Makita BO6040 Manual

Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output(W)
110
120
220
230
240
Models No.
Description
PRODUCT
Current (A)
TECHNICAL INFORMATION
CONCEPTION AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
< Note > The standard equipment for the tool shown may differ from country to country.
P 1 / 10
BO6040
150 mm Random Orbit Sander
W
L
H
Dimensions : mm ( " )
Width ( W )
Height ( H )
Length ( L )
150 (5-7/8)
132 (5-3/16)
316 (12-1/2)
Orbits per min. : (min -1= spm)
Orbit diameter : mm (")
Pad diameter : mm (")
Net weight :Kg (lbs )
Cord length : m ( ft )
1,600 - 5,800
3,200 - 11,600
180 - 670
5.5 ( 7/32)
150 ( 6 )
2.5 ( 8.2 )
2.7 ( 5.9 )
7.2
6.6
3.6
3.4
3.3
50 / 60
50 / 60
50 / 60
50 / 60
50 / 60
750 390 850
750 390 850
750 390 850
750 390 850
750 390 850
* Pad 150 (soft ) ........................................................... 1pc. (factory-attached to the machine)
* Abrasive disc 150-120 (Hook and loop type) ........... 1 pc.
* Hex wrench 6 ........................................................... 1 pc.
* Joint ........................................................................... 1 pc. ( only for European market)
* Pad 150 ( hard)
* - ditto - ( soft)
* - ditto - ( super soft)
* Abrasive disc 150 - 40, 60, 80, 120, 180, 240, 400
* Sanding cloth 150 - 100, 200, 800
* Sponge pad 150 ( hook and loop type)
* Felt pad 150 ( hook and loop type )
* Wool pad 150 ( hook and loop type )
* Side grip
This models is versatile random orbit sander for
professional use.
Due to the two mode selection,
"Forcible rotation mode" / "Free-rotation mode",
rough sanding, fine finishing and polishing can be done
only with this machine.
Oscillation rate per min.: spm = min-1
Rpm.of pad with Forcible-Rotation : rpm = min-1

Repair P 2 / 10
< 1 > Replacing armature and spiral bevel gear 9
1) Take off tapping screw 4x18 and detach rear cover from motor housing.
And detach carbon brush as illustrated in Fig1.
Tapping screw 4x18
Rear cover
Motor housing
Carbon brush
Fig. 1
2) Put the torsion spring installed on brush holder, on the side of brush holder after detaching carbon brush
as illustrated in Fig.2. This is necessary for avoiding to scratch the armature's commutator, when armature is
pulled out from motor housing.
3) After pulling out armature from motor housing, remove retaining ring 6 with retaining ring plier, and detach
spiral bevel gear 9 as illustrated in Fig.3.
4) Remove armature from gear housing cover
by pressing the armature shaft with arbor press
as illustrated in Fig.4.
5) Take reverse step of the above, when
assembling armature and spiral bevel gear.
Fig.2 Fig.2A
The torsion spring put on the side of
brush holder
The torsion spring positioned as illustrated
in Fig.2A can scratch the armature's commutator.
Torsion spring
Brush holder
It is not necessary to remove brush holder itself, when removing armature.
Motor housing
Spiral bevel gear 9
Gear housing cover
Retaining ring 6
Armature
Fig.3
Gear housing cover
Armature
Flat washer 12
Bal bearing 6001LLB
Press
Fig.4

Repair P 3 / 10
< 2 > Replacing ball bearing 6201LLB installed in skirt
(1) Unscrew flat head screw M8x11
and detach head cover from gear housing. See Fig.5.
Fig. 5
(2) Unscrew pan head screw M4x12 and
detach skirt from gear housing. See Fig.5.
(3) Unscrew pan head screw M4x12 and
detach bearing retainer 80 from skirt. See Fig.6.
Flat head
screw M8x11
Head cover
Pan head
screw M4x12 x 4 pcs.
Gear housing
Skirt
Fig. 6
Skirt
Pan head
screw M4x12 x 3 pcs.
Bearing retainer 80
Hex nut M10
Fig. 7
(4) Set box wrench 17 on hex nut M10 and insert hex wrench 6 into the hole
of "spur gear 26 complete" as illustrated in Fig. 7. And loosen hex nut M10 with box wrench 17.
Hex wrench 6
Box wrench 17
View from hex nut 10 side
View from pad setting side
Box wrench 17 Hole of
"spur gear 26 complete"
"Spur gear 26 complete"
including sleeve,
2 ball bearings 6001DDW
and retaining ring S-12

Repair P 4 / 10
(4-A) If "spur gear 26 complete" is loosened first,
Remove "spur gear 26 complete". And loosen hex nut M10 with box wrench 17, gripping upper balance weight
with monkey wrench 250mm. See Fig. 8.
(4-B) If hex nut M10 is loosened first,
Tighten hex nut M10 provisionally And remove upper balance weight with monkey wrench 250m,
holding "spur gear 26 complete" with hex wrench 6. See Fig. 9.
Fig. 8
"Spur gear 26 complete"
(including sleeve,
ball bearing 6001DDW x 2 pcs.
and retaining ring S12)
Box wrench 17
Monkey wrench 250mm
Upper balance
weight Spiral bevel gear 42
Fig. 9
Hex wrench 6
Monkey wrench 250mm Hole of
"spur gear 26 complete"
(5) Remove flat washer 10, upper balance weight and spiral bevel gear42 from spindle as illustrated in Fig.10.
Fig.10
Flat washer 10
Upper balance weight
Spiral bevel gear42
Spindle
Upper balance weight
Sleeve
Ball bearing 6001DDW
Ball bearing 6001DDW
Retaining ring S12
Spur gear 26
Spur gear 26 complete

Repair P 5 / 10
(7) Remove internal gear 29, ball bearing 6811LLB and stop ring WR-55 by striking skirt on the work-table
covered with soft sheet as illustrated in Fig.11. And then, remove lower balance weight.
Skirt
Internal gear 29
Ball bearing
6811LLB
Stop ring WR-55
Lower balance
weight
Fig.11
(8) Remove spindle from skirt with arbor press as illustrated in Fig. 12. Take off 3 pan head screws M4x12
holding ball bearing 6201LLB. And then, remove ball bearing 6201LLB with arbor press from skirt.
(9) Assembling skirt section
(9-1) Assemble ball bearing 6201LLB by pressing it with arbor press. Fix the ball bearing 6201LLB
with 3 pan head screws M4x12. And then, assemble spindle with arbor press.
See Fig. 13.
Spindle
Press spindle with
arbor press. 3 Pan head
screws M4x12
Round bar for arbor
Press ball bearing with
arbor press.
Ball bearing 6201LLB
Fig. 12
Strike on the work-table
3 Pan head
screws M4x12
Spindle
Round bar for arbor
Press spindle with
arbor press.
Ball bearing
6201LLB
Round bar
for arbor
Press spindle with
arbor press.
Fig. 13

Repair P 6 / 10
Flat washer 10
Upper balance
weight
Spiral bevel
gear42
Spindle
(9-2) Assemble spiral bevel gear 42,upper balance weight and flat washer 10. And then, tighten
hex nut M10 provisionally. Assemble internal gear 29 after installing lower balance weight.
(9-3) Set box wrench 17 on hex nut M10 and insert hex wrench 6 into the hole
of "spur gear 26 complete" as illustrated in Fig. 15. And fasten hex nut M10 with box wrench 17.
Hold bearing retainer 80 with 3 pan head screws M4x12.
Fig. 14
Hex nut M10
Lower balance
weight
Internal gear 29
Hex wrench 6
Box wrench 17
Hole of
"spur gear 26 complete"
Fig. 15
Pan head
screw M4x12 x 3 pcs.
< Note > Apply grease on the sponge portion of bearing retainer 80.
Rubber guard
Assemble it in the groove of skirt firmly,
after installing bearing retainer 80.
Bearing retainer 80
Apply grease on
the sponge portion

Repair P 7 / 10
< 3 > Replacing ball bearing 6001DDW installed in "spur gear 26 complete"
See Fig. 16.
1) In order to replace ball bearing 6001DDW, the removed spindle is
needed as a repairing tool.
Screw spindle into sleeve installed in "spur gear 26 complete"
as illustrated in Fig. 17.
2) Hold "spur gear 26 complete" with No.1R232 pipe 30 and
No.1R037 bearing setting plate as illustrated in Fig. 18.
Remove spindle together with sleeve unit (including
2 ball bearings 6001DDW and retaining ring S-12)
from spur gear 26, by pressing No.1R235 "round bar for arbor"
with arbor press as illustrated in Fig. 18. And then, remove spindle from sleeve unit by unscrewing.
3) Remove retaining ring S-12 from sleeve with retaining ring plier ST-1.
Press No.1R235 "round bar for arbor" set on sleeve. Then, Ball bearing 6001DDW can be separated
from sleeve. See Fig. 19.
Fig. 16
Fig. 17
Sleeve
Ball bearing 6001DDW
Ball bearing 6001DDW
Retaining ring S12
Spur gear 26
Spur gear 26 complete
Spindle
Fig. 18
No.1R232 Pipe 30
No.1R037 Bearing
setting plate
Arbor press
Spur gear 26 complete
No.1R235 Round bar for arbor
No.1R037 Bearing
setting plate
Sleeve unit
Spur gear 26
Spindle
Sleeve unit
Retaining ring S-12
Sleeve
Ball bearing
6001DDW
Sleeve
No.1R235 Round
bar for arbor
Remove from sleeve unit
by unscrewing.
Fig. 19

Repair P 8 / 10
4) Assembling ball bearing 6001DDW installed in "spur gear 26 complete"
Assemble sleeve to new ball bearings 6001DDW by pressing it, and assemble retaining ring S-12 to sleeve.
And then, press them into spur gear 26. See Fig. 20.
Ball bearing 6001DD
Sleeve
Fig. 20
Spur gear 26
Retaining ring S-12
< 4 > Replacing ball bearing 6811LLB installed in internal gear 29
1) Remove stop ring WR-55 with No.1R003 retaining plier from internal gear 29. The, ball bearing 6811LLB
can be removed from internal gear 29 with hand. See Fig. 21.
< 5 > Replacing holder for action mode change
Ball bearing
6811LLB
Internal gear 29
Stop ring WR-55
Fig. 21
When assembling ball bearing 6811LLB, take reverse step of Fig. 21.
3) Remove holder from skirt. And apply grease
to the surface of new holder.
4) When assembling, install new holder, compression spring 4,
spring holder and knob. And assemble cap
by fastening it with pan head screw M4x12.
Cap
Pan head screw
M4x12
Knob,
Spring holder
Compression
spring 4
Holder
2) Detach cap. And then, remove pan head screw
M4x12, knob, spring holder and compression
spring 4 as illustrated in Fig. 22.
1) Install unit of internal gear 29 (including
ball bearing 6811LLB and stop ring WR-55)
in skirt.
Fig. 22

Circuit diagram P 9 / 10
Controller
Speed
Control
Dial
Field
Brush holder
( controller side )
Brush holder
( switch block side )
SB1
SB2
SB3
Switch block
Power supply
cord
SB4
White or blue
White
Black
P2
P1
Model BO6040
< Note >
The lead wire (orange) for connection of controller and brush holder is not used in some countries.
Fig. 23
White
Red
Orange

Fix lead wires of controller
with lead holder.
Put their slack part in the place
as illustrated in Fig.25.
Do not loosen the lead
wires of filed in motor
housing.
Put the loosened ones in the
place as illustrated
in Fig.25.
Put lead wires of power
supply cord by strain relief
as illustrated in Fig. 25.
Wiring diagram P 10 / 10
Put the lead wires of controller in the lead holder
so that they are not slacken.
Be careful not to loosen the lead wires of field in motor housing.
Put the loosened lead wires in the above place.
Model BO6040
Speed
Control
Dial
Fig. 25
Fig. 24
Pin A
Pin B
Fix lead wire of controller with lead holder
between pin A and pin B.
Inflect the lead wire at the terminal
in right angle. See Fig 24A.
Fig.24A
Sink plate
Controller
Terminal