Makita M9204 Manual

Dimensions: mm (")
Length(L)
153 (6)
Width (W)
123 (4-7/8)
Height (H)
144 (5-5/8)
Specification Model
M9204
Orbits per minute: opm= min-1
12,000
Sanding strokes: spm= min-1
24,000
Paper fastening system
Hook & Loop
Pad size: mm (")
ø123 (4-7/8)
Abrasive paper size: mm (")
ø125 (5)
Orbit diameter: mm (")
ø2.8 (1/8)
Sanding pad brake
Yes
Built-indust extraction system
Yes
Protection from electric shock
Doubleinsulation
Power supply cord: m (ft)
2.0 (6.6)
Weight according to
EPTA-Procedure 01/ver.2.1: kg (lbs)
1.2 (2.6)
Voltage (V)
Current (A)
Cycle (Hz)
Continuous Rating (W)
Max Output (W)
Input
Output
110
2.3
50/60
240
65
150
120
2.1
50/60
N/A
65
150
220 - 240
1.1
50/60
240
65
150
January 2016
M9204
125mm (5”) Random Orbit Sander
Model M9204 is a 125mm (5") Random Orbit Sander that has been
developed
as Makita-mt-series.
Its main features are
:
•
New appearance; Features the same design concept as
maktec/SSP-Makita brand series; however, the logo has been
replaced by “Makita-mt-” for new series development.
•
Orange housing
•Built
-in dust extraction system to comply with the regulations
of the EU directives
•Industrial performance and durability
with less expense
Abrasive paper 125-120 (Hook & Loop)
Dust
bag assembly
Note:
The standard equipment may vary by country or model variation.
Pad 123 set
W
L
H
OFFICIAL USE for
ASC & Sales Shop
1/ 6

1INDEX
1INDEX..........................................................................................................................................................................................2
2CAUTION....................................................................................................................................................................................3
3NECESSARY REPAIRING TOOLS...........................................................................................................................................3
4REPAIR ........................................................................................................................................................................................4
4-1 Switch, Power supply cord and Carbon brush......................................................................................................................4
4-1-1 Disassembling.............................................................................................................................................................4
4-1-2 Assembling..................................................................................................................................................................4
4-2 Pad 123, Ball bearing 6202DDW andArmatureAss’y.........................................................................................................4
4-2-1 Disassembling.............................................................................................................................................................4
4-3 Pad 123, Ball bearing 6202DDW andArmatureAss’y (cont.)..............................................................................................5
4-3-1 Disassembling.............................................................................................................................................................5
4-4 Assembling ..........................................................................................................................................................................5
5Circuit diagram.............................................................................................................................................................................6
6Wiring diagram.............................................................................................................................................................................6
2/ 6

2CAUTION
Repair the machine in accordance with “Instruction manual” or “Safety instructions.
Follow the instructions described below in advance before repairing:
· Wear gloves.
· In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what are the parts.
It is also recommended to have boxes ready to keep disassembled parts by group.
· Handle the disassembled parts carefully. Clean and wash them properly.
· If some bolts and screws are too tight, use Impact driver.
3NECESSARY REPAIRING TOOLS
Code No.
Description
Use for
1R269
Bearing extractor
removing Ball bearing
3/ 6

4REPAIR
4-1 Switch, Power supply cord and Carbon brush
4-1-1 Disassembling
4-1-2 Assembling
4-2 Pad 123, Ball bearing 6202DDWandArmatureAss’y
4-2-1 Disassembling
.
Fig. 4-1-1-1
[1] Switch and Power supply cord are accessible by just removing
Top cover and three 4x18 Pan head screws.
[2] Remove Brush holders with Carbon brushes as follows:
Pull out flag terminals of lead wires from tabs of Brush holder.
Hold the tab with long nose pliers, then push one of Carbon brush
toward Commutator side and lift up Brush holder vertically.
Remove the other Brush holder and Carbon brush in the same manner.
Note: Do not bend tabs of Brush holders.
Do not scratch commutator.
Tab of Brush
holder
4x18 Pan head screws (3pcs.)
Commutator
Carbon brush
Brake ring
Bearing box cover
Pad 123
M4x18 Pan
head screws(3pcs)
Bearing box
Vent of Skirt
Flat washer 15
Insert slotted screwdriver so
as not to revolve Fan 88.
Ball bearing 6202DDW
Flat washer 4
M4x14 Pan head screw
Fan 88
Fig. 4-2-1-1
[1] Remove three M4x18 Pan head screws .then separate Pad 123, Bearing box cover and Brake ring.
[2] Hold Fan 88 by inserting slotted screwdriver from a vent of Skirt, then remove M4x14 Pan head screw with Flat washer
4 from Armature ass’y. Flat washer 15, Bearing box and Ball bearing 6202DDW can be removed.
Fig. 4-2-1-2
[3] Separate Skirt set (L) and (R) by removing M4x20 Pan head screws (2pcs.), then pull out Fan 88.
[4] Remove four 4x18 Tapping screws, then pull out Armature ass’y with Bracket from Motor housing set.
M4x20 Pan head screw(2pcs)
Skirt set
Fan 88
Motor housing set
Bracket
Armature ass’y
4x18 Tapping screws
Assemble by reversing Disassembling procedure.
4/ 6

4-3 Pad 123, Ball bearing 6202DDWandArmatureAss’y (cont.)
4-4 Disassembling
4-5 Assembling
Fig. 4-3-1-1
[5] Remove Bracket with arbor press.
[6] Remove Ball bearings fromArmature ass’y using 1R269 and Water pump pliers.
Note: here is little space between Ball bearing 606ZZ and Insulation washer / Ball bearing 629DDW and Washer 9.
Therefore, hold the jaws of 1R269 with water pump pliers to retain Ball bearing securely.
Temporarily tighten M4x14 Pan head screw toArmature shaft to protect the female thread when removing Ball bearing
629DDW.
Bracket
Arbor press
Armature ass’y
Water pump pliers
1R269
Insulation washer
Ball bearing 606ZZ
Ball bearing 629DDW
Washer 9
M4x14 Pan head screw
Water pump pliers
1R269
Fig. 4-3-2-1
Assemble by reversing Disassembling procedure.
Note: When fixing Washer 9 to Armature shaft, face the convex portion to outside as drawn in below.
Fit Brake ring into Skirt set as drawn in below.
Convexportion
ofWasher 9
Protrusions on
the rim portion
of Brake ring
Rim portion ofBrake ring
Groove on Skirt set
(1) Face the rim portion to the machine side.
(
2) Fit the protrusions on the rim portion of
brake ring into the notches of Skirt set.
(
3) Insert the rim portion of Brake ring into
the groove on Skirt set.
Notches of Skirt set
5/ 6

5Circuit diagram
6Wiring diagram
Blue lead wire is used for some countries
Brush holder
Brush holder
Connect the receptacles
of lead wires to Brush
holders
Put the slack portion of
Lead
wires in the space here
Noise suppressor
(Insert
it between ribs around here.)
The
noise suppressor is not used
for
some countries
Terminalblock (Insert it
between ribs around here.)
Fix lead wires (white) for Switch
with these Lead wire holders.
Switch
Put the slack portions of Lead
wires
in the space here.
Fix lead wires (black) to Brush
holders in these Lead wire
holders.
Route one of Lead
wire
of Power supply
cord
through this
groove
and connect
the
lead wire with
Switch
terminal.
Fix Lead wires of Noise suppressor
in
these Lead wire holders.
Brown lead wire is used
for
some countries.
Brush holder
Brush holder
Straight terminal with lock
(AWG187,0.5mm)
Straight terminal with lock
(AWG187, 0.5mm)
AWG20
AWG20
Fig. 5-1
Color index of lead wires' sheath
Black
White
Field
Switch
Noise suppressor (if used)
Fig. 6-1
AWG: American wire gauge
6/ 6