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Repair Finishing sanders Makita BO4555 Repair CAUTION: Unplug the machine for safety before repair/ maintenance, in accordance with the instruction manual! [1] NECESSARY REPAIRING TOOLS [2] LUBRICATION Lubrication is not required for this product because no gear is used for transmission. [3] DISASSEMBLY/ASSEMBLY DISASSEMBLING 1) Remove Top cover from Motor housing by unscrewing three 4x18 Tapping screws, then disconnect Flag terminal from each Brush holder. (Fig. 1) 2) Carbon brush can be removed from Motor housing together with Brush holder as described in Fig. 2. 3) Remove Pad complete from Base by unscrewing four 4x12 Tapping screws. (Fig. 3) 4) Lock Armature shaft by inserting screwdriver from the discharge nozzle of Fan guide between the lower Fan blades Fan 63 as illustrated in Fig. 4. Balancer can now be removed by removing Countersunk head screw M4x12 from Armature shaft. [3] DISASSEMBLY/ASSEMBLY DISASSEMBLING 5) Remove Base from Motor housing. Some adjacent parts can be also removed in this step as illustrated in Fig. 5. 6) Remove Fan guide from Motor housing by unscrewing two 4x12 Tapping screws. (Fig. 6) 7) Remove Fan 63, then remove four 4x18 Tapping screws. (Fig. 7) 8) Bearing box and Armature can now be removed as an assembly by tapping the end surface of Motor housing with plastic hammer. (Fig. 8) 9) Remove Armature from Bearing box using 1R027 and arbor press. (Fig. 9) [3] DISASSEMBLY/ASSEMBLY DISASSEMBLING 10) Remove Ball bearing 607LLB from the commutator-end of Armature shaft using 1R269 and adjustable pliers (Fig. 10), Note: Be sure to firmly grasp the claws of 1R269 with adjustable pliers because the space between Insulation washer and Ball bearing 607LLB is so tight that Ball bearing 607LLB cannot be securely grasped with the claws of 1R269. 11) Remove Ball bearing 629DDW from the drive-end of Armature shaft using 1R269 and adjustable pliers in the same way as described above in 10). (Fig. 11) Important: Before attaching 1R269 to Ball bearing 629DDW, be sure to fasten Countersunk head screw M4x12 to the drive-end of Armature shaft in order not to damage to the threads inside Armature shaft. ASSEMBLING Do the reverse of the disassembling steps. Note: Flat washer 9 is not reversible when assembled to Armature.The side with the raised center portion must face towards Fan 63 as illustrated in Fig. 12. Circuit diagram Wiring diagram Route Lead wires as illustrated in Fig. D-2. 1 and 4 Field lead wire (black): Route through the opening 1/opening 2 of Motor housing, then connect to Brush holder. Note: Be sure to fix with Lead wire holder 1/Lead wire holder 6. 2 Field lead wire (white): Route through the opening 1 of Motor housing, then connect to Switch. Note: Be sure to fix with Lead wire holders 2, 3. 3 Lead wire of Noise suppressor (white): Connect to Switch. Note: Be sure to fix with Lead wire holders 4, 5. 5 Field lead wire (white): Route through the opening 2 of Motor housing, then connect to Terminal block. 6 Lead wire (white) of Noise suppressor: Connect to Terminal block. 7 Lead wire (white or blue) of Power supply cord: Connect to Terminal block. 8 Lead wire (black or brown) of Power supply cord: Connect to Switch. Note: Be sure to route through the groove of Motor housing. Note: Put slack portions of Lead wires in spaces 1 and 2.