Makita XBU02 Operating instructions

REPAIR MANUAL
XBU02

Repair
CAUTION: Repair the machine in accordance with "Instruction manual" or "Safety instructions".
[1] NECESSARY REPAIRING TOOLS
[2] LUBRICATION
Code No. Description Use for
1R028 Bearing setting pipe 20-12.2 press-tting Motor housing cover to Rotor
1R032 Bearing setting plate 8.2 holding Rotor when press tting Motor housing cover
1R045 Gear extractor (large) removing Fan 110, Rotor
1R247 Round bar for arbor 20-100 press-tting Rotor and Motor housing cover
1R269 Bearing extractor removing Ball bearing 626DDW, 698LLU from Rotor
No need to lubricate.
Repair
[3] DISASSEMBLY/ASSEEMBLY
(1) Remove Front nozzle, Rear cover and Housing set R. (Fig. 1)
Fig. 1
4x18 Tapping screw
1. Remove four 4x18 Tapping
screws and separate Rear cover.
2. Remove Rear cover by prying it off
with a slotted screwdriver.
[3] -1. Fan 110, Rotor
DISASSEMBLING
Rear cover
Rear cover
3. Remove twelve 4x18 Tapping screws.
5. Remove two 4x18 Tapping screws. 6. Remove Front nozzle.
4. Separate Housing set R.
Housing set R.
Front nozzle
P 2/ 13

P 3/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
(2) Separate Motor housing from Housing set L. (Fig. 2)
(3) Remove M5 Coned disc spring hex nut from the rotor shaft and remove Fan 110. (Fig. 3)
Fig. 2
Fig. 3
While paying attention not to loosen Switch section in Handle portion,
separate Motor housing section from Housing set L.
2. Lock Fan 110 with the grip of plastic hammer,
and then remove M5 Coned disc spring hex nut
from the rotor shaft by turning it counterclockwise
with the impact driver.
4. Fan 110 can be
removed using 1R045,
if it is difcult to
remove by hand.
[3] -1. Fan 110, Rotor (cont.)
DISASSEMBLING
Switch section
Motor housingHousing set L
Fan 110 is removed from
this side in the next step.
Fan 110 Flat washer 5
Socket bit 8-55
55 mm
8 mm
Grip of plastic
hammer
M5 Coned disc
spring hex nut
1. Attach Socket bit 8-55 to an impact driver
to remove M5 Coned disc spring hex nut.
Fan 110
3. Remove Fan
110 by hand.
Note: Make sure not to
lose Flat washer 5.
1R045
M5 Coned disc spring hex nut

P 4/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
(4) Remove Rotor from Motor housing. (Fig. 4)
(5) Remove Motor housing cover and Ball bearings from Rotor. (Fig. 5)
Fig. 4
Fig. 5
[3] -1. Fan 110, Rotor (cont.)
DISASSEMBLING
Flat washer 8
Rotor shaft
Rotor
Rotor
Motor housing
Cap
Motor housing cover
1. Remove Flat washer 8 from the rotor shaft.
1. Remove Rotor from Motor housing cover with 1R045. 2. Remove Ball bearings from Rotor using 1R269.
Motor housing
2. Loosen four 3x20 Tapping screws, and
disassemble Cap from Motor housing
so that Rotor can be removed from the
cap side.
3. Tap the rotor shaft
with a plastic hammer.
4. Remove Rotor and Motor housing cover
from Motor housing.
Plastic hammer Motor housing
Rotor
Motor housing cover 1R045
Rotor
Ball bearing 626DDW
1R269
Rotor
Motor housing
cover
Ball bearing
698LLU
Ball bearing
698LLU
Ball bearing
626DDW

P 5/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 6
because Rotor has a strong magnetic force.
Failure to follow this instruction could result in:
• Finger injury caused by pinching between Rotors
• Magnetic loss of Rotors or damage on the magnet portion of Rotor (Fig. 7)
Fig. 6 Fig. 7
[3] -1. Fan 110, Rotor (cont.)
Caution for Handling of Rotor
* Magnetic loss of Rotors
* Damage on the magnet portion of Rotor
(1) Assemble Ball bearings 626DDW/ 698LLU to Rotor. (Fig. 5)
(2) Assemble Motor housing cover to Rotor. And assemble them to Motor housing. (Fig. 8)
ASSEMBLING
Fig. 8
Rotor
Rotor
Stator
1R032
1R028
Motor housing
1. Set Rotor onto 1R032.
Put Motor housing cover onto Rotor.
Press-t Motor housing cover using 1R028
and Arbor press.
Motor housing cover
Motor housing cover
and Rotor
Motor housing
Motor housing cover
2. Assemble Rotor and Motor housing cover
to Motor housing.
Note: Take care that your ngers are not pinched between
Motor housing cover and Motor housing.
1R247
3. Press-t Motor housing cover and Rotor to Motor
housing using 1R247 and Arbor press.

P 6/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
(3) Assemble Fan 110 to the rotor shaft. (Fig. 9)
Fig. 9
[3] -1. Fan 110, Rotor (cont.)
ASSEMBLING
Motor housing
Cap
Flat washer 8
Rotor
1. Fix Cap to Motor housing with four 3x20
Tapping screws.
2. Assemble Fan 110 to the rotor shaft while
aligning their ats on Fan110 and the rotor shaft.
3. Using an awl or a small screwdriver as a guide
rail, assemble Flat washer 5 to the rotor shaft.
2. Assemble Flat washer 8 to
the rotor shaft.
Socket bit 8-55
Rubber ring 8
Housing set L
4. Lock Fan 110 with the grip
of plastic hammer.
5. Attach M5 Coned disc spring
hex nut to Socket bit 8-55, and
tighten M5 Coned disc spring
hex nut by turning it clockwise.
6. Rubber ring 8 must be mounted to
Motor housing as shown in the gure
on the left. Otherwise, Motor housing
can not be properly mounted to
Housing set L.
Fan 110
Fan 110
Flat Rotor shaft
Awl or small
screwdriver Flat washer 5
M5 Coned disc spring hex nut

P 7/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
ASSEMBLING
Assemble Lock ON button. (Fig. 10)
Fig. 10
[3] -2. Fan Lock ON button
Cut portion
of boss
Compression spring 5
Compression
spring 5
Lock ON button Lock ON button
Lock ON
button
1. Join Lock ON buttons and Compression spring 5
together while aligning their protrusions on Lock
ON buttons in the same direction.
If not, Housing set R may not be xed properly.
2. Assemble Lock ON button to Housing set L
while tting one protrusion to the cut
portion of boss.
Protrusions
Protrusions
Housing set L
3. If the Lock ON button protrudes from the
mounted Housing set R , Lock ON button is
assembled properly.
Note:
If Lock ON button does not protrude from
Housing set R, align their protrusions on
Lock ON buttons in the same direction.

P 8/ 13
Repair
[3] DISASSEMBLY/ASSEEMBLY
Disassemble Sub controller. (Fig. 11)
Fig. 11
[3] -3. Sub Controller
DISASSEMBLING
Dial 28
Sub controller
Connector
Axis for Dial 28
Lead wires of
Sub controller
1. Remove Dial 28. 2. Disconnect the connector.
3. Remove Sub controller by prying it off
with a slotted screwdriver.
Slotted screwdriver
Note:
When removing Sub controller, be sure
not to grip or pick up the axis for Dial
28 or Lead wires of Sub controller.

P 9/ 13
Repair
[4] TROUBLESHOOTING
Whenever you nd any trouble in your machine, refer to this chapter rst.
Trouble on Controller can be checked with Tester as follows.
(1) Use a full charged battery which has the star mark. (Fig. T-1)
(2) When Housing is disassembled, check the conditions of the electrical parts
(Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc.
(3) Do a running test 10 times.
Black test probe
Red test probe
(-) pole (+) pole
Lock ON
button
Switch lever
１.１
Note in Repairing
Star mark
Fig. T -1
Fig. T -2
Test for recognizing the trouble on FET (Field effect transistor) of Controller
2. After removing the battery from the machine,
lock Switch lever to ON position by pushing
Lock ON button.
1. Set Digital tester (1R402) in the diode mode
( mark on the tester).
3. Connect Black test probe to the plus pole,
Red test probe to minus pole of Terminal.
And, check the value display on the tester.
Note: Be careful not to connect the probes in reverse.
4. Wait until the reading is stable.
If it reads within 0.9V - 1.3V,
there is no fault on FET of Controller.
If it reads 0V or 0.4V approx., Controller is
broken. Replace it with a new one.

P 10/ 13
Repair
[4] TROUBLESHOOTING
Check the items from top of the following list. (Description of the item is referred to Circuit diagram in Fig. D-1.)
After corrective action, return to the start of Trouble shooting and check again.
Symptom Cause Corrective action
Check List for Troubleshooting
Motor runs when the machine
is switched on.
(Check by repeating 10 times.)
In case of running inconstantly,
go to “No”.
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
Does it read 0.9V ~ 1.3V on the tester?
When a tester cannot be prepared, go to “Yes”.
If your problem cannot be solved although
its corrective action has been carried out.
Connectors are in incomplete
connection.
Connectors are in incomplete
connection.
The machine does
not have any trouble.
Check Lead wires,
or replace them.
Check Terminal,
or replace it.
Check Lead wires,
or replace them.
Battery fuel gauge
lights on.
Rotor is rubbed to
Stator.
Lead wires are broken.
Switch is broken.
Controller is broken.
Stator is broken.
Replace Controller.
Replace Stator.
Replace Rotor.
Replace Sub controller.
Connect them rmly.
Replace Switch.
Connect them rmly.
Replace Controller.Controller is broken.
Controller is broken. Replace Controller.
Replace Controller.
Terminal is broken.
Rotor is broken.
Switch is broken.
Controller is broken.
Sub controller is broken.
Lead wires are broken.
Replace Switch.
Replace Controller.
Variable control
can be functioned
by trigger.
Air volume/speed
selection can be
functioned by dial.
3 lamps on each
battery fuel gauge
light on.