Model DGA405
Work mode: surface grinding
Vibration emission (ah,AG): 4.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2

Model DGA455
Work mode: surface grinding with normal side grip
Vibration emission (ah,AG): 5.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: surface grinding with anti vibration side grip
Vibration emission (ah,AG): 5.0 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2

Model DGA505
Work mode: surface grinding with normal side grip
Vibration emission (ah,AG): 6.0 m/s2
Uncertainty (K): 1.5 m/s2
Work mode : surface grinding with anti vibration side grip
Vibration emission (ah,AG): 5.5 m/s2
Uncertainty (K): 1.5 m/s2
Work mode: disc sanding
Vibration emission (ah,DS): 2.5 m/s2 or less
Uncertainty (K): 1.5 m/s2

ENG902-1

• The declared vibration emission value has been measured in accordance with the standard test method and may be used for comparing one tool with another.
• The declared vibration emission value may also be used in a preliminary assessment of exposure.
• The declared vibration emission value is used for main applications of the power tool. However if the power tool is used for other applications, the vibration emission value may be different.

WARNING:

• The vibration emission during actual use of the power tool can differ from the declared emission value depending on the ways in which the tool is used.
• Be sure to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off  and when it is running idle in addition to the trigger time).

For European countries only
ENH101-18
EC Declaration of Conformity
Makita declares that the following Machine(s):
Designation of Machine:
Cordless Angle Grinder
Model No./Type: DGA405, DGA455, DGA505
Conforms to the following European Directives: 2006/42/EC
They are manufactured in accordance with the following standard or standardized documents:
EN60745
The technical file in accordance with 2006/42/EC is available from:
Makita, Jan-Baptist Vinkstraat 2, 3070, Belgium

Yasushi Fukaya
Director
Makita, Jan-Baptist Vinkstraat 2, 3070, Belgium

Makita Jan-Baptist Vinkstraat 2, 3070, Belgium
Makita Corporation Anjo, Aichi, Japan
www.makita.com

References

• MAKITA Industrial Power Tools - The Leader In Cordless with 18V LXT Lithium-Ion

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