Makita M9400G Operating instructions

M9400G
REPAIR MANUAL
Belt Sander
OFFICIAL USE
For ASC

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1CONTENTS
1CONTENTS ................................................................................................................................................................................. 2
2CAUTION .................................................................................................................................................................................... 3
3NECESSARY REPAIRING TOOLS ........................................................................................................................................... 3
4LUBRICANT AND ADHESIVE APPLICATION ...................................................................................................................... 3
5REPAIR ........................................................................................................................................................................................ 4
5-1 Armature .............................................................................................................................................................................. 4
5-1-1 Disassembling ............................................................................................................................................................. 4
5-1-2 Assembling .................................................................................................................................................................. 6
5-2 Driving Roller ...................................................................................................................................................................... 7
5-2-1 Disassembling ............................................................................................................................................................. 7
5-2-2 Assembling .................................................................................................................................................................. 8
5-3 V-pulley 6-52.9, Helical gear 10 .......................................................................................................................................... 9
5-3-1 Disassembling ............................................................................................................................................................. 9
5-3-2 Assembling .................................................................................................................................................................. 9
6Circuit diagram ........................................................................................................................................................................... 10
7Wiring diagram ........................................................................................................................................................................... 11

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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.
3NECESSARYREPAIRINGTOOLS
Code No.
Description
Use for
1R041
Vise plate
disassembling V-pulley 6-52.9, Helical gear 10
1R269
Bearing extractor (small)
removing Ball bearings
A-43343
Socket 24-45
use with Nut spinner handle
782412-6
Lock nut wrench 28
disassembling Driving roller,
removing/assembling Poly V-belt 6-355
-
Nut spinner handle (Square drive: 12.7 mm)
disassembling Driving roller
4LUBRICANTANDADHESIVEAPPLICATION
Apply the following lubricants and adhesives.
Lubricant
Amount
Makita grease N No.2
7g
Lubricating oil VG46
a little
Fig. 1
Gear room
Frame
complete
Helical gear 42
complete
Tension
roller arm

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5REPAIR
5-1 Armature
5-1-1 Disassembling
1Remove Brush holder caps and Carbon brushes.
Fig. 2
Fig. 3
2Remove M4x18 (+) Pan head screw, and remove
Belt cover.
3Insert Lock nut wrench 28 between Poly V-belt
6-355 and Motor housing complete. And then pry up
the wrench while turning V-pulley 6-52.9. Poly
V-belt 6-355 is now removed.
Fig. 4
4While inserting a slotted screwdriver into the hole for Dust bag assembling in order to lock Fan 80, and protecting
V-pulley 6-23 with a scrap Poly V-belt, turn V-pulley 6-23 clockwise with water pump pliers. Now, V-pulley 6-23
(driving V-pulley) is removed from Armature shaft.
M4x18 (+) Pan head screw
Belt cover
V-pulley 6-52.9
Poly V-belt 6-355
Lock nut wrench 28
Slotted
screwdriver
Hole for Dust
bag assembling
Water pump
pliers
V-pulley 6-23
scrap Poly V-belt

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Fig. 5
Fig. 6
5Remove M4x45 (+) Pan head screw and four 4x40
Tapping screws, and remove Dust collector cover.
And then, remove Separator.
6Remove M5x12 (+) Pan head screw, and remove Fan
80. And then, separate Dust collector bracket
together with Armature from the machine by
loosening two 4x18 Tapping screws.
Fig. 7
Fig. 8
7Remove Ball bearing 6000ZZ from the commutator
end of Armature while holding the claws of 1R269
with water pump pliers so that the claw of 1R269
does not slip from the tight gap between the bearing
and Insulation washer. Then, remove Insulation
washer from Armature.
8To protect the screw hole on the other end of
Armature shaft, temporarily tighten M5x12 (+) Pan
head screw for Fan 80. And then remove Ball
bearing 6000ZZ from Armature with 1R269.
M4x45 (+) Pan
head screw
4x40 Tapping
screw (4 pcs.)
Dust collector cover
Fan 80
M5x12 (+) Pan
head screw
4x18 Tapping screw(2 pcs.)
Dust collector
bracket
M5x12 (+) Pan
head screw
1R269
Ball bearing
6000ZZ
Armature
Water pump
pliers
Claw
1R269
Insulation
washer
Ball bearing
6000ZZ

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5-2 Assembling
Fig. 9
1Hook Poly V-belt 6-355 completely with V-pulley 6-23.
2Set two spikes of Lock nut wrench 28 to the holes of V-pulley 6-52.9.
3While pressing the Poly V-belt 6-355 with your finger, turn V-pulley 6-52.9 with Lock nut wrench 28
counterclockwise. Poly V-belt is now engaged with both V-pulleys.
V-pulley 6-23
V-pulley 6-52.9
Lock nut wrench 28
Poly V-belt 6-355

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5-3 Driving Roller
5-3-1 Disassembling
1Remove Belt cover and Poly V-belt 6-355. (Refer to Fig. 2 and Fig. 3.)
Fig. 10
Fig. 11
2Remove three M4x18 (+) Pan head screws, and
remove Gear cover section* from the machine.
*It consists of V-pulley 6-52.9, Helical gear 10, M10
Hex nut and Ball bearing 6200ZZ/ LLB.
3Remove two M4x18 (+) Pan head screws, and
remove Safety cover.
Note:
Make the lever of Tension roller arm flat to Safety cover.
Otherwise, Safety cover cannot be removed.
Fig. 12
4Insert the two spikes of Lock nut wrench 28 into the holes on Helical gear 42 complete to lock Driving roller.
M4x18 (+) Pan head
screw (3 pcs.)
Gear cover
Lever of Tension
roller arm
M4x18 (+) Pan
head screw (2 pcs.)
Safety cover
Lock nut wrench 28
Helical gear 42
complete

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Fig. 13
5Attach Socket 24-45 to Nut spinner handle. And fit the Socket to the hex portion of Driving roller. And then remove
Driving roller by turning the hex portion of Driving roller clockwise.
5-3-2 Assembling
1Assemble by reversing the disassembly procedure.
Socket 24-45
Hex portion of
Driving roller
Nut spinner
handle
Driving roller

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5-4 V-pulley 6-52.9, Helical gear10
5-4-1 Disassembling
1Disassemble Gear cover section. (Refer to Fig. 10.)
Fig. 14
2Fix Helical gear 10 of Gear cover section in Vise.
Fig. 15
3Insert the two spikes of Lock nut wrench 28 into the holes on V-pulley 6-52.9. And then, remove V-pulley 6-52.9 and
Helical gear 10 by turning Lock nut wrench 28 counterclockwise.
5-4-2 Assembling
1Assemble by reversing the disassembly procedure.
1R041
Helical gear 10
Vise
Lock nut wrench 28
V-pulley 6-52.9

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6Circuit diagram
Fig. 16
Black/AWG18
Field
Switch
Power supply cord
Noise suppressor
(If it is used.)
White/AWG20
Brown/Black
Blue/White
AWG: American wire gauge
Circuit of Switch
Terminal block
(Closed end splice
for some countries.)
Insulated terminal
for M3.5 screw
Non-insulated
terminal
Black/AWG18
Black/AWG18
View from Fan side

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7Wiring diagram
Fig. 17
Field
Field lead wire
Motor housing
Assemble Field as shown below.

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Fig. 18
Field lead wire
Hole
Pass Field lead wires through the hole.
Fix Field lead wires in Lead wire holders.
Pass Field lead wires through this groove.
Switch
Groove
Lead wire holder
Terminal block
(If it is used.)
Noise suppressor
(If it is used.)