How to disassemble gearbox angle grinder Makita 5030

Possible electrical faults

Electrical faults Makita angle grinder can be divided into control circuit faults, rotor breakage and stator malfunction.

Assembling angle grinder Makita 9565

Before assembling the Makita angle grinder, check the integrity of all parts and their cleanliness. The assembly begins with the installation of the bearing and the driven gear on the spindle.

Spindle assembly

On the spindle of pos. 50, a boot of pos. 51 is put on, the cover of the body is in pos. 53, and the bearing housing is in pos. 54. Insert the pre-lubricated 6201LLB bearing into the bearing housing. Press on the driven gear, pos. 56. on the spindle. Spindle assembled.

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Checking the electric motor

In addition to control circuits, the electric circuit of the angle grinder includes a rotor and a stator. These are complex units, which are recommended to be repaired in specialized centers. But there is nothing inaccessible for Russian craftsmen. We recommend our own methods of repairing a stator or rotor with our own hands.

Mechanical damage

In addition to the electrical part, the angle grinder also includes a mechanical part, the main unit of which is a gearbox.

Tool required for repair

DIY repair of Makita angle grinders requires the use of a specific tool. You can’t do without a set of screwdrivers. It is preferable that they be equipped with a ratchet mechanism. The best option is to use a cordless screwdriver. To repair the electrical part of the Makita angle grinder, you will need a tester, a device for determining the short-circuited turns of the IK-2. And also prepare an open-end wrench, bearing pullers, a hammer, a soft metal adapter. Well, you can not do without the necessary lubricant, cleaning materials, liquids to remove old grease.

You need to start repairing an angle grinder with your own hands by preparing the workplace, installing the correct lighting. You will need a diagram of an angle grinder of the required model and the proposed instruction.

Any malfunctions of power tools are divided into two types: electrical and mechanical.

We will consider the repair of units of the Makita angle grinder using the example of the Makita 9565 angle grinder diagram.

Design Features Angle Grinder Makita

an angle grinder is an angle grinder, which received this name only in the vastness of the former USSR. Structurally, any angle grinder (angle grinder) has the same structure.

The principle of operation of the Makita angle grinder is based on the transformation of electrical energy into mechanical energy. This leads to the rotation of the shaft, on which the disc is installed for cutting, grinding, polishing. And it is called angular for the reason that in the gearbox used, the torque is transmitted at an angle of 90º.

Since the cooling of the electric motor in Makita angle grinders is provided by sucking in external air through the ventilation holes, the working parts of the Makita angle grinder are covered with a special protective powder varnish that prevents dust from settling. Structurally, Makita angle grinders have a labyrinth system of seals and a pressurized “Start” button.

But each company, to attract a buyer, introduces its own zest into the design. The Makita angle grinder is not lacking in this either. Makita angle grinder is conventionally divided into powerful and small.

Makita small angle grinder disassemble and find problem Makita GA5030

Makita angle grinder are marked depending on the power of the electric motor.

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The design features of Makita angle grinders include:

Makita Angle Grinder Repair – How to replace the Gear Housing

  • The presence of a labyrinth device that protects the bearings from dirt and dust.
  • Electric motor windings in high power angle grinders are protected by an armored coating.
  • Makita angle grinders are equipped with a special system that protects the tool from jerking during start-up, called the Super-Joint-System.

A few words about the SJS system. The system prevents the impact of a kickback, excludes jerking and jamming of the working body, protects the electric motor from overloads.

The system uses a spring, the purpose of which is to transfer forces from the rotor to the gears of the gearbox. The spring acts as a buffer, prevents jerks when starting and stopping. This design greatly reduces vibration and ensures smooth operation of the Makita angle grinder.

Makita angle grinder are divided into classes according to the size of the working disc width. The angle grinder is conventionally divided into three classes: light, medium, heavy. In turn, each class is divided into an angle grinder for professionals and for household needs. The professional models of the Makita angle grinder have an increased power reserve, an integrated safety system, and an increased working life. Professional angle grinders withstand heavy loads for a long time.

Household angle grinders Makita have high performance, but very affordable prices. The Makita angle grinder can be used with a disc with a maximum diameter of 230 mm.

Depending on the diameter of the disc, the Makita angle grinder is divided into classes:

  • Diameter 115-125 mm characterizes the light class. Easy to hold with one hand by the body, which acts as a handle. But professional angle grinders of this class can be equipped with a rear handle, which has a built-in button for turning on the tool;
  • Diameter 150-180 mm refers the Makita angle grinder to the middle class. This category includes professional and amateur models equipped with electric motors of various powers. Modern models have a swivel rear handle;
  • The diameter of 230 mm characterizes the heavy-class angle grinder. In this class, the Makita angle grinder is produced exclusively for professionals. These machines are designed to work on concrete, stones, bricks, etc. All modern consumer protection systems from injuries are incorporated in their design.

Makita angle grinder models are available for discs with diameters of 115 mm, 125 mm, 150 mm, 180 mm and 230 m.

In high-power angle grinders, carbon brushes can be replaced without removing the stator housing cover.

Makita angle grinders of various capacities differ in appearance. The professional angle grinder over 1000 W has a large body and a comfortable back handle. The handle is equipped with protective anti-vibration pads in black. angle grinder with power up to 1000 W has a convenient body, which acts as a handle.

A quick-detachable cover is installed on Makita angle grinders. This design allows for quick removal of the protective cover.

A few words about fakes

In the Russian market of the tool, there are often fakes of the Makita angle grinder. A popular and well-promoted brand is popular not only among users, but also of various stripes of crooks.

When choosing a Makita angle grinder, pay attention to the following details:

    quality of molded plastic parts;
    workmanship of the additional handle;
    the low price should alert you;
    carefully study the plate, you can find a lot of inaccuracies on it;
    a serial number must be present on Makita angle grinders;
    the Makita angle grinder has a mandatory inscription on the cases, which you will not find on fakes;
    the carbon brushes of the original Makita have serial numbers;
    as a rule, screws with a hex head are used in the assembly, on fakes “Phillips” screws;
    armature and stator windings in fakes are covered with artisanal varnish.

By being careful when choosing a Makita angle grinder, you will not run into a fake and buy a real tool from Japanese manufacturers.

How to disassemble the Makita angle grinder

Spindle assembly

On the spindle of pos. 50, a boot of pos. 51 is put on, the cover of the body of pos. 53, the bearing housing of pos. 54. Insert the pre-lubricated 6201LLB bearing into the bearing housing. Press on the driven gear, pos. 56. on the spindle. Spindle assembled.

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An anchor is a rotating element of an electric motor containing windings. A collector is a place on an anchor to which the windings are brought out to our client. It looks like a row of insulated plates. The stator is the fixed part of the electric motor containing the windings. Brushes are carbon parallelepipeds that supply current to the collector.

Reducer. a mechanical device for transmitting rotation with changes in power not rotation speed.

Repair angle grinder makita GA5030

The most popular tool in everyday life after a drill is an angle grinder or, as it is often called, an angle grinder. The angle grinder is used for cutting metals, wood, concrete, grinding various surfaces, cutting openings, doors, niches. If there is an angle grinder, then it can always be used and it is especially offensive when it ceases to function normally, jerks, twitching, burning smell appear.

the angle grinder is all arranged in the same way: an elongated body in which the engine and gearbox are located, a handle and a protective cover are screwed on the side.

A sticker with initial data is located on the body of the angle grinder. Here you can find both the personal number of the angle grinder and the supply voltage. 230 V. This refers to the maximum permissible mains voltage. The frequency of the current in the network is 50 Hz. Consumption current. 5 A. Power consumed from the network. 1100 W, it is obtained as a product between voltage (220 V) and current (5 A) multipliers. The rotational speed of the disk installed on the angle grinder is 2800-11000 rpm. The armature itself rotates at a higher speed than the disc. Specifically on this angle grinder, step regulation of the rotation speed is possible. The disc mounted on the angle grinder has an outer diameter of 125 mm, the fastening nut of the disc has an M14 thread.

A household tool designed for a phase voltage of 220 V has an armature winding and a stator winding. The transfer of energy from the network to the armature is carried out using graphite brushes. Mains voltage is applied to a switch, which is mechanically connected to the power button of the angle grinder. The stator winding consists of two halves that are not electrically connected. The armature winding consists of many windings, but at any given time, the brushes connect only two armature windings.

When the angle grinder is turned on, the current is supplied to the input of half of the stator winding, the output of the stator winding is connected to the brush holder into which the brush is inserted with the help of a spring. The brush transfers current to half of the armature winding, on the other hand, the other brush receives current and through the brush holder transfers current to the other half of the stator winding. The current went in and out of the angle grinder. If the entire electrical circuit is in good working order, then the armature will begin to rotate.

Reverse, i.e. the change in the direction of rotation of the disk can be carried out by interchanging the wires going to the brushes from the stator windings. Just disconnect the wires on the brushes and swap.

At the end of the case of the angle grinder there is a red wheel for stepwise control of the armature rotation speed and a screw for removing the casing.

In this type of angle grinder, the brushes themselves are located inside the case and there is no access to them, but the developers have simplified the replacement of the brushes when removing the casing. After unscrewing the screw, the plastic plate is removed and the outer casing moves towards the cord, exposing all the insides, including the brush holders.

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The speed control mechanism is electronic. The entire circuit is filled with epoxy resin and only the speed control wheel and radiator are taken out. What’s hidden inside. the trade secret of the company. When the unit fails. the speed ceases to be regulated, but remains at the maximum level. In any case, you should not despair, but in series with an angle grinder, you can turn on the most ordinary dimmer. dimmer. It can be used to adjust the speed of any AC collector motor, the main thing is that the engine power does not exceed the dimmer power.

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To get to the components of the control circuits, it is necessary to remove the back cover of the case, pos. 38, by unscrewing the self-tapping screw 4 × 18, pos. 39. Switch ST115-40 K9565, pos.28, is fixed in the holder of the switch, pos.27. The holder of the switch is closed by a cover, pos. 29, which is attached to the motor housing, pos. 33.

The power cable pos. 37 is suitable for the switch. Using a tester, check the continuity of the circuits from the contact of the plug to the terminals of the switch. The switch, pos. 28, is controlled by the lever, pos. 30. Check the circuit from the contacts of the switch to the carbon brushes pos. 42.

In control circuits, the carbon brushes are the weakest link. The Makita 9565 angle grinder uses CB-318 carbon brushes with auto shut-off, so check the brushes.

In professional angle grinders, speed regulators are installed. In the angle grinders Makita with a power of more than 1000 W, the installation of a soft start system is provided. The Makita 9077SF angle grinder is equipped with such a system.

If the switch fails, the malfunction is eliminated by its complete replacement. In the event of a break or breakdown of the power supply wire, the malfunction is eliminated by replacing the whole wire or removing damaged parts of it.

The activation process is carried out using the lever pos. 30. If you disassemble the angle grinder body for repair or maintenance, lubricate the lever movement grooves with silicone grease before assembly.

Checking the electric motor

In addition to control circuits, the electric circuit of the angle grinder includes a rotor and a stator. These are complex units, which are recommended to be repaired in specialized centers. But there is nothing inaccessible for Russian craftsmen. We recommend our own methods of repairing a stator or rotor with our own hands.

How to repair the stator Makita angle grinder

The failure of the stator, pos. 24, is indicated by the appearance of a burning smell, overheating of the case of the angle grinder, and the spontaneous set of revolutions of the angle grinder. In the case of the angle grinder, pos. 33, the stator is fastened with four self-tapping screws 4 × 70, pos. 21. To prevent damage, the stator is covered with a protection pos. 20.

Repair of the stator of the Makita angle grinder consists in determining the short circuit or breakage of the windings. It is best to diagnose the stator with a special device called IK-2. The stator is considered faulty if traces of darkening of the winding are visible, an open or short circuit of the winding turns is determined.

The stator is easy to repair. Gotta rewind his windings.

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