Makita 9561CR Manual

PRODUCT
P 1/ 9
TECHNICAL INFORMATION
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Note: The standard equipment for the tool shown above may differ by country.
9561CR/9561CVR, 9562CR/9562CVR
Angle Grinders 115mm (4-1/2"), 125mm (5")
Models 9561CR/9561CVR, 9562CR/9562CVR are upgraded sister tools of
9561CH/9561CVH, 9562CV/9562CVH, featuring anti-restart function for
added safety.
Side grip (standard soft grip) ........ 1 (Anti-vibration grip instead if required)
Toolless wheel cover ..................... 1 (Standard type instead if required)
Lock nut wrench ........................... 1
Depressed center wheel ................ 1 (115-24 for 9561CR/9561CVR, 125-24 for 9562CR/9562CVR)
Model No.
No load speed:
min.-1 = rpm
Diameter
Hole diameter
Wheel size:
mm (")
Protection against electric shock
Power supply cord: m (ft)
Net weight: kg (lbs)
Weight according
EPTA-Procedure 01/2003*: kg
9561CR 9561CVR 9562CR
115 (4-1/2)
Australia, Chile, Brazil : 2.0 (6.6), Other countries: 2.5 (8.2)
2.2 (4.8)
11,000
125 (5)
9562CVR
Double insulation
22.23 (7/8)
Super Joint System (SJS) Yes
2.2
North America
Other countries
10,500
11,000
10,500
Optional accessories
9561CR/ 9561CVR: Same optional accessories as available for 9561CH/ 9561CVH
9562CR/ 9562CVR: Same optional accessories as available for 9562CH/ 9562CVH
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
Model No.
289 (11-3/8)
9561CR
9561CVR
9562CR
9562CVR
129 (5-1/8) 139 (5-1/2)
103 (4-1/16)
L
H
W
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output
750
Max. Output (W)
110
120
220
230
240
11.5
11.0
5.7
5.5
5.3
50/60
50/60
50/60
50/60
50/60
1,200
---
1,200
1,200
1,200
2,000
2,000
1,800
2,000
2,000
Current (A)
750
800
800
800
*with Wheel cover, Inner flange, Lock nut, Side grip; without Power supply cord
2,800 - 11,000
2,800 - 10,500
2,800 - 11,000
2,800 - 10,500
Yes
Yes
Yes
Yes
Constant speed control
Variable speed control by dial
Soft start
Electronic current limiter
Anti-restart function
Electronic
control
YesYes NoNo

P 2/ 9
Repair
CAUTION: Unplug the tool and remove the wheel cover and grinding wheel from the machine
for safety before repair/ maintenance in accordance with the instruction manual!
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATIONS
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature, Spiral Bevel Gear 11 on Armature shaft
Fig. 1
Code No. Description Use for
1R217 Ring 22 Supporting Bearing box when Removing spindle from Spiral bevel gear 38
1R041 Vise plate Use with Vise to protect the clamped part
1R268 Spring pin extractor 3 Removing Pin for Shaft lock
1R269 Bearing extractor Removing Ball bearing 627DDW from Armature of commutator end
1R291 Retaining ring S & R pliers Removing / mounting Retaining ring S-12 from / to the drive end of Armature
shaft
1R340 Bearing retainer wrench Removing / mounting Bearing retainer
1R350 Ring 60 Supporting Gear housing when removing Pin for Shaft lock
Item No.
Apply Makita grease SG No.0 and Disulfied molybdenum to the following portions designated with triangles to protect
parts and product from unusual abrasion.
Description Portion to lubricate Lubricant Amount
DISASSEMBLING
3M6 Hex. nut
Flat washer 6
6
7
6
7 Lock ring 12
Armature
3 Gear housing complete Gear room
Cylindrical portion where armature shaft
is inserted
Cylindrical portion which accepts 6 ‘s drum
portion
Makita grease SG No.0.
Spiral bevel gear 11
15g
a little
Disulfied molybdenum
(1) In order to protect Armature’s commutator, disconnect carbon brushes from the Commutator as illustrated in Fig. 2.
4x18 Tapping screw
First, remove Rear cover by unscrewing
4x18 Tapping screw.
Shift Spiral spring from
Carbon brush top.
Disconnect Carbon brush from
commutator by pulling up.
No need to remove.
Rear cover
Brush holder
Fig. 2

P 3/ 9
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature, Spiral Bevel Gear 11 on Armature shaft (cont.)
DISASSEMBLING
Gear housing
complete
Gear housing
cover
Motor housing
Armature
M6 Hex nut
Wrench 10
4x18 Tapping
screw (4pcs.)
(2) Remove Motor housing and Gear housing complete by loosening 4x18 Tapping screws (4pcs.). And then remove
M6 Hex nut from Armature as illustrated in Fig. 3.
Fig. 3
Spiral bevel
gear 11
Remove Flat washer 6.
Hooking Spiral bevel gear 11 with the jaws of 1R269, remove the gear together
with Lock spring 12.
Lock spring 12 Spiral bevel gear 11
Lock spring 12
Armature
1R269
Armature
Remove Retaining ring S-12. And remove Armature from Gear housing cover with arbor press.
Now the disassembly of Armature’s drive end is finished.
Retaining
ring S-12
1R291
Fig. 4
Fig. 5
Retaining
ring S-12
(3) Armature’s Drive end can be disassembled as illustrated in Figs. 4, 5.
(4) Armature’s Commutator end can be disassembled as illustrated in Fig. 6.
Fig. 6
Remove three tabs of Self lock 6 from
Armature shaft with tweezers, and
separate Self lock 6 from Armature.
Remove Magnet sleeve, Wave washer 6
and Labyrinth rubber ring 22 .
Remove Ball bearing
627DDW with 1R269.
Remove Flat washer 7
and Insulation washer.
Self lock 6
Tweezers
Wave
washer 6
Magnet
sleeve
Labyrinth
rubber
ring 22
Ball
bearing
627DDW
1R269
Flat
washer 7
Insulation
washer

P 4/ 9
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Armature, Spiral Bevel Gear 11 on Armature shaft (cont.)
ASSEMBLING
Fig. 7F Fig. 7R
Wrong
Wave washer 6 can
not press Magnet
sleeve toward Self
lock 6 to stabilize
Magnet sleeve.
Press down Self lock 6 until
Wave washer 6geats flat.
Magnet sleeve is
stabilized between
Self lock 6 and
Wave washer 6
by the reaction of
Wave washer 6.
Return tabs of Self lock 6 to their
normal shape before assembling.
Correct
Wave washer 6
Magnet sleve
Self lock 6
(1) Assemble Armature to Gear housing cover. Refer to Fig. 5.
(2) Assemble Lock spring 12 and Spiral bevel gear (small). Refer to Fig. 4.
< Note> Lock spring 12 has to be replaced with the fresh one, when Spiral bevel gear (small) is replaced.
(3) Assemble M6 hex nut or Retaining ring. Refer to Fig. 3.
(4) Assemble the commutator end of Armature as illustrated in Fig. 7R.
(5) Assemble Gear housing cover with Armature and Gear housing complete to Motor housing as illustrated in Fig. 8.
Gear housing complete
Gear housing cover
Spindle
Spindle has to be located on bottom side when Switch
knob is controled by the right hand thumb.
Fig. 8
Right hand thumb
Switch knob
[3]-2 Spiral Bevel Gear 38 on Spindle and Ball Bearing 6201DDW
DISASSEMBLING
Strike the illustrated position with Plastic hammer
if it is difficult to remove the Bearing box by hand.
Bearing box
M4x16 Hex socket
head bolt (4pcs.)
Remove M4x16 hex socket head bolt.
When disassembling the above mentioned parts from Bearing box, it is not necessary to disassemble Gear housing
complete from Motor housing.
(1) Remove bearing box from Gear housing complete as illustrated in Fig. 9.
Fig. 9

P 5/ 9
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2 Spiral Bevel Gear (large) on Spindle and Ball Bearing 6201DDW
DISASSEMBLING
Spindle Labyrinth ring
Spindle
Spiral bevel
gear (large)
Bearing Box
(2) Spiral bevel gear (large), Spindle, Labyrinth ring, Ball bearing 6201DDW are disassemble from Bearing box in
the order of Figs. 10, 11, 12 or 12A.
Remove Spindle with Arbor press. Now Spiral bevel gear 38 and Labyrinth
ring are removed from Bearing box.
Fig. 10
Fig. 11 Fig. 12
Fig. 12A
1R217
1R217
1R217
Spiral bevel gear 38
Bearing box
Bearing
retainer
Bearing
retainer
Ball bearing
6201DDW
Ball bearing
6201DDW
1R041
1R340
Fit the claws of iR340 to the groove of Bearing retainer.
And turn it counterclockwise. Now Bearing retainer is
removed from Bearing box.
Fix Bearing retainer with Vise.
Use 1R041 to protect Bearing retainer.
Strike Gear housing gently with work table
to remove Ball bearing 6201DDW.
If it is difficult to remove Ball bearing 6201DDW as illustrated in Fig. 11,
Use Arbor press.
Note: Cover the work table with something
soft to avoid the damage on Gear
housing before disassembling.
Ball Bearing
6201DDW
Bearing boxRound bar
for Arbor

P 6/ 9
Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3 Shaft Lock Mechanism
Applying 1R268 to Shoulder pin 5 through the small Hole
on Pin cap, strike 1R268 with Hammer.
Now, Shoulder pin 5 comes out from Gear housing complete.
Release 1R268 from Pin cap, while paying
Attention that the Pin cap would not be
slung by Compression spring 8.
Shoulder pin 7
Disassemble Shaft lock mechanism as illustrated in Fig. 15, 16.
Take the disassembling step in reverse.
Note: Be sure to apply adhesive to the threads of M4x16 Hex. socket head bolts (4pcs.) for securing Bearing box to Gear
housing complete when reusing the bolts.
Pin cap
Impossible to reuse Pin cap, because
removal of Shoulder pin 4 damages the
inside surface of Pin cap, producing
plastic dust.
Pin cap
Pin cap
Compression
Spring 8
1R268
1R350
Fig. 15 Fig. 16
ASSEMBLING
Fig. 17 Fig. 18
(1) Be sure to use a new Pin cap for replacement and to remove all the plastic dust on Shoulder pin 5. (Fig. 17)
(2) Assemble the components for Shaft lock mechanism as illustrated in Fig. 18.
Plastic Dust
O Ring 6
Shoulder Pin 7
Shoulder
pin 7
Assemble Pin cap by pressing it
to Shoulder pin 7.
Insert Shoulder pin 5
through the Hole of Gear
housing complete. Pin cap
Do not forget to assemble
Compression spring 8.
Compression
spring 8
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
[3]-2 Spiral Bevel Gear (large) on Spindle and Ball Bearing 6201DDW (cont.)
ASSEMBLING

Circuit diagram
P 7/ 9
Color index of lead wires' sheath
Black
White
Red
Blue
Noise
Suppressor
Noise Suppressor is built in the Switch block.
However, that without Noise suppressor
is used for some countries.
This Lead wire
is blue for some
countries. This Lead wire is
brown for some
countries.
This Lead wire is white
for some countries.
Switch lever
side
Controller
Brush
holder
Brush
holder
Field viewed
from Rear
cover side
Switch
Switch lever
The dotted lines in Switch
block are built in plate lead.
Fig. D-1
Switch block

Wiring diagram
P 8/ 9
Field lead wire (red)
Put sag portion of Field lead wire (red)
in this position.
Tighten Field lead wires (red, black)
in Motor housing.
Switch lever
Dial of controller
(for 9561CVR and
9562CVR only)
(Bottom view)
Fix Controller’s Lead wire
(blue or white) and that of
(red) with this Lead wire
holder.
Controller’s Lead wire
(blue or white)
Controller’s Lead wire
(red)
Field lead wire (black)
Brush holder
Motor housing
Fig. D-1
Motor housing

Wiring diagram
P 9/ 9
(right side view)
Lead wire of Power supply
cord (black or brown)
Guide Lead wire of Power
supply cord (black or brown)
between Strain relief and Rib.
Fig. D-3
Motor housing
Brush holder
Fix Controller’s lead
wire (black) with
Lead wire holder
Strain relief
Field lead wire (red)
connecting with
Switch block
Controller’s
Lead wire (black)
Controller’s
Lead wire (red)
Controller’s Lead wire
(blue or white)
Lead wire holder
Rib
Tighten Field lead wires (red, black)
in Motor housing.
Put sag portion of Field lead wire (red)
in this position.
Put sag portion of Controller’s
lead wires (red, blue or white)
in this position.
Put sag portion of Controller’s
lead wires (black) in this position.