Makita KP0800 Manual

PRODUCT
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
P 1/ 8
Specification
Standard equipment
Optional accessories
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
110
120
220
230
240
5.9
6.5
3.0
2.9
2.7
50/60
50/60
50/60
50/60
50/60
620
---
620
620
620
280
360
280
280
280
650
650
650
650
650
Current (A)
Dimensions: mm (")
Width (W)
Height (H)
Length (L) 285 (11-1/4)
158 (6-1/4)
158 (6-1/4)
Model KP0800 has been developed as the successor model of
N1900B and 1902.
Additionally to the same well balanced design for easy handling,
features the following main advantages;
Planing depth adjustment knob for precise depth setting
Power input of 620W
New aesthetic design
Also available with plastic carrying case as Model KP0800K.
L
W
H
* Weight according to EPTA-Procedure 01/2003
82 (3-1/4)
2.5 (3/32)
9 (11/32)
2.6 (5.7)
Brazil, Australia: 2.0 (6.6), Other countries: 2.5 (8.2)
17,000No load speed: min-1=rpm
Planing width
Planing depth
Shiplapping
Net weight*: kg (lbs)
Double insulation
Power supply cord: m (ft)
Protection against electric shock
Capacities: mm (")
Planer blade (re-sharpenable type) or T.C.T. Mini planer blade (disposable type)
Sharpening holder assembly (for countries using re-sharpenable type Planer blade)
Dressing stone (for countries using re-sharpenable type Planer blade)
Blade gauge assembly
Socket wrench 9
Guide rule
Dust nozzle
Plastic carrying case (for KP0800K)
Note: The standard equipment for the tool shown above may vary by country.
Planer blade (re-sharpenable type)
T.C.T. Mini planer blade (disposable type)
Set plate (for countries using T.C.T
Mini planer blade)
Dust bag assembly
Blade gauge assembly
Sharpening holder assembly
Plastic carrying case
Guide rules
Extension guide set
Dust nozzle
Elbow
Models No.
Description
KP0800
Power Planer 82mm (3-1/4")

Repair
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATIONS
Fig. 1
17
24
Code No.
Apply the following lubricants to protect parts and product from unusual abrasion.
Description Use for
1R004 Retaining ring pliers ST-2 Removing / mounting Retaining ring S-8
1R045 Gear extractor (large) Removing Armature from Bracket
1R263 Bearing extractor Removing Knob cover
1R269 Bearing extractor (small) Removing Ball bearings
1R346 Center attachment Using with 1R045
Item No. Description Portion to lubricate Lubricant Amount
a little
17 Cam plate
24 Front base complete
The surface where Knob contacts
(a) Cylindric portion where Main frame contacts
(b) Thread portion
(a)
(b)
Knob
Main frame
complete
Rubber plate
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Remove the blades before repair.
Makita grease N No.2
VG100
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Poly V-belt 4-241
DISASSEMBLING
Fig. 2 Fig. 3
M4x16 Pan
head screw
Remove M4x16 Pan head screw and separate Belt cover from Main frame complete.
Cut Poly V-belt 4-241 with nippers when it has damaged. (Fig. 2)
Note: When replacing Armature, Drum and V Pulleys and reusing Poly V-belt 4-241,
Lever up Poly V-belt 4-241 with screwdriver while turning V pulley 4-37 as illustrated in Fig. 3.
Poly V-belt can be removed without cutting.
Belt cover
V pulley 4-37
Poly V-belt 4-241
Main frame
complete
P 2/ 8

Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-1. Poly V-belt 4-241 (cont.)
ASSEMBLING
DISASSEMBLING
Fig. 4 Fig. 5
1) Hook Poly V-belt 4-241 with V-pulley 4-20L. (Fig. 4 )
2) Hook a part of Poly V-belt with V-pulley 4-37. (Fig. 4 )
3) Turn V-pulleys 4-20L and 4-37 counterclockwise by hands to fit Poly V-belt 4-241 to the V-pulleys while holding
Poly V-belt firmly. (Fig. 4 )
Note: If it is difficult to completely fit Poly V-belt to V-pulleys, continue turning V-pulleys until all the grooves are
engaged with the protrusions of V-belt.(Fig. 5)
V-pulley 4-20L
on Motor side
1 2
3
1
2
3
V-pulley 4-37 on Drum side Protrusions on Poly V-belt 4-241
Two positions of
Poly V-belt 4-241 Grooves on V-pulleys
[3]-2. Motor section
Fig. 6 Fig. 7
Fig. 8 Fig. 9
1) Remove Belt cover and Poly V-belt 4-241 as illustrated in Fig. 2 or Fig. 3
Note: Separating Armature from Bracket is impossible without removing Poly V-belt.
2) Loosen M4x16 Pan head screw and remove Chip cover. (Fig. 6)
3) Remove Brush holder caps and Carbon brushes, then remove four 4x18 Tapping screw on Bracket. (Fig. 7)
4) Remove Bracket by tapping Main frame complete. (Fig. 8) Armature and Drum complete come with Bracket.
5) Hold Armature by gloved hand and turn V-pulley 4-20L clockwise using wrench 13. (Fig. 9)
V-pulley 4-20L can be removed.
Note: V-pulley 4-20L has a left hand thread.
.
Wrench 13
M4x16 Pan head screw Carbon brush
Bracket
Bracket
Bracket
Brush holder cap
4x18 Tapping
screw (4pcs.)
Chip cover
V-pulley 4-20L
Armature Drum complete
P 3/ 8

Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-2. Motor section (cont.)
DISASSEMBLING
ASSEMBLING
Fig. 10
Ball bearing
6000DDW
Armature
6) Remove Armature from Bracket using 1R045 with 1R346. Then remove Ball bearing 6000DDW with 1R269. (Fig. 10)
7) There are few clearance between Insulation washer and Ball bearing 607DDW. Therefore, it is hard to insert the jaws
of 1R269.
Remove Ball bearing 607DDW and Insulation washer while holding the jaws of 1R269 using water pump pliers.
(Fig. 11)
Take the disassembling step in reverse.
Note: When assembling V-pulley 4-20L to Armature shaft using Wrench 13, it is not necessary to tighten the V-pulley
to very high torque.
Driving of Poly V-belt 4-241 prevents V-pulley 4-20L from being loose.
1R269
1R045
Water pump pliers
1R346
Fig. 11
Ball bearing 607DDW
Insulation washer
P 4/ 8

Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Drum section
DISASSEMBLING
Fig. 12
(1) Remove Chip cover and Carbon brushes, and separate Bracket from Main frame complete.
(2) Remove V Pulley 4-37, then separate Drum from Bracket as illustrated in Fig. 12.
Note: V-pulley 4-37 has a right handed thread.
Wrench 13
Drum can be removed from Bracket.
Remove Ball bearing 6000DDW with 1R269.
V- pulley 4-37
Remove V- Pulley 4-37 by turning it with Wrench 13
counterclockwise.
Armature
1R269
Ball bearing
6000DDW
Drum complete
Ball bearing
6000DDW
ASSEMBLING
Fig. 13
Fig. 14
The clearance between Ball bearing 608DDW and Drum is too small to insert
the jaws of 1R269.
Therefore, sharpen the jaws.
Ball bearing
608DDW
Drum
Insert the jaws of 1R269 into the clearance Ball bearing 608DDW and Drum,
and fix the jaws of 1R269 in Vise.
Remove Ball bearing 608DDW from Drum.
Ball bearing 608DDW
(3) Remove Ball bearing 608DDW with 1R269 as illustrated in Figs. 13 and 14.
Take the disassembling step in reverse. Refer to Figs. 14, 13 and 12.
Take the disassembling step in reverse.
Note: When assembling V-pulley 4-37 to Drum using Wrench 13, it is not necessary to tighten the V-pulley
to very high torque.
Reaction torque caused by stopping the rotation prevents V-pulley 4-37 from being loose.
P 5/ 8

Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Front base, Base (rear)
DISASSEMBLING
ASSEMBLING
Fig. 16
Fig. 15
(1) Front base and Bas (rear) can be removed as illustrated in Fig. 15.
1) Assemble Foot to Base (rear) before assembling Base to Main frame as illustrated in Fig. 16.
2) Assemble the Base with Foot to Main frame. And assemble Front base section to Main frame complete.
No need to assemble retaining ring S-8 to thread portion of Front base in this step. Refer to Fig. 15.
1R263
1R263 Knob cover
Remove Knob cover by levering up
with 1R263.
Retaining ring S-8, M10 Hex nut and
thread portion of Front base come
into sight.
Knob
Knob
Knob Knob
Retaining ring S-8
Remove Retaining ring S-8
with 1R004 from thread portion
of Front base.
Thread portion
of Front base
M10 Hex nut
M10 Hex nut
Knob cover
Use Knob cover as a socket wrench
temporarily for removing M10 Hex nut.
Turn Knob cover counterclockwise
while fixing Knob by hand.
M10 Hex nut can be removed from
the thread of Front base.
Front base
Compression spring 18 Base (rear)
Foot can be removed
in separating Base from
Main frame complete.
Remove Base (rear) by unscrewing four 4x18
Tapping screws.
4x18 Tapping
screw (4pcs.)
Front base can be removed as illustrated below.
Foot
Pass the long pin of Foot through Torsion spring 7.
Hook this tail
with Foot.
Long pin
of Foot
Torsion spring 7
Foot
Hook this tail with
Base (rear).
Base (rear)
P 6/ 8

Repair
[3] DISASSEMBLY/ASSEMBLY
[3]-3. Front Base, Base (rear)
ASSEMBLING
3) Adjust the level of Bases as illustrated in Figs. 17 and 18.
(4) Set Retaining ring S-8 in place. And install Knob cover by pressing to Knob as illustrated in Fig. 19.
Attach Rule to Base (rear) as illustrated in Fig. 17F and turn Knob cover clockwise until Front base
contacts the rule completely as illustrated in Fig. 17R.
Planing depth will be set at zero level by the above adjustment.
Front base Base (rear)
Front base
Base (rear)
Drum Drum
Front base Base (rear)
Fig. 17RFig. 17F
Fig. 17
Fig. 18
Fig. 19
Rule
Knob cover
Align the indication “0” on Knob to the triangle mark on Main frame complete,
while holding M10 Hex nut with Knob cover so as not to move.
Knob
M10 Hex Nut that has been adjusted
to the position of 0mm planing depth.
Knob cover functioning
as Socket wrench temporarily
Knob
Retaining ring S-8
Thread portion
of Front base
M10 Hex nut
P 7/ 8

Circuit diagram
Wiring diagram
P 8/ 8
Brown color is used
for some countries.
White color is used
for some countries.
White
Color index of lead wires' sheath
Black
Switch
Switch
Noise suppressor
Fig. D-1
Fig. D-2
Field
Noise
suppressor
Insulated connector is used for some
countries, instead of Terminal block.
If using Noise suppressor, put it
in the position illustrated.
Terminal
block
Terminal block
Power supply cord
If Insulated connector is used in
stead of Terminal block, put it in
the same position.
Rib
Lead wire holder
Route Field lead
wire near Rib.
Tightening the Field lead wires
in the Motor section, put them
in Lead wire holder.
Put their sag in Handle.