Makita M0900B Betriebsanleitung

M0900B

REPAIR MANUAL

Angle Grinder

OFFICIAL USE

For ASC

4x18 Tapping screw

P 2/ 13

Repair

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

[1] NECESSARY REPAIR TOOLS

[2] LUBRICANT AND ADHESIVE APPLICATION

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Armature, Spiral Bevel Gear 13, Ball Bearing 629ZZ, Ball Bearing 607ZZ

Code No. Description Use for

1R005 Retaining Ring Pliers RT-2N

Retaining Ring S & R Pliers

removing/ mounting Retaining ring R-32

1R026 Bearing Setting Pipe 16-8.2 removing Spindle from Spiral bevel gear 37

1R217 Ring 22 removing Spindle from Spiral bevel gear 37

1R268 Spring Pin Extractor 3 disassembling Shaft lock mechanism

1R269 Bearing Extractor removing Ball bearing 629ZZ/ 607ZZ

1R291 removing Retaining ring S-12

1R281 Round Bar for Arbor 7-50 removing Spindle from Spiral bevel gear 37

removing Switch knob from Switch lever

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

DISASSEMBLING

(1) Remove Rear cover, then disconnect Carbon brush from Armature’s commutator. (Fig. 2)

Fig. 2

4x22 Tapping screw (4 pcs.)

Rear cover

Armature

Gear housing complete

1. Remove Rear cover by unscrewing one

4x18 Tapping screw.

2. Remove the end of Spiral spring from Carbon brush,

then pull out Carbon brush half way.

No need to remove Carbon brush completely.

3. Unscrew four 4x22 Tapping screws,

then separate Gear housing complete

together with Armature from Motor housing.

Motor housing

Spiral spring

Item No. Description Lubricant AmountPortion to lubricate

LUBRICANT

Fig. 1 : Makita grease FA No.2 (10g)

Gear Housing Complete Gear room Makita grease FA No.2 10g

O Ring 26 Whole portion Makita grease FA No.2 a little-

P 3/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[[3]-1. Armature, Spiral Bevel Gear 13, Ball Bearing 629ZZ, Ball Bearing 607ZZ

DISASSEMBLING

ASSEMBLING

M6 Hex nut

Ball bearing

629ZZ

Ball bearing

607ZZ

Flat washer 9

Wrench 10 Spiral bevel gear 13

4. Disassemble Armature from

Gear housing complete. 5. Disassemble Spiral bevel gear 13 from Armature by removing

M6 Hex nut with Wrench 10.

(2) Remove Spiral bevel gear 13, Ball bearings from Armature. (Fig. 3)

Do the reverse of the disassembling steps.

Note in Assembling:

When Motor housing and Gear housing complete are joined together,

Spindle must be positioned on the opposite side of Switch knob. (Fig. 4)

6. Using 1R269, remove Ball bearing 629ZZ and Flat washer 9 from the Fan side, then Ball bearing 607ZZ

from Commutator end.

Armature

Fig. 3

Fig. 4

Gear housing

complete

Motor housing

Spindle

Switch knob

M6 Hex nut

Ball bearing

607ZZ

Ball bearing

629ZZ

[Wrong][Correct]

Switch knob

Spindle

P 4/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Field

DISASSEMBLING

ASSEMBLING

2. Drive two 4x22 Tapping screws in holes in two diagonal corners.

Then remove Field from Motor housing by alternately tapping

the screw heads.

Note: Do not tap the end surface of Motor housing directly

because its inlaid portion is rather fragile.

1. Disconnect the receptacles from

Brush holders, Terminal block

and Switch. (Refer to Fig. D-1.)

Remove two 4x60 Tapping screws

that secure Field in Motor housing.

Fig. 5

Fig. 6

4x22 Tapping screw

M4x16

Pan head screw

Bearing box

1. Unscrew four M4x16 Pan head screws, then separate

Bearing box from Gear housing complete.

(1) Separate gear housing complete together with Armature as illustrated in Fig. 2.

(2) Remove Filed from Motor housing. (Fig. 5)

(1) Disassemble Bearing box from Gear housing complete, then remove Retaining ring S-12 from Spindle. Fig. 6

Note in Assembling:

Field must be mounted to Motor housing so that its Lead wires can be routed out through the openings of Motor housing

as described in Fig. D-2.

[3]-3. Spiral Bevel Gear 37, Ball Bearing 6201DDW

4x60 Tapping screw

2. Remove Retaining ring S-12 with 1R291.

Retaining ring S-12

1R291

P 5/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Spiral Bevel Gear 37, Ball Bearing 6201DDW

DISASSEMBLING

Fig. 7

1R026

1R281

1R217

approx.

10 mm

(2) Disassemble Spindle as illustrated in Fig. 7.

(3) Disassemble Ball bearing 6201DDW from Gear housing complete. (Fig. 8)

Bearing box

Spindle

Spiral bevel

gear 37

4. Push Spindle out a little by striking 1R026

carefully using arbor press with a down stroke

of approx.10mm long. Then remove 1R026.

3. Put Bearing box on 1R217,

then put 1R026 over the

stepped portion of Spindle.

Spindle

Fig. 8

1R005

6. Remove Retaining ring R-32 with 1R005. 7. Remove Ball bearing 6201DDW from

Bearing box.

In this step, Flat washer 12 is removed.

Ball bearing

6201DDW

Flat washer 12

Retaining

ring R-32

5. Put 1R281 on Spindle.

Then, using arbor press,

press 1R281 to remove

Spindle from Spiral bevel

gear 37.

Note:

Do not reuse removed Ball bearing 6201DDW

because it is damaged in this step.

P 6/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Spiral Bevel Gear 37, Ball Bearing 6201DDW

ASSEMBLING

Fig. 9

1R028

Ball bearing

6201DDW

Flat washer 12

Spindle

1R217

1. Mount Flat washer 12

on Spindle. 2. Set Spindle on 1R217, then set

Ball bearing 6201DDW and

1R028 as drawn below.

Then press-fit the Ball bearing

on Spindle by pressing 1R028

with arbor press.

Bearing box

1R005

Ball bearing 6201DDW and Spiral bevel gear can be assembled as described in Fig. 9.

1R028

4. Install Retaining ring R-32 with 1R005

to secure Ball bearing 6201DDW.

Retaining ring

R-32

Spiral bevel

gear 37

6. Install Retaining ring S-12 with 1R291.

Spindle

3. Set Bearing box on 1R217,

then set 1R028 on Spindle

as drawn below.

Then press-fit Spindle into

Bearing box by pressing 1R028

with arbor press.

1R028

Bearing box

Spindle

Important:

Apply lubricant to

this portion of Spindle

for smooth press-fitting

of Spiral bevel gear 37.

5. Set Bearing box on 1R217, then set 1R028 on Spiral bevel

gear 37 as drawn below.

Then, keeping Spiral bevel gear 37 in parallel with 1R217,

press-fit the Gear on Spindle of Bearing box by pressing

1R028 with arbor press.

1R217

Bearing box

P 7/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Switch Lever

DISASSEMBLING

ASSEMBLING

Fig. 10

Fig. 11

1. Slide Switch knob to OFF position,

then insert 1R281 between Switch knob

and Motor housing to lock Switch knob

in the position.

2. Push Switch lever back towards ON position

to disconnect Switch knob from Switch lever.

3. Switch knob can now be removed. 4. Pull out Switch lever from Motor housing

while bending it to release the link from

the toggle of Switch.

(1) Remove Rear cover. (Fig. 2)

(2) Switch lever can now be disassembled as described in Fig. 10.

toggle of Switch

Switch knob Switch lever

Switch Knob and Switch lever can be mounted in place as described in Fig. 11.

Switch knob

1R281

Motor housing

Switch knob

Switch lever

1. Insert Switch lever into Motor housing

until the square loop of Switch lever’s

front end is seen through the Switch knob

hole of Motor housing, and keep the loop

in the position. 2. Engage the hook of Switch Knob through Motor housing

in the square loop of Switch lever’s front end.

Hook of

Switch knob

Square loop of

Switch lever’s front end

P 8/ 13

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-5. Shaft Lock

DISASSEMBLING

(1) Separate Gear housing complete and Armature from Motor housing. (Fig. 2)

(2) Pull offArmature from Gear housing complete. (Fig. 3)

(3) Remove Bearing box by unscrewing four M4x16 Pan head screws. (Fig. 6)

(4) Disassemble Shaft lock mechanism as described in Fig. 12.

1. Put gear housing complete on 1R258.

Then remove Shoulder pin 4 from Gear housing complete

by inserting 1R268 through the small hole of Pin cap onto

Shoulder pin 4 and then tapping 1R268 with hammer.

2. Slowly remove 1R268 from Pin cap.

Be careful not to lose Compression spring 8

as the compressed spring may fly away.

Shoulder pin 4

Pin cap

Compression

spring 8

Fig. 12

1R268

1R258

Pin cap

plastic dust

Shoulder pin 4

ASSEMBLING

Assemble Shaft lock. (Fig. 13)

Then do the reverse of the disassembling steps.

Fig. 13

3. Assemble Compression spring 8

and new Pin cap by pressing them

to Shoulder pin 4.

2. Insert Shoulder pin 4 through

the hole of Gear housing complete.

Pin cap

Compression

spring 8

Shoulder

pin 4

Note: Do not reuse removed Pin cap.

1. Remove from Shoulder pin 4

all the plastic dust produced

in the disassembling process.

Note: Do not reuse the Pin cap removed

from Gear housing complete

because the inside surface of Pin cap

is damaged by Shoulder pin 4

when it is removed.

Circuit diagram

P 9/ 13

Fig. D-1

White

Red

Blue

Brown

Field,

viewed from

Rear cover side

Power supply cord

Noise suppressor

(not used for some

countries)

Terminal block

(Closed end splice

is used for some

countries instead

of Terminal block.)

Brush holder A

Brush holder B

Switch

Color index of lead wires' sheath

Black

Insulated terminal (M4)

For countries where suppression of radio interference is required

Blue/White Brown/Black

20 AWG*

*AWG: American Wire Gauge

18 AWG*

Magnet wire

Straight receptacle

(Without lock,

#110, t=0.8mm) Straight receptacle

(Without lock,

#110, t=0.8mm)

Circuit of Switch

Circuit diagram

P 10/ 13

Fig. D-2

White

Red

Blue

Brown

Field,

viewed from

Rear cover side

Power supply cord

Terminal block

(Closed end splice

is used for some

countries instead

of Terminal block.)

Brush holder A

Brush holder B

Switch

Color index of lead wires' sheath

Black

Insulated terminal (M4)

For countries where suppression of radio interference is not required

Blue/White Brown/Black

*AWG: American Wire Gauge

18 AWG*

Magnet wire

Straight receptacle

(Without lock,

#110, t=0.8mm) Straight receptacle

(Without lock,

#110, t=0.8mm)

Circuit of Switch

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