Makita Maktec MT961 Handbuch

Specification

Standard equipment

Note: The standard equipment for the tool shown above may vary by country.

Lock nut wrench 20 ...................... 1 (for MT961)

Lock nut wrench 35 ...................... 1 (for MT962/ MT963)

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

Model No.

No load speed: min.-1 = rpm

Diameter

Hole diameter

Wheel size: mm (")

Protection against electric shock

Power supply cord: m (ft)

Weight according to

EPTA-Procedure 01/2003*: kg (lbs)

MT961

100 (4)

2.0 (6.6)

1.9 (4.1) 2.0 (4.4)

11,000

Double insulation

16 (5/8)

MT962

115 (4-1/2)

22.23 (7/8)

MT963

125 (5)

Optional accessories

Wheel cover for Cut-off wheel

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output

320

Max. Output (W)

110

120

220

230-240

5.5

5.0

2.7

2.5

50/60

570

---

570

650

550

Current (A)

320

350

*With Side grip, Wheel cover, Inner flange, Lock nut

Specification

Dimensions: mm (")

Width (W)

Height (H)

Length (L)

Model No. MT961

270 (10-5/8)

118 (4-5/8)

MT962 MT963

129 (5-1/8)

96 (3-3/4)

139 (5-1/2)

105 (4-1/8)

CONCEPT AND MAIN APPLICATIONS

Model No.

Description

MT961, MT962, MT963

Angle Grinders 100mm (4"), 115mm (4-1/2"), 125mm (5")

These new angle grinders have been developed as the aesthetic

change models of the predecessors MT951/ MT952/ MT953.

Their main features are:

New slide switch (two action safety switch) and wheel cover

in compliance with the requirements of the new regulations

Industrial performance and durability at less expense

P 1/ 10

PRODUCT

TECHNICAL INFORMATION

P 2/ 10

Repair

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

[1] NECESSARY REPAIRING TOOLS

[2] LUBRICATIONS

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Armature, Spiral bevel gear 11, Ball bearings 6000ZZ and 607ZZ

Fig. 1

Fig. 2

Code No. Description Use for

1R004 Retaining ring S pliers ST-2N removing Ring spring 11 from Spindle

1R005 Retaining ring R pliers RT-2N removing Retaining ring R-32 from Bearing box

1R026 Bearing setting pipe 16-8.2 removing Spindle from Spiral bevel gear 36

1R232 Pipe 30 supporting Bearing box when removing Spindle

1R268 Spring pin extractor 3 disassembling Shaft lock mechanism

1R269 Bearing extractor removing Ball bearing

1R281 Round bar for arbor 7-50 locking Switch knob when separating Switch lever from Switch knob

1R282 Round bar for arbor 8-50 removing Spindle

1R291 Retaining ring S and R pliers removing / assembling Retaining ring S-6 from / to Armature shaft

Item No.

Apply the following lubricant to protect parts and product from unusual abrasion.

Description

1. Remove Carbon brushes and

two 4x18 Tapping screws,

and then remove Rear cover

from Motor housing.

2. Remove four 4x22 Tapping screws

and Gear housing section from

Motor housing.

3. Remove Armature together with

Bearing box from Gear housing

complete.

AmountPortion to lubricate

DISASSEMBLING

17 Gear housing complete

(1) Remove Armature. (Fig. 2)

Gear room 10g

Lubricant

Makita grease N No.1

4 x 18 Tapping screw

(2pcs.)

Rear cover

Carbon brush

Bearing box

Gear housing complete

Armature

Carbon brush 4x22 Tapping screw (4pcs.)

P 3/ 10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-1. Armature, Spiral bevel gear 11, Ball bearings 6000ZZ and 607ZZ (cont.)

Fig. 3

DISASSEMBLING

ASSEMBLING

(2) Remove Helical gear 11, Ball bearing 6000ZZ and Bearing retainer 69 from Armature. (Fig. 3)

(3) Remove Ball bearing 607ZZ from the commutator end of Armature. (Fig. 4)

(1) Do the reverse of the disassembling steps. (Figs. 4, 3, 2)

Note:

a. Do not forget to put two Flat washer 7 before assembling Ball bearing 607ZZ. (right in Fig. 4)

b. Put Flat washer 10, before assembling Ball bearing 6000ZZ. (center of Fig. 3)

c. Be sure to use new Retaining ring S-6 because removed one was damaged in the removal process. (left in Fig. 3)

d. Assemble Gear housing section to Motor housing by screwing four 4 x 22 Tapping screws. (Fig. 5)

4. Remove Retaining ring S-6

with 1R291. Helical gear 11

can now be removed by hand.

After removing Rubber ring 19, remove Ball bearing 607ZZ

with 1R269.

Remove two Flat washers 7 and

Insulation washer.

Spindle face from Gear housing section

to the opposite side of Switch knob of

Motor housing.

5. Remove Ball bearing 6000ZZ with 1R269,

and then remove Flat washer 10.

6. Armature can be now

removed from Bearing

retainer 69.

Armature

Bearing

retainer 69

Retaining

ring S-6

Helical

gear 11

Flat washer 10

Flat washer 7 (2pcs.)

Ball bearing

6000ZZ

1R269

Ball bearing 607ZZ Insulation

washer

Rubber ring 19

Fig. 4

Switch knob

Spindle

Fig. 5

P 4/ 10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Spiral bevel gear 36

Fig. 6

DISASSEMBLING

(1) Separate Bearing box from Gear housing complete and remove Ring spring from Spindle. (Fig. 6)

(2) Disassemble Spindle. (Fig. 7)

2. Opening Ring spring 11 with 1R004, lift the spring up from

the opposite side of 1R004 with Slotted screwdriver and

remove it from Spindle.

1. Separate Bearing box by unscrewing four M4 x 16

Pan head screws.

M4x16 Pan head

screw (4pcs.)

Bearing box

Ring spring 11

1R004

Fig. 7

1R026

3. Put Bearing box onto 1R232

and set 1R026 over Spindle.

7. Set 1R282 on Spindle, and remove

Spindle by pressing down with Arbor

press.

4. Set Ram of Arbor press to 20mm

higher position from the top of 1R026.

5. Strike 1R026 carefully with Ram until

Spindle is slightly shifted as illustrated

below.

6. Remove 1R026.

1R232

Bearing

box

20 cm

Spindle Ram

1R282

Spindle

Spiral bevel gear 36

Slotted screwdriver

Note: Do not reuse Ball bearing 6201DDW when Bearing box section is disassembled.

It is inevitably damaged.

P 5/ 10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-2. Spiral bevel gear 36 (cont.)

Fig. 8

DISASSEMBLING

(3) From Bearing box, remove Flat washer 12 and Ball bearing 6201DDW. (Fig. 8)

(1) Assemble Flat washer 12 and Ball bearing 6201DDW into Bearing box, and then set Retaining ring R-32

with 1R005. (Fig. 8)

Note: Ball bearing 6201DDW has to be replaced with new one. (Fig. 7)

(2) Assemble Spindle to Bearing box by pressing with Arbor press. (Fig. 7)

(3) Assemble Spiral bevel gear 36 to Spindle by pressing Arbor press and secure Spiral bevel gear 36

with Ring spring 11. (Figs. 7, 6)

Note: Removed Ring spring 11 is always deformed. (right in Fig. 6)

Fit Ring spring 11 to the groove of Spindle with pliers as illustrated in Fig. 9.

6. Remove Retaining ring

R-32 with 1R005.

7B. If the work mentioned

in 7A. is not successful,

remove Ball bearing

6201DDW and Flat

washer 12 with Arbor

press.

Retaining

ring R-32

1R005

Flat washer 12

Ball bearing

6201DDW

Ball bearing

6201DDW

7A. Remove Ball bearing

6201DDW and Flat

washer 12 by striking

Bearing box against

Worktable.

ASSEMBLING

Deformed

Ring spring 11

Ring spring 11 has to be corrected

with pliers to be fit to the groove.

Fig. 9

P 6/ 10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-3. Switch lever

DISASSEMBLING

ASSEMBLING

Disassemble Switch lever and Switch knob. (Fig. 10)

Assemble Switch lever and switch knob. (Fig. 11)

3. Bending Switch lever, pull it

out from Motor housing.

1. Blocking Switch knob to OFF position

by putting 1R281, strongly push

Switch lever as illustrated below.

2. Linkage of Switch knob is now

disconnected from Switch lever.

Switch knob can be removed.

Switch knob

Motor

housing

Switch knob

Switch

knob

2. Fit the hook of Switch Knob

to the hole of Switch lever.

Switch lever

1R281

Switch lever

Fig. 10

Fig. 11

Switch Switch

Rear end of

Switch lever

1. Insert Switch lever into Motor housing

until the hole of Switch lever comes

into sight through Switch knob

assembling hole on Motor housing.

And keep this position.

Motor

housing

Hook of

Switch knob

Front end of

Switch lever

P 7/ 10

Repair

[3] DISASSEMBLY/ASSEMBLY

[3]-4. Shaft Lock

DISASSEMBLING

ASSEMBLING

Assemble Shaft lock. (Fig. 13)

Fig. 12

(1) Remove Bearing box by unscrewing four M4 x 16 Pan head screws. (left in Fig. 6)

(2) Disassemble Shaft lock mechanism. (Fig. 12)

1. Setting 1R268 to Shoulder pin 4 through

the small hole on Pin cap, tap 1R268 with

Hammer. Shoulder pin 4 comes out from

Gear housing complete.

2. Slowly release 1R268 from Pin cap not to lose

Compression spring 8.

Note: Impossible to reuse Pin cap, because removal of

Shoulder pin 4 damages the inside surface of Pin cap,

producing plastic dust.

1R268

Pin cap

Compression

spring 8

Shoulder pin 4

Fig. 13

Plastic dust

Shoulder pin 4

3. Assemble Compression spring 8

and new Pin cap by pressing it to

Shoulder pin 4.

2. Insert Shoulder pin 4 through

hole of Gear housing complete.

Pin cap

Compression

spring 8

Shoulder

pin 4

Note: Do not reuse the removed Pin cap.

1. Remove all the plastic dust

from the constricted part of

Shoulder pin 4.

Circuit diagram

Wiring diagram

P 8/ 10

White

Color index of lead wires' sheath

Black

Fig. D-1

Fig. D-2

Fig. D-3

Noise suppressor is not used

for some countries.

Noise

suppressor

Terminal

block

Switch

Power supply cord

Field

Field lead wire (white)

to Switch

Field lead

wire (white)

Noise suppressor’s

lead wire (black)

Pull out Field lead wire

(white) from the opening

space designated with

gray color, and connect

it to Switch.

Pull out Field lead wire

(black) from the opening

space designated with

gray color, and connect

it to Terminal block.

Field lead wire (black)

to Terminal block

Wiring of Field lead wires

Wiring to Switch terminals

Rib for Switch knob

Inflecting Insulated connectors

as drawn to right, connect them

to Switch terminals.

Wiring diagram

P 9/ 10

Bottom view

Switch

Fix the following Lead wires with this

lead wire holder.

* Field lead wire (white)

* Noise suppressor’s lead wire for

connecting Switch (black)

And tighten them between this Lead

wire holder and Switch terminals.

Rib B

Put the following Lead wires, for

connecting to Switch, between

Rib A and Rib B.

* Noise suppressor’s Lead wire (black)

* Field lead wire (white)

Fix the following Lead wires, for connecting

to Terminal block, with Lead wire holders.

* Noise suppressor’s Lead wire (black)

* Field lead wire (black)

Rib A

Noise suppressor’s

lead wires (black)

Terminal block

Field lead wire (black)

Field lead wire

(white)

Noise suppressor

Switch

Fig. D-4

Fig. D-5

Wiring on Support

Right side view

Lead wire of

Noise suppressor (black)

Filed lead wire (white)

Filed lead wire

(white)

Fix Lead wires of Power supply cord

with Lead wire holder.

Lead wires of

Power supply cord

Wiring diagram

P 10/ 10

Put Noise suppressor to the

illustrated position, if it is used.

Fig. D-6

Tighten Field lead wire (white) in this section.

And passing under Noise suppressor, connect it to Switch.

When passing the Field lead wire (white) under Noise suppressor,

put it into the groove as illustrated in Fig. A.

Wiring on Support

Fig. A

Fig. B

When passing Field

lead wire (white) under

Noise suppressor, put it

into the groove.

Switch

Terminal block

Lead wire

holder

Field lead wire (white)

Top view

Fig. D-7

Left side view

Switch

Field lead

wire (white)

Field lead

wire (black)

Tighten Field lead wire (black) between

Lead wire holder and Terminal block.

Hook

Noise suppressor

Noise suppressor’s

lead wires

Hook

Pass Noise suppressor’s

lead wires (black) and

Field lead wire (white)

through Hook.

Groove

Field lead

wire (white)

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