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

150

120

2.1

50/60

N/A

150

220 - 240

1.1

50/60

240

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

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

these Lead wire holders.

Brown lead wire is used

for

some countries.

Brush holder

Straight terminal with lock

(AWG187,0.5mm)

Straight terminal with lock

(AWG187, 0.5mm)

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

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