Service Manuals, User Guides, Schematic Diagrams or docs for : MAKITA BO6040-TE
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T ECHNICAL INFORMATION
Models No. BO6040
PRODUCT
P 1 / 12
Description 150 mm Random Orbit Sander L
CONCEPTION AND MAIN APPLICATIONS
This models is versatile random orbit sander for
professional use.
Due to the two mode selection,
"Forcible rotation mode" / "Free-rotation mode",
rough sanding, fine finishing and polishing can be done H
only with this machine.
W
Dimensions : mm ( " )
Width ( W ) 150 (5-7/8)
Height ( H ) 132 (5-3/16)
Length ( L ) 316 (12-1/2)
Specification
Continuous Rating (W)
Voltage (V) Current (A) Cycle (Hz) Max. Output(W)
Input Output
110 7.2 50 / 60 750 390 850
120 6.6 50 / 60 750 390 850
220 3.6 50 / 60 750 390 850
230 3.4 50 / 60 750 390 850
240 3.3 50 / 60 750 390 850
Orbits per min. : (min -1= spm) 1,600 - 5,800
Oscillation rate per min.: spm = min-1 3,200 - 11,600
Rpm.of pad with Forcible-Rotation : rpm = min-1 180 - 670
Orbit diameter : mm (") 5.5 ( 7/32)
Pad diameter : mm (") 150 ( 6 )
Cord length : m ( ft ) 2.5 ( 8.2 )
Net weight :Kg (lbs ) 2.7 ( 5.9 )
Standard equipment
* Pad 150 (soft ) ........................................................... 1pc. (factory-attached to the machine)
* Abrasive disc 150-120 (Hook and loop type) ........... 1 pc.
* Hex wrench 6 ........................................................... 1 pc.
* Joint ........................................................................... 1 pc. ( only for European market)
< Note > The standard equipment for the tool shown may differ from country to country.
Optional accessories
* Pad 150 ( hard) * Sponge pad 150 ( hook and loop type)
* - ditto - ( soft) * Felt pad 150 ( hook and loop type )
* - ditto - ( super soft) * Wool pad 150 ( hook and loop type )
* Abrasive disc 150 - 40, 60, 80, 120, 180, 240, 400 * Side grip
* Sanding cloth 150 - 100, 200, 800
Features and benefits Durable Cord Guard
P 2 / 12
BO6040 More durable against disconnection than ever,
due to the flexible and elastic rubber cord guard.
Easy Palm-gripping makes
operation comfortable
Speed Control Dial
Low Tool Height for More For getting optimum rotating speed
Efficient Operation to suit various work piece.
Tool height of the part is Can adjust speed, according to applications.
lower than that of FESTO.
Hose can be connected to
Vacuum Cleaner
(Diameter of Nozzle is
same as that of #BO5020.)
Hook-and-Loop Backing Pad
The position of hole for dust collection is Two Mode Selection By Easy Operation
same and interchangeable with those of "*Forcible rotation mode" or "**Free-Rotation mode"
FESTO and BOSCH type. can be selected by change lever.
*Forcible rotation mode : Orbital action plus mechanical
rotary drive for rough sanding and polishing.
**Free-Rotation mode : Orbital action for fine sanding.
Typical applications for sanding and polishing
Sanding
Rotation mode Speed control
Use / Material Forcible / Free setting Pad
(Paint work)
Sanding Free 1-3 Soft
Repairs (scratches, rust spots) Forcible / Free 2-3 Hard
Rough paint removal Forcible 4-5 Soft
(Plastics)
Soft plastics (PVC / ABS) Forcible / Free 1-3 Super soft / Soft
Hard plastics (FRP) Forcible 1-3 Soft / Hard
(Woods)
Soft wood Free 1-3 Super soft / Soft
Hard wood Forcible / Free 3-5 Soft
Veneers Forcible 1-2 Super soft
(Metals)
Non-ferrous metal Forcible / Free 1-3 Soft
Steel Forcible 3-5 Soft / Hard
Rust removal on steel Forcible 4-5 Super soft
Hard metal (stainless steel ) Forcible 4-5 Soft
Polishing
Rotation mode Speed control
Use / Material Forcible / Free setting Pad
Applying wax Forcible 2-4 Sponge pad
Removing wax Forcible 4-5 Felt pad
Polishing Forcible 4-5 Wool pad
< Note >
The above information is intended only as a guide. Please select most suitable rpm. by pre-sanding
with test piece, before starting your work.
Comparison of products P 3 / 12
The following diagram is showing Mod.BO6040's superiority to competitor B in the sanding work.
Numbers in chart below are relative values when setting competitor B 's capacity as 100.
Mod.BO6040 of MAKITA Competitor B
The conditions The conditions
* Work piece : Hard wood * Work piece : Removal of paint (fine)
* Grit of abrasive disc : 60 * Grit of abrasive disc : 120
* Action mode : Forcible rotation mode * Action mode : Free-Rotation mode
145 115
100 100
0 50 100 150 200 0 50 100 150 200
The conditions The conditions
* Work piece : Dougras pine (produced in USA.) * Work piece : Removal of paint (coarse)
* Grit of abrasive disc : 60 * Grit of abrasive disc : 60
* Action mode : Forcible rotation mode * Action mode : Forcible rotation mode
115 115
100 100
0 50 100 150 200 0 50 100 150 200
The conditions
* Work piece : Spruce (soft wood produced in USA.)
* Grit of abrasive disc : 120
* Action mode : Free-Rotation mode
155
100
0 50 100 150 200
Manufacturer MAKITA Competitor B Competitor A
Specification Model No. BO6040 B A
Power input ( W ) 750 500 550
Equipped motor S60-40 50-50 58-40
Orbits
1,600 - 5,800 2,000 - 5,600 2,400 - 6,000
per min.: opm = min-1
Oscillation rate
3,200 - 11,600 4,000 - 11,200 4,800 - 12,000
per min.: spm = min-1
Orbit diameter : mm ( " ) 5.5 ( 7/32) 5.0 ( 13/64) 4.5 ( 3/16)
Change of action mode
Yes Yes Yes
(Forcible-Rotation / Free-Rotation)
Rpm.of pad with
Forcible-Rotation : rpm = min-1 180 - 670 240 - 560 80 - 200
Type of pad Hook and loop Hook and loop Hook and loop
Electronic for constant speed Yes Yes Yes
Braking pad No Yes Yes
Yes Yes Yes
Connection to vacuum cleaner
Available for self dust
extraction, too.
Hight of machine : mm ( " ) 132 (5-3/16) 138 (5-7/16) 152 (6 )
Net weight :Kg (lbs ) 2.7 (5.9) 2.3 (5.1) 2.4 (5.3)
Plastic carrying case Yes Yes No
* Abrasive disc * Abrasive disc * Abrasive disc
Standard equipment * Hex wrench 6 * Hex wrench 6 * Dust bag
* Joint (only for Europe) * Side grip * Side grip
Repair P 4 / 12
< 1 > Replacing armature and spiral bevel gear 9
1) Take off tapping screw 4x18 and detach rear cover from motor housing.
And detach carbon brush as illustrated in Fig1.
Carbon brush
Tapping screw 4x18
Rear cover
Motor housing
Fig. 1
2) Put the torsion spring installed on brush holder, on the side of brush holder after detaching carbon brush
as illustrated in Fig.2. This is necessary for avoiding to scratch the armature's commutator, when armature is
pulled out from motor housing.
The torsion spring put on the side of The torsion spring positioned as illustrated
brush holder in Fig.2A can scratch the armature's commutator.
Torsion spring
Brush holder
Fig.2 Fig.2A
It is not necessary to remove brush holder itself, when removing armature.
3) After pulling out armature from motor housing, remove retaining ring 6 with retaining ring plier, and detach
spiral bevel gear 9 as illustrated in Fig.3.
Gear housing cover Armature
Retaining ring 6
Spiral bevel gear 9
Motor housing
Fig.3
Press
4) Remove armature from gear housing cover
by pressing the armature shaft with arbor press Bal bearing 6001LLB
as illustrated in Fig.4.
Flat washer 12
5) Take reverse step of the above, when Gear housing cover
assembling armature and spiral bevel gear.
Fig.4
Armature
Repair P 5 / 12
< 2 > Replacing ball bearing 6201LLB installed in skirt
Head cover
(1) Unscrew flat head screw M8x11
and detach head cover from gear housing. See Fig.5.
(2) Unscrew pan head screw M4x12 and
detach skirt from gear housing. See Fig.5.
Flat head
screw M8x11
Pan head
screw M4x12 x 4 pcs.
Gear housing
Skirt
(3) Unscrew pan head screw M4x12 and
detach bearing retainer 80 from skirt. See Fig.6.
Fig. 5
Hex nut M10
Skirt
Bearing retainer 80
Pan head
screw M4x12 x 3 pcs.
Fig. 6
(4) Set box wrench 17 on hex nut M10 and insert hex wrench 6 into the hole
of "spur gear 26 complete" as illustrated in Fig. 7. And loosen hex nut M10 with box wrench 17.
Box wrench 17 Hole of
Box wrench 17 "spur gear 26 complete"
"Spur gear 26 complete"
including sleeve,
2 ball bearings 6001DDW
and retaining ring S-12
Hex wrench 6
View from hex nut 10 side
View from pad setting side
Fig. 7
Repair P 6 / 12
(4-A) If "spur gear 26 complete" is loosened first,
Remove "spur gear 26 complete". And loosen hex nut M10 with box wrench 17, gripping upper balance weight
with monkey wrench 250mm. See Fig. 8.
Box wrench 17
Monkey wrench 250mm
Upper balance
weight Spiral bevel gear 42
Sleeve
Ball bearing 6001DDW
"Spur gear 26 complete"
Ball bearing 6001DDW
(including sleeve,
ball bearing 6001DDW x 2 pcs. Retaining ring S12
and retaining ring S12)
Spur gear 26 Fig. 8
(4-B) If hex nut M10 is loosened first,
Tighten hex nut M10 provisionally And remove upper balance weight with monkey wrench 250m,
holding "spur gear 26 complete" with hex wrench 6. See Fig. 9.
Monkey wrench 250mm
Hole of
"spur gear 26 complete"
Upper balance weight
Spur gear 26 complete
Fig. 9
Hex wrench 6
(5) Remove flat washer 10, upper balance weight and spiral bevel gear42 from spindle as illustrated in Fig.10.
Flat washer 10
Upper balance weight
Spiral bevel gear42
Spindle
Fig.10
Repair P 7 / 12
(7) Remove internal gear 29, ball bearing 6811LLB and stop ring WR-55 by striking skirt on the work-table
covered with soft sheet as illustrated in Fig.11. And then, remove lower balance weight.
Skirt
Stop ring WR-55
Lower balance
Strike on the work-table weight
Ball bearing
6811LLB
Internal gear 29
Fig.11
(8) Remove spindle from skirt with arbor press as illustrated in Fig. 12. Take off 3 pan head screws M4x12
holding ball bearing 6201LLB. And then, remove ball bearing 6201LLB with arbor press from skirt.
Press spindle with 3 Pan head Press ball bearing with
arbor press. screws M4x12 arbor press.
Round bar for arbor
Spindle
Ball bearing 6201LLB
Fig. 12
(9) Assembling skirt section
(9-1) Assemble ball bearing 6201LLB by pressing it with arbor press. Fix the ball bearing 6201LLB
with 3 pan head screws M4x12. And then, assemble spindle with arbor press.
See Fig. 13.
Press spindle with
arbor press.
Press spindle with
arbor press.
Round bar for arbor 3 Pan head Round bar
screws M4x12 for arbor
Ball bearing
6201LLB
Spindle
Fig. 13
Repair P 8 / 12
(9-2) Assemble spiral bevel gear 42,upper balance weight and flat washer 10. And then, tighten
hex nut M10 provisionally. Assemble internal gear 29 after installing lower balance weight.
Flat washer 10 Hex nut M10
Upper balance
weight
Spiral bevel
gear42
Spindle
Lower balance
weight
Internal gear 29
Fig. 14
(9-3) Set box wrench 17 on hex nut M10 and insert hex wrench 6 into the hole
of "spur gear 26 complete" as illustrated in Fig. 15. And fasten hex nut M10 with box wrench 17.
Hold bearing retainer 80 with 3 pan head screws M4x12.
< Note > Apply grease on the sponge portion of bearing retainer 80.
Hole of
Box wrench 17 "spur gear 26 complete"
Apply grease on Bearing retainer 80
the sponge portion
Pan head
screw M4x12 x 3 pcs.
Hex wrench 6
Rubber guard
Fig. 15 Assemble it in the groove of skirt firmly,
after installing bearing retainer 80.
Repair P 9 / 12
< 3 > Replacing ball bearing 6001DDW installed in "spur gear 26 complete"
See Fig. 16. Sleeve
1) In order to replace ball bearing 6001DDW, the removed spindle is
needed as a repairing tool.
Screw spindle into sleeve installed in "spur gear 26 complete" Ball bearing 6001DDW
as illustrated in Fig. 17. Ball bearing 6001DDW
Spindle Sleeve unit
Retaining ring S12
Spur gear 26 complete Spur gear 26
Fig. 16
Fig. 17
2) Hold "spur gear 26 complete" with No.1R232 pipe 30 and
No.1R037 bearing setting plate as illustrated in Fig. 18.
Remove spindle together with sleeve unit (including
2 ball bearings 6001DDW and retaining ring S-12)
from spur gear 26, by pressing No.1R235 "round bar for arbor"
with arbor press as illustrated in Fig. 18. And then, remove spindle from sleeve unit by unscrewing.
Arbor press
No.1R235 Round bar for arbor Spur gear 26
Spur gear 26 complete
No.1R232 Pipe 30
Sleeve unit
No.1R037 Bearing
setting plate Spindle
Fig. 18 Remove from sleeve unit
by unscrewing.
3) Remove retaining ring S-12 from sleeve with retaining ring plier ST-1.
Press No.1R235 "round bar for arbor" set on sleeve. Then, Ball bearing 6001DDW can be separated
from sleeve. See Fig. 19.
Retaining ring S-12 No.1R235 Round
bar for arbor
Sleeve
Ball bearing
6001DDW
No.1R037 Bearing
setting plate
Sleeve
Fig. 19
Repair P 10 / 12
4) Assembling ball bearing 6001DDW installed in "spur gear 26 complete"
Assemble sleeve to new ball bearings 6001DDW by pressing it, and assemble retaining ring S-12 to sleeve.
And then, press them into spur gear 26. See Fig. 20.
Sleeve
Ball bearing 6001DD
Retaining ring S-12
Spur gear 26
Fig. 20
< 4 > Replacing ball bearing 6811LLB installed in internal gear 29
1) Remove stop ring WR-55 with No.1R003 retaining plier from internal gear 29. The, ball bearing 6811LLB
can be removed from internal gear 29 with hand. See Fig. 21.
Stop ring WR-55
Internal gear 29
Ball bearing
6811LLB
Fig. 21
When assembling ball bearing 6811LLB, take reverse step of Fig. 21.
< 5 > Replacing holder for action mode change
1) Install unit of internal gear 29 (including Compression
ball bearing 6811LLB and stop ring WR-55) spring 4
in skirt. Pan head screw
M4x12
2) Detach cap. And then, remove pan head screw
Cap
M4x12, knob, spring holder and compression
spring 4 as illustrated in Fig. 22. Holder
Knob,
Spring holder
3) Remove holder from skirt. And apply grease
to the surface of new holder.
4) When assembling, install new holder, compression spring 4,
Fig. 22
spring holder and knob. And assemble cap
by fastening it with pan head screw M4x12.
Circuit diagram P 11 / 12
Model BO6040 Brush holder
( switch block side )
White
P2 SB4
SB2 Black
White or blue
P1 Switch block Field
SB1
SB3
Power supply
Red
cord
Orange
Speed Controller
Control
Dial
White Brush holder
( controller side )
< Note >
The lead wire (orange) for connection of controller and brush holder is not used in some countries.
Fig. 23
Wiring diagram P 12 / 12
Model BO6040
Fix lead wire of controller with lead holder
between pin A and pin B.
Put the lead wires of controller in the lead holder Inflect the lead wire at the terminal
so that they are not slacken. in right angle. See Fig 24A.
Speed Pin B
Control
Dial
Pin A
Be careful not to loosen the lead wires of field in motor housing.
Put the loosened lead wires in the above place.
Fig. 24 Terminal
Sink plate
Controller
Fig.24A
Put lead wires of power
supply cord by strain relief
as illustrated in Fig. 25. Do not loosen the lead
wires of filed in motor
housing.
Put the loosened ones in the
place as illustrated
in Fig.25.
Fix lead wires of controller
with lead holder.
Put their slack part in the place
as illustrated in Fig.25.
Fig. 25
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