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9566C-TE


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T         ECHNICAL INFORMATION
   Model No.                          9566C / 9566CV
                                                                                                                                   PRODUCT
                                                                                                                                     P 1 / 10

   Description                        150mm (6" ) Angle grinders
                                                                                                  W
CONCEPT AND MAIN APPLICATIONS
   Model 9566C and 9566CV are 150mm (6" ) version
   of 1,400W class models 9565C and 9565CV.
   The features of 9566C
    * Equipped with electronic for soft start,                                       H
      current limiter and speed control
    *"Super Joint System-SJS".
                                                                                                                            L
   The features of 9566CV
    * Pre-setting dial for speed control is added                             Dimensions : mm ( " )
      to the 9566C's features.
                                                                         Length ( L ) 299 ( 11-3/4 )
                                                                         Width ( W ) 169 ( 6-5/8 )
                                                                         Height ( H ) 103 ( 4-1/16 )
 Specification
                                                                                          Continuous Rating (W)
            Voltage (V)             Current (A)                 Cycle (Hz)                                            Max. Output(W)
                                                                                         Input           Output
                 120                      12.0                     50 / 60               1,400             840                  1,800
                 220                       6.7                     50 / 60               1,400             840                  2,100
                 230                       6.4                     50 / 60               1,400             840                  2,100
                 240                       6.1                     50 / 60               1,400             840                  2,100

        Model No.                                                          9566C                         9566CV
                                Diameter                                               150 ( 6 )
    Wheel size
                                Hole diameter                                        22.23 (7/8 )
       : mm ( " )
                                Thickness                                               6 (1/4)
                                                                        10,000                   4,000 - 10,000
    No load speed : min.-1 = rpm.                                  9,000 for USA, Brazil,    4,000 - 9,000 for USA, Brazil,
                                                                   Switzerland               Switzerland
     Safety clutch                                                               Yes (SJS system)
        Current limiter                                                     Yes                           Yes
    Electronic




        Pre-setting dial for speed control                                  No                            Yes
        Soft starter                                                        Yes                           Yes
        Constant speed                                                      Yes                           Yes
     Cord length : m ( ft )                                                               2.5 (8.2)
     * Net weight : kg ( lbs )                                                            2.4 (5.3)

     * Net weight : without wheel and grip
 Standard equipment
         * Lock nut wrench ......................................... 1 pc.
         * Depressed center wheel 150 - 36 ................. 1 pc.
         * Grip 36 ......................................................... 1 pc.


   < Note > The standard equipment for the tool shown may differ from country to country.

 Optional              accessories
   * Depressed center wheel 150 - 24                                 * Rubber pad
   * Depressed center wheel 150 - 36                                 * Lock nut 16 - 48
   * Abrasive disc 150 - 24                                          * Wire cup brush 90
   * Abrasive disc 150 - 30                                          * Super flange 47 (only for DIN type spindle thread)
   * Abrasive disc 150 - 50                                          * Diamond wheel 150
   * Abrasive disc 150 - 80                                          * Head cover
   * Abrasive disc 150 - 120
 Features               and benefits                                                                                               P 2 / 10

                Electronic limiter
               stops the electric current when accidental over load on          Electronic controller
               the machine, and protects motor from burning.                    for keeping constant rpm.
               And when the machine will be freed from the load,                even under loaded condition,
               restart the motor automatically. At this time, the soft          and for suppressing starting shock.
               starter functions for suppression of starting shock.
                                                                                                             Tough Cord guard
                               High sealed gear housing                                                     excellent in flexibility
                               to prevent leaking of grease                                                 to protect power supply cord
                                                                                                            from disconnection.
Adjustable wheel
cover's position
Wheel cover's position can be
adjusted without any tool.
                                                                                                                         Speed control
                                                                               High power and                  2
                                                                                                                         dial for 9566CV
"Super Join System - SJS"                                                      tough motor
                                                                                                    for getting optimum rotating
provides you the following                                                     1,400W
                                                                                                    speed to suit various work piece.
benefits.
* Smooth and comfortable grinding work.
* Suppression of shock by accidental                                                      150mm (6") wheel can
  wheel lock during work.                                                                 be attached
* Prevention of damage on gear coming
  from accidental wheel lock.                                                             All ball bearings are firmly
                                                                                          protected from dust.
 Comparison                 of products for USA, Brazil and Switzerland
                           Model No.                               MAKITA                                            Competitor A
    Specifications                         9566C / CV           9565C / CV                     9016B                   Model A
   Assorted wheel                          Grinding wheel     Grinding wheel              Grinding wheel           Grinding wheel
                 Diameter : mm ( " )
  Wheel




                                              150 ( 6 )          125 ( 5 )                  150 ( 6 )                 150 ( 6 )
  size




                 Arbor : mm ( " )             22 ( 7/8 )         22 ( 7/8 )                 22 ( 7/8 )                22 ( 7/8 )
   Power input ( W )                            1,400              1,400                      1,050                    1,200
   No load speed : min -1= rpm 9,000/4,000 - 9,000 10,500/2,800 - 10,500                      9,000                    9,100
   Shock absorbing system                    Yes ( SJS)        Yes ( SJS)                      No                        No
                        Soft start              Yes                Yes                         No                        Yes
   Electronic Constant speed                    Yes                Yes                         No                        Yes
   for        Current limiter                  Yes                 Yes                         No                        Yes
                        Speed control         No/Yes               No/Yes                      No                        No
   Auto Cut-out brush                      Yes (one side)     Yes (one side)                   No                  Yes (both sides)
   Protection from                           by double          by double                    by double               by double
   electric shock                            insulation         insulation                   insulation              insulation
    Cord length : m (ft)                       2.5 (8.2)         2.5 (8.2)                   2.5 (8.2)                2.5 (8.2)
  Dimensions




       Length : mm( " )                      299 ( 11-3/4 )    299 ( 11-3/4 )              381 ( 15 )               299 ( 11-3/4 )
               Width : mm( " )               169 ( 6-5/8 )     139 ( 5-1/2 )               169 ( 6-5/8 )            166 ( 6-1/2 )
               Height : mm( " )              103 ( 4-1/16 )    103 ( 4-1/16 )              119 ( 4-11/16 )          106( 4-3/16 )
  Net weight : kg (lbs)
                                              2.4 ( 5.3)        2.2 ( 4.9 )                 3.0 ( 6.617 )           2.4 ( 5.3 )
  w/o wheel and grip
                 Grinding wheel
  equipments
  Standard




                 Grip
                 Lock nut wrench
Comparison              of products for other countries                                                                      P 3 / 10

                     Model No.         MAKITA                     Competitor A Competitor B Competitor C Competitor D
 Specifi-             Single speed
                               9566C    9565C                      Model A        Model B                       Model D
 cations      Variable speed * 9566CV * 9565CV                                                   Model C
  Assorted wheel              Grinding   Grinding                  Grinding       Grinding       Grinding      Grinding
                                wheel     wheel                     wheel          wheel          wheel         wheel
        Diameter : mm           150      125                         150            150            150           150
 Wheel




                   (")          (6)      (5)                         (6)            (6)            (6)           (6)
 size




       Arbor : mm                       22.23       22.23           22.23          22.23           22.23         22.23
                (")                     ( 7/8 )     ( 7/8 )         ( 7/8 )        ( 7/8 )         ( 7/8 )       ( 7/8 )
  Power input ( W )                      1,400      1,400           1,400          1,500           1,400         1,200
                                         10,000    11,000
  No load speed                      * 4,000      * 2,800                          8,500         6,000           7,000
                                                                     9,300
         : min -1= rpm                   - 10,000     - 11,000                                      - 9,000
  Shock absorbing system              Yes ( SJS) Yes ( SJS)           No             No         Yes (Clutch)      No
                     Soft start          Yes           Yes           Yes             Yes            Yes           Yes

  Electronic Constant speed              Yes           Yes           Yes             Yes            Yes           Yes
  for        Current limiter             Yes           Yes           Yes             Yes            No            Yes
             Speed control               No             No            No             No             Yes            No
             dial                      * Yes          * Yes
                                        Yes             Yes           Yes            Yes            Yes            Yes
 Auto Cut-out brush
                                     (one side)      (one side)   (both sides)    (one side)     (one side)    (both sides)
   Protection from                   by double      by double      by double      by double      by double     by double
   electric shock                    insulation     insulation     insulation     insulation     insulation    insulation
   Cord length : m (ft)                 2.5 (8.2)     2.5 (8.2)       2.5 (8.2)     2.5 (8.2)     2.5 (8.2)     2.5 (8.2)
      Length : mm                        299             299            299           323           300            310
 Dimensions




               (")                    ( 11-3/4 )     ( 11-3/4 )     ( 11-3/4 )     ( 12-3/4 )    ( 11-3/4 )     ( 12-1/4 )
      Width : mm                          169           139             166           168           169            163
              (")                      ( 6-5/8 )     ( 5-1/2 )       ( 6-1/2 )      ( 6-5/8 )     ( 6-5/8 )      ( 6-3/8 )
      Height : mm                        103           103              106           110           112            103
               (")                   ( 4-1/16 )     ( 4-1/16 )     ( 4-3/16 )     ( 4-5/16 )     ( 4-3/8 )     ( 4-1/16 )
      ** Net weight : kg (lbs)            1.8            1.8           1.85            2.0           1.9            2.1
                                         ( 4.0)        ( 4.0 )        ( 4.1 )        ( 4.4 )       ( 4.2 )        ( 4.6 )
 equipments




              Grinding wheel
 Standard




              Grip
              Lock nut wrench

      ** Net weight : w/o wheel, grip, wheel cover, flange and lock nut
Repair                                                                                                              P 4 / 10
< 1 > Lubrication
     Apply MAKITA grease SG. No.0 to the following portions marked with black triangle to protect
     parts and product from unusual abrasion.

                                                  Gear housing
                                                         Spiral bevel gear 9




                                                  Spiral bevel gear 35



< 2 > Disassembling spiral bevel gear 9 and armature
   (1) Remove tapping screw 4x18 and separate rear cover from motor housing.
      And remove carbon brush as illustrated in Fig. 1.
   (2) Remove tapping screw 4x28 and detach gear housing from motor housing.
      And remove armature with gear housing cover as illustrated in Fig. 1.
   (3) Disassemble retaining ring S-6 and flat washer 6 from armature shaft as illustrated in Fig. 1A.
   (4) Grip spiral bevel gear 9 with your gloved hand, and pull off spiral bevel gear 9 with turning anti-clockwise.
       Then, flat washer 12 and lock spring 12 can be separated from armature shaft together with spiral bevel gear 9
       as illustrated in Fig. 1B.
   (5) Disassemble spiral bevel gear 9 with No. 1R269 "Bearing extractor" as illustrated in Fig. 1C, if it is difficult to
       disassemble with hand.


                         Gear housing
                         cover
                                                             Carbon brush
          Gear housing              Armature
                                    assembly                                        Rear cover



                                                                                                    Tapping screw 4x18


                                                    Motor housing           Carbon brush
  Tapping screw 4x28      Spiral bevel gear 9

                                                    Fig. 1
                                                                                     Lock spring 12

       Flat washer 6                                                   Spiral bevel gear 9
  Retaining ring S-6



                                                                                                  Flat washer 12
                          Fig. 1A                                                                 Fig. 1B

                           1R269 Bearing extractor



                                                                           Gripping spiral bevel gear 9 together with
                                                                           flat washer 12, disassemble them from
                                                             Fig. 1C       armature shaft.
                                                                                                                      P 5 / 10
 Repair
     (6) Take off retaining ring S-12 from armature shaft as illustrated in Fig. 1D. And disassemble armature
         from gear housing cover with No. 1R045 "Gear extractor (large)" as illustrated in Fig. 1E.

           Retaining ring S-12                         No. 1R045 Gear extractor (large)




                             Fig. 1D                                              Fig. 1E


< 3 > Assembling spiral bevel gear 9 and armature
     (1) Put gear housing over on No.1R217 "ring 22", and assemble armature to gear housing cover by pressing
         with arbor press as illustrated in Fig 2.
     (2) Assemble retaining ring S-12 to armature shaft. And then, assemble lock spring 12 and flat washer 12
        to armature shaft as illustrated In Fig. 2A.
     (3) Assemble spiral bevel gear 9 to armature shaft with turning clock wise as illustrated in Fig. 2B.
     (4) Assemble flat washer 6. And then, fix the parts on armature shaft with retaining ring S-6 as illustrated in fig. 2C.




                                                Lock spring 12                              Spiral bevel gear 9



   1R217 Ring 22



                                            Flat washer 21     Retaining ring S-12

                                                   Fig. 2A                                                Fig. 2B

                     Gear housing cover
                                                  Flat washer 6
                    Fig. 2



                                        Retaining ring S-6
                                                                   Fig. 2C


          < Note in assembling >
          When replacing spiral bevel gear 9 with new one, also retaining ring S-6
          and flat washer 6 have to be replaced with new ones.
Repair                                                                                                         P 6 / 10
< 4 > Disassembling gear section
    (1) Separate gear section by unscrewing 4 pcs. of hex socket head bolts M4 x 16 as illustrated in Fig 3.
        It is recommended to unscrew hex socket head bolts M4 x 16 with impact driver,
        because they are adhesive bolts.
    (2) Put gear section on No.1R217 "Ring 22". And disassemble spindle from spiral bevel gear 35 by pressing
        with arbor press as illustrate in Fig. 3A.
    (3) Disassemble bearing retainer by turning anti-clockwise as illustrate in Fig. 3B.
         < Note >
          For disassembling bearing retainer, remodel No.1R043 "Wrench for bearing retainer" by expanding the distance
          between the spikes from 20mm to 21 or 22mm as illustrated in Fig. 3C.
    (4) Disassemble ball bearing 6201DDW by slightly hitting the edge of bearing box with plastic hammer
        as illustrate in Fig. 3D.


                                                                               Wrench for bearing retainer




                                                                            Spindle
                                                                             Spiral bevel
                                                                             gear 35

                                                                                                       Bearing retainer
                                    1R217 Ring 22
                                                                                   Bearing box       Fig 3B

                            Hex socket head bolt M4 x 16
              Fig 3         (with adhesive)                       Fig 3A




                   20mm                           21 - 22mm
                   32mm                           32mm

                                 Fig. 3C                                                         Fig. 3D

< 5 > Assembling gear section
     (1) Assemble ball bearing 6201DDW to bearing box by pressing with arbor press as illustrated in Fig. 4.
     (2) Assemble bearing retainer to bearing box by turning clockwise as illustrated in Fig. 4A.




                                   Round bar for arbor

                                   Ball bearing
                                   6201DDW

                                     Bearing box
                                                         Bearing retainer

                                                                Fig. 4A
                   Fig. 4
Repair                                                                                                         P 7 / 10



 (4) Supporting spiral bevel gear 35 with 1R028 "Bearing setting pipe", assemble spindle to spiral bevel gear 35
     by pressing with arbor press as illustrated in Fig. 4B.

 (5) Assemble the gear section to gear housing by fastening with 4 pcs. of hex socket head bolts M4 x 16
     as illustrated in Fig. 4C.

     < Note in assembling >
     The hex socket head bolts M4 x 16 are adhesive ones. The used hex socket head bolts have to be replaced
     with fresh ones.




                          Bearing box


  Spindle




                             Spiral bevel gear 35

                          1R028 Bearing setting pipe
                                                                                          Fig. 4C
                            Fig. 4B
Repair                                                                                     P 8 / 10

     < 6 > Attaching carbon brush
           Connect the receptacle of carbon brush with the terminal of brush holder
           by pushing in the direction of the arrow, as illustrated in Fig. 5.



         Receptacle of carbon brush
                                                       Carbon brush



    Terminal of
    brush holder                                        Brush holder




                                                             Fig. 5


           Push the receptacle of carbon brush until it stops as illustrated in Fig. 4A.

         Completely attached receptacle
         of carbon brush




                                                              Fig. 5A
            Incompletely attached receptacle
            of carbon brush




                                                              Fig. 5B
Circuit   diagram                                                                                P 9 / 10

   Color index of lead wires
  Black
  White                                                                    Brush holder
  Red                                                                      (Switch block side)
  Blue                                           SB2


                                                                     SB4
                                                Switch block

                                                               SB3
                  Power supply                    SB1
                  cord




                                                     Controller
                                                                      Brush holder
                                                                      (Controller side)


Wiring    diagram

     Model 9566C,CV
     with electronic features
     Model 9566C : without speed control dial
     Model 9566CV : with speed control dial

             Put the lead wires of controller in the lead holder
             so that they are not slacken.




                                 Speed
                                 Control
                                 Dial




                     Be careful not to loosen the lead wires of field in motor housing.
                     Put the loosened lead wires in the above place.
Wiring    diagram                                                                    P 10 / 10
 Model 9566C,CV
  with electronic features



  Put lead wires of power                                       Do not loosen the lead
  supply cord by strain relief                                  wires of filed in motor
  as illustrated in Fig. 8.                                     housing.
                                                                Put the loosened ones in the
                                                                place as illustrated
                                                                 in Fig.8.




          Fix lead wires of controller
          with lead holder.

         Put the slack part of controler's lead wire
         in the place as illustrated in Fig.8.




                                                       Fig. 8



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