Makita SA4540C Manual

PRODUCT
P 1/ 12
Model No.
Description
CONCEPT AND MAIN APPLICATIONS
SA4540C/ SA4542C, SA5040C/ SA5042C
Angle Sanders 115mm (4-1/2"), 125mm (5")
For Models SA5040C/ SA5042C
Rubber pad 115
Lock nut 14-48
Abrasive disc 125-24, 30, 50, 80, 120
Abrasive disc (Hook and loop type) 125-40, 60, 80, 120, 180
Wire cup brush 90 set
Wheel cover for wire cup brush 90
Dust collecting wheel cover
etc.
For Models SA4540C/ SA4542C
Rubber pad 100
Lock nut 14-48
Abrasive disc 115-24, 30, 50, 80, 120
Abrasive disc (Hook and loop type) 115-40, 60, 80, 120, 180
Wire cup brush 90 set
Wheel cover for wire cup brush 90
Dust collecting wheel cover
etc.
L
H
W
1,400W Angle sander series models, SA4540C, SA4542C, SA5040C and
SA5042C are successor models of 9565CVL, featuring:
•"Super Joint System II"developed for effective vibration absorption
• Electronic current limiter, speed control and soft start
• Anti-restart function (for models SA4540C, SA5040C only)
• Re-designed durable gear housing
• Ergonomically best possible barrel grip
Specification
Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output
840
Max. Output (W)
110
120
220
230
240
13
12
6.7
6.4
6.1
50/60
50/60
50/60
50/60
50/60
1,400
1,400
1,400
1,400
1,400
2,100
2,100
1,800
2,000
2,100
Current (A)
840
127 12 50/60
---
2,000
840
840
840
840
*1 with Side grip
Model No.
No load speed: min.ˉ¹=rpm
Abrasive disc
Pad
Capacity: mm (")
Protection against electric shock
Power supply cord: m (ft)
Weight according to EPTA-Procedure 01/2003*1: kg (")
European countries except UK: 4.0 (13.2),
Brazil, Australia: 2.0 (6.6), Other countries: 2.5 (8.2)
2,000 - 7,800
Double insulation
115 (4-1/2)
Shock absorbing System
Mechanical brake
Super Joint System II
Yes
Yes
Yes
SA4540C, SA5040C: Yes/ SA4542C, SA5042C: No
Constant speed control
Variable speed control by dial
Soft start
Electronic current limiter
Anti-restart function
Electronic
control
Yes
No
SA5040C/ SA5042CSA4540C/ SA4542C
125 (5)
105 (4-1/8)
115 (4-1/2)
2.4 (5.2)
Standard equipment
Note: The standard equipment for the tool shown above may vary by country.
Side grip ................................ 1 (normal type or anti-vibration type)
Lock nut wrench .................... 1
Pad 115 .................................. 1 (for SA4540C/ SA4542C)
Pad 125 .................................. 1 (for SA5040C/ SA5042C)
Optional accessories
TECHNICAL INFORMATION
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
105 (4-1/8)
315 (12-3/8)
Model No. SA4540C
SA4542C
121 (4-3/4)
SA5040C
SA5042C
115 (4-1/2)

P 2/ 12
Repair
[1] NECESSARY REPAIRING TOOLS
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Code No. Description Use for
1R045 Gear extractor (Large) separate Armature from Gear housing cover
1R049 Drill chuck remover 15 fixing Spiral bevel gear 37 when removing Spindle
1R050 Drill chuck remover 22
1R232 Pipe 30 removing Cup ring and Ball bearing 6903ZZ from Spiral bevel gear 37
1R258 V block supporting Bearing box
1R268 Spring pin extractor M3 disassembling Shaft lock mechanism
1R269 Bearing extractor removing Ball bearings 627DDW/ 696ZZ from Armature
1R281 Round bar for Arbor 7-50 removing Switch knob from Switch lever
1R286 Round bar for Arbor 12-50 removing Spiral bevel gear 37 section from Bearing box
1R291 Retaining ring S & R pliers removing Retaining ring S-9
1R340 Bearing retainer wrench removing Bearing retainer 20-33 from Bearing box
1R350 Ring 60 supporting Gear housing when disassembling Shaft lock mechanism
Apply Makita grease to the following portions designated with the black triangle and gray triangle to protect parts and
product from unusual abrasion.
[2] LUBRICATION
Fig. 1
Item No. Description
Gear housing
C-type plate
Lubricant AmountPortion to lubricate
Coupling
Spindle
Gear room 15 g
a little
a little
a little
70
56
1
Joint sleeve
Spiral bevel gear 37
Ball bearing 6903ZZ
56
58
58
Outer surface where 58 Coupling contacts
Drum portion where 58 Coupling contacts
Cylindrical portion where 56 C-type plate contacts
Makita Grease FA No. 2:
Makita Grease FA No. 2:
Makita Grease FA No. 2:
Makita Grease SG No. 0:
1
70

P 3/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Armature, Spiral bevel gear 7
DISASSEMBLING
(1) Remove Spiral bevel gear 7from the drive end of Armature as drawn in Fig. 2.
Fig. 2
1. Remove Rear cover by unscrewing
one 4x18 Tapping screw.
4x18 Tapping screw
4. Unscrew four 4x13 Tapping screws. Then separate Gear housing cover from Motor housing
while applying a slotted screwdriver to the groove on Gear housing cover.
Rear cover
2. Shift Spiral spring from
Carbon brush top.
3. Disconnect Carbon brush from
commutator by pulling up.
Note: No need to remove in this step
Groove on
Gear housing cover
Gear housing cover
Armature
Wrench 8
Flat washer 12
Gear housing
cover
Ball bearing
6001LLB
5. Remove M5-8 Hex nut to turn it with Wrench 8
counterclockwise. Then, remove Flat washer 5
and Spiral bevel gear 7 from Armature.
6. Remove Gear housing cover with 1R045.
Then, remove Flat washer 12.
Flat washer 6
Spiral bevel
gear 7
M5-8 Hex nut
Armature
1R045

P 4/ 12
Repair
(2) Disassemble the commutator end of Armature as drawn in Fig. 3.
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Armature, Spiral bevel gear 7 (cont.)
DISASSEMBLING
ASSEMBLING
Fig. 3
1. Pick up three tabs of
Self lock 6 with tweezers
to remove it from Armature.
2. Remove Magnet sleeve,
Wave washer 6 and
Labyrinth rubber ring 22.
3. Remove Ball bearing 627DDW with 1R269. 4. Remove Flat washer 7 and
Insulation washer.
Self lock 6
Tabs
Tweezers
Wave washer 6
Magnet sleeve
Labyrinth rubber ring 22
Ball bearing 627DDW
1R269 Flat washer 7
Insulation washer
(1) Assemble Spiral bevel gear 7 to Armature end by reversing the disassembly procedure. (Refer to Fig. 2)
(2) Assemble the commutator end of Armature as drawn in Fig. 4.
Fig. 4
2. Press down Self lock 6 until
Wave washer 6 gets flat.
3. Magnet sleeve is stabilized
between Self lock 6 and
Wave washer 6 by the reaction
force of Wave washer 6.
1. Return tabs of Self lock 6 to their
normal shape before assembling.
Then, mount Wave washer 6 to
the commutator end of Armature.
Note: Be sure to mount the washer
as following direction.
Wave washer 6
Magnet sleeve
Self lock 6
Wave washer 6
Magnet sleeve
Self lock 6

P 5/ 12
Repair
ASSEMBLING
(3) Assemble Gear housing cover with Armature and Gear housing to Motor housing as drawn in Fig. 5.
Fig. 5
Armature
Notch on Gear housing cover Name plate
1. Assemble Gear housing cover together with Armature
while facing its notch to the same side as Name plate.
2. Assemble Gear housing while facing Spindle
to the same side as the notch and Name plate.
Name plate
Gear housing
Spindle
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Armature, Spiral bevel gear 7 (cont.)
[3] -3. Spiral bevel gear 37, Ball bearings 696ZZ/ 6201DDW
DISASSEMBLING
Note: The gear and the ball bearings can be replaced without disassembling the motor section.
(1) Remove Ball bearing 696ZZ, Retaining ring S-9, Flat washer 10 and C-type plate from Spindle as drawn in Fig. 6.
Fig. 6
1. Removing four M4x16 Hex socket head bolts, then separate Bearing box section from Gear housing.
Bearing box
section
2. Remove Ball bearing 696ZZ
with 1R269.
3. Remove Retaining ring S-9
with 1R291.
4. Remove Flat washer 10.
Then, remove C-type plate.
Ball bearing
696ZZ Retaining
ring S-9
Flat washer 10
C-type plate.

P 6/ 12
Repair
DISASSEMBLING
(2) Disassemble Spiral bevel gear 37 from Spindle and Separate Coupling from the gear as drawn in Fig. 7.
Fig. 7
1. Put Bearing box on the turn base of Arbor press. Then, inert 1R049
and 1R050 into the gap between Bearing box and Spiral bevel
gear 37. And then, remove Spindle by pressing it with Arbor press.
2. Joint sleeve can be removed.
Note: Do not re-use the removed
Joint sleeve because of
falling its slip torque.
3. Tap Bearing box to shift Flat washer 12
to the possible eccentric position.
Then, put Bearing box on 1R258.
1R049
Spindle
1R050
Spindle
Joint sleeve
Bearing retainer
Bearing box
Flat washer 12
4. While applying 1R286 to Flat washer 12 through Bearing
retainer, press it to remove Spiral bevel gear 37 section
(including Coupling and Ball bearing 6903ZZ) from
Bearing box.
1R286
Spiral bevel gear 37
Ball bearing
6903ZZ
Coupling
Flat washer 12
1R232
Coupling
Ball bearing 6903ZZ
Spiral bevel gear 37
5. While applying 1R232 to Coupling, press it to remove Coupling together with Ball bearing 6903ZZ
from Spiral bevel gear 37.
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Spiral bevel gear 37, Ball bearings 696ZZ/ 6201DDW (cont.)

P 7/ 12
Repair
ASSEMBLING
(3) Disassemble Ball bearing 6201DDW from Bearing box as drawn in Fig. 8.
Fig. 8
1. Clamp Bearing box with Vise. Then, while fitting the claw of 1R340 to the notch of Bearing retainer 20-33,
turn 1R340 clockwise to remove the retainer.
2. Take out Felt ring 17 and Flat washer 21
from Bearing box.
3. Remove Ball bearing 6201DDW with Arbor press.
1R340
Bearing
retainer 20-33
Bearing
retainer 20-33
Felt ring 17
Felt ring 17
Flat washer 21
Assemble by reversing the disassembly procedure. (Refer to Figs. 8, 7 and 6)
Note: •Do not re-use the removed Joint sleeve. New Joint sleeve has to be mounted.
(Refer to the upper right illustration in Fig. 7)
• Apply the following thread locker to the thread of M4x16 Hex socket head bolts, if the unscrewed bolts are used.
* Three bond 1342
* Lock tight 242
(Refer to the upper left illustration in Fig. 6)
Ball bearing
6201DDW
Ball bearing
6201DDW
DISASSEMBLING
[3] DISASSEMBLY/ASSEMBLY
[3] -3. Spiral bevel gear 37, Ball bearings 696ZZ/ 6201DDW (cont.)

P 8/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -4. Switch Lever
DISASSEMBLING
(1) Remove Rear cover from Motor housing by removing 4x18 Tapping screw. (Fig. 2)
(2) Disassemble Switch lever and Switch knob from the machine as drawn in Fig. 9.
Assembled Switch lever and Switch knob as drawn in Fig. 10.
Note: Make sure that Compression spring 4 is assembled to Switch lever in advance.
Fig. 9
3. Bend Switch lever to make it
free from the wall of Switch
box. Then, Pull out Switch
lever from Motor housing.
1. While locking Switch knob with 1R281,
strongly push Switch lever in a direction
designated with black arrow.
2. Switch lever is disconnected
from the locking claw of
Switch knob.
Then, remove Switch knob.
Switch Lever
Tumbler
Switch Lever
1R284
Switch Knob
Switch Switch
Switch Knob
Tumbler of
Switch
Tumbler of
Switch Switch Lever
Fig. 10
Switch knob
2. Fit the hook of Switch knob to the hole of Switch lever.
Then, release Switch lever. (The hook of Switch knob
interlocks with the hole of Switch lever when Switch
lever is pushed back to OFF position by Compression
spring 4.)
Switch lever
Switch
Knob
1. Push Switch lever into Motor housing
until the hole of Switch lever comes into
sight through Switch knob assembling hole
on Motor housing. And keep the position.
ASSEMBLING

P 9/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -5. Switch Block
[3] -6. Switch
DISASSEMBLING
After removing Switch Lever (Refer to Fig. 9), separate Switch block from Motor housing as drawn in Fig. 11.
After removing Switch lever (Refer to Fig. 9), remove Switch from Switch block as drawn in Fig. 12.
Fig. 11
Insert Slotted screwdriver into the gap between
Switch block and Motor housing, remove
Switch block from Motor housing.
Fig. 12
Fig. 13
Switch block
Controller
ASSEMBLING
Connect Switch block as drawn in Fig. D-3.
DISASSEMBLING
[3] -7. Brush Holder
DISASSEMBLING
Insert Slotted screwdriver into the gap between Switch and Switch block.
While fitting the tip of the screwdriver to the side groove of Switch,
remove Switch by levering it up.
Remove 3x10 Tapping screw. Then, insert Slotted screwdrivers into the gap between Motor housing
and Brush holder’s plastic portion. And then, disassemble Brush holder by levering them up.
Brush holders can be disassembled as drawn in Fig. 13.
Brush holder
Slotted screwdriver
Switch
Slotted screwdrivers
Slotted screwdriver

P 10/ 12
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -8. Shaft Lock
DISASSEMBLING
While applying 1R268 to Shoulder pin 6 through the small hole
on Pin cap, tap 1R268 with a hammer.
Now, Shoulder pin 6 comes out from Gear housing complete.
Release 1R268 from Pin cap carefully
so that Pin cap is not slung by
Compression spring 8.
Shoulder Pin 6
Pin Cap
Note: Do not re-use removed Pin cap
because removal one damages
the inside surface of the cap,
producing plastic dust.
Pin Cap
Pin Cap
Compression
spring 8
1R268
1R350
Fig. 14 Fig. 15
(1) Disassemble Bearing box section from Gear housing. (Refer to Fig. 6)
(2) Disassemble Shaft lock mechanism as drawn in Figs. 14 and 15.
Fig. 16 Fig. 17
(1) Be sure to use a new Pin cap for replacement and to remove all the plastic dust on Shoulder pin 6. (Fig. 16)
(2) Assemble the Parts for Shaft lock mechanism as drawn in Fig. 17.
Plastic Dust
O Ring 7
Shoulder Pin 5 Shoulder
Pin 6
2. Assemble new Pin cap by pressing
it to Shoulder pin 6.
Note: Do not forget to assemble
Compression spring 8.
1. Insert Shoulder pin 6 through
the hole of Gear housing
complete.
Pin Cap
Compression
Spring 8
ASSEMBLING

P 11/ 12
Circuit diagram
Color index of lead wires' sheath
Switch
Blue
Fig. D-1
Brown
Controller
Noise suppressor* is installed
in Switch block.
*Noise suppressor is not used
for some countries.
Field Brush holder
Noise
suppressor
7
Black lead wire is used
for some countries.
White lead wire is used
for some countries.
8
6
1
45
2
3
Switch block

P 12/ 12
Wiring diagram
Fig. D-2
Fig. D-3
Wiring of Lead wires of Power supply cord
Connecting of Switch block to Motor housing
Brush holder
Connecting terminal
1. Before mounting Switch block to Motor housing,
make sure that these three Connecting terminals
of Switch block are not deformed or broken.
Put Lead wires of Power supply cord
into this place designated with gray color.
2. Make sure that these connecting terminals
of Switch block fit to Brush holders’
connecting terminals, push Switch block
to Motor housing until it stops.