Maktec MT902 Manuel

Specification

Standard equipment

Dimensions: mm (")

Width (W)

Height (H)

Length (L)

Model No. MT902 MT903

466 (18-3/8)

200 (7-7/8) 250 (9-7/8)

138 (5-7/16)

Note: The standard equipment for the tool shown above may vary by country.

Models MT902 and MT903 have been developed as the aesthetic

change models of maktec angle grinders MT900 and MT901.

Feature the same advantages the current models as follows:

Anti-dust, heavy-duty 2,000W motor

Industrial performance and durability at less expense

High dust-proof construction

Rear handle with anti-slip surface for more control

Machined spiral bevel gear for durability and long

service life of the machine

Lock nut wrench ................ 1 pc.

Side grip ............................. 1 pc.

Model No.

No load speed: min.-1 = rpm

Diameter

Hole diameter

Wheel size: mm (")

Protection against electric shock

Power supply cord: m (ft)

Net weight*: kg (lbs)

MT902 MT903

180 (7) 230 (9)

2.0 (6.6)

5.4 (12.0) 5.7 (12.6)

8,500 6,600

Double insulation

22.23 (7/8)

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output Max. Output (W)

120

110 15 1,650

---

1,100 2,70050/60

9.6 2,000 1,400 3,00050/60

8.8 2,000 1,400 3,00050/60

15 1,100 2,70050/60

220

9.2 2,000 1,400 3,00050/60230

240

Current (A)

Optional accessories

MT902: Accessories for 180mm angle grinder

MT903: Accessories for 230mm angle grinder

*Weight according to EPTA-Procedure 01/2003, with Side grip, Wheel cover, Inner flange, Lock nut

Model No.

Description

MT902, MT903

Angle Grinders 180mm (7")/ 230mm (9")

CONCEPT AND MAIN APPLICATIONS

P 1/ 9

PRODUCT

TECHNICAL INFORMATION

P 2/ 9

Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

[2] LUBRICATIONS

[3] DIFFERENCE OF GEARS BETWEEN MT902 AND MT903

[4] DISASSEMBLY/ASSEMBLY

[4]-1. Small spiral bevel gear, Armature, Ball bearings 6301ZZ and 6200ZZ

Code No. Description Use for

1R004 Retaining ring pliers ST-2 disassembling/ assembling Ring spring 15

disassembling/ assembling Retaining ring R-421R005 Retaining ring pliers RT-2N

1R027 Bearing setting pipe 18-10.2 disassembling Large spiral bevel gear from Spindle

1R269 Bearing extractor (small) removing Ball bearings

1R286

Model No. Small spiral bevel gear

(Gear on Armature shaft)

Large spiral bevel gear

(Gear on Spindle)

Round bar for Arbor disassembling large Spiral bevel gear from Spindle

Apply approx. 70g of Makita grease N No.1 to Gear room.

Refer to the following gears. They are not interchangeable.

DISASSEMBLING

MT902

MT903

Number of teeth: 16

Spiral bevel gear 16

Spiral bevel gear 12

Spiral bevel gear 53B

Spiral bevel gear 53A

Number of teeth: 12

28mm

22mm

grooved

not grooved

1. Remove Brush holder caps and

Carbon brushes from Motor

housing.

(1) Disassemble Gear housing complete and Bearing box. (Fig. 1)

2. Remove Gear housing complete together

with Armature from Motor housing by

unscrewing four 5x35 Tapping screws.

3. Remove Bearing box section

by unscrewing four 5x35

Hex socket head bolts.

Fig. 1

Brush holder caps

Carbon brushes Gear housing complete

Motor housing

Armature

Bearing box

section

5x35 Tapping screw (4pcs.)

5x35 Tapping

screw (4pcs.)

P 3/ 9

Repair

[4] DISASSEMBLY/ASSEMBLY

[4]-2. Small spiral bevel gear, Armature, Ball bearings 6301ZZ and 6200ZZ (cont.)

DISASSEMBLING

(2) Disassemble Armature and Small spiral bevel gear. (Fig. 2)

(3) Disassemble Ball bearings 6301ZZ and 6200ZZ. (Fig. 3)

Holding M8 Hex nut with Wrench 13,

turn Armature counterclockwise by hand.

M8 Hex nut can be removed.

Wrench 13 for holding

M8 Hex nut

Pull off Armature while holding

Small spiral bevel gear.

Small spiral bevel gear

M8 Hex nut

Armature

Fig. 2

Note: If it is difficult to pull off Armature by hand, do the following steps.

1. Lubricate Small spiral bevel gear and Armature shaft with spray lubricant.

2. Wrap the gear with cloth to protect the gear teeth.

3. By

using water pump pliers, firmly grip the gear wrapped with cloth and then turn and pull Armature.

Retaining

ring R-42

Flat

washer 20

1. Remove Retaining ring R-42

with 1R005.

2. Remove flat washer 20.

3. Assemble Armature into Gear housing

complete then set Small spiral bevel gear

and M8 Hex nut in place on Armature

shaft temporarily.

1R005

Ball bearing

6301ZZ

Ball bearing 6301ZZ

M8 Hex nut

Small spiral

bevel gear

4. Tapping end of Gear housing

complete with Plastic hammer.

Ball bearing 6301ZZ can be

removed together with Armature.

5. Remove M8 Hex nut and Small spiral bevel gear again.

Ball bearing 6301ZZ can be removed by hand.

M8 Hex nut

1R269

Ball bearing 6301ZZ Ball bearing 6200ZZ

6. Remove Ball bearing 6200ZZ with 1R269.

Small spiral bevel gear

Fig. 3

P 4/ 9

Repair

[4] DISASSEMBLY/ASSEMBLY

[4]-2. Small spiral bevel gear, Armature, Ball bearings 6301ZZ and 6200ZZ (cont.)

ASSEMBLING

(1) Armature can be also used as an assembling jig for Ball bearing 6301ZZ. (Fig. 4)

(2) Assemble Spiral bevel gear 16 or 12 and M8 Hex nut to Armature shaft. Reverse step of disassembling. (Fig. 3)

Fig. 4

2. Set Ball bearing 6301ZZ to Armature temporarily and Assemble Ball bearing

6301ZZ into Gear housing complete by using with Armature as a jig,

and then pull off Armature from Ball bearing 6301ZZ.

1. Make sure that Rubber

ring 38 is set in Bearing

box of Gear housing

complete in advance.

Rubber ring 38

Ball bearing

6301ZZ

Ball bearing

6301ZZ

3. Put Flat washer 20 on Ball bearing 6301ZZ,

and secure them with Retaining ring R-42.

Retaining

ring R-42

Flat washer 20

1R005

Ball bearing

6301ZZ

Ball bearing 6301ZZ

P 5/ 9

Repair

[4] DISASSEMBLY/ASSEMBLY

[4]-3. Large spiral bevel gear, Ball bearing 6203DDW

DISASSEMBLING

(1) No need to separated Motor housing from Gear housing complete. Separate Bearing box section from Gear housing

complete, and remove Ball bearing and Ring spring from Spindle. (Fig. 5)

(2) Disassemble Spindle. (Fig. 6)

1. Remove bearing box section

by unscrewing four M6x22

Hex socket head bolts.

2. Remove Ball bearing 6000ZZ

with 1R269.

Fig. 5

Fig. 6

Bearing box

1R027

4. Strike 1R027 carefully with Ram until

Spindle is slightly shifted as illustrated

below.

5. Remove 1R027.

6. Set 1R286 onto Spindle,

and remove Spindle by

pressing down with Arbor

press.

Ram of Arbor press

1. Put Bearing box onto Turn base of Arbor

press with its Labyrinth ring side faced

to Turn base.

Note: Labyrinth ring must not touch

Turn base.

2. Insert 1R027 over Spindle.

3. Set Ram of Arbor press to 20 mm higher

position than the top of 1R027.

Bearing box

Turn base of

Arbor press

Spindle

3. Opening Ring spring 15 with 1R004,

lift the spring up from the opposite side

of 1R004 with Slotted screwdriver

and remove the spring from Spindle.

1R269

Ball bearing

6000ZZ

Ring spring 15

Slotted

screwdriver

1R004

Large spiral bevel

gear

1R286

Note: Do not reuse Ball bearing 6203DDW when Bearing box section

is disassembled. It is inevitably damaged.

20 mm

Labyrinth ring

Large spiral

bevel gear

P 6/ 9

Repair

[4] DISASSEMBLY/ASSEMBLY

[4]-3. Large spiral bevel gear, Ball bearing 6203DDW (cont.)

DISASSEMBLING

ASSEMBLING

(3) Disassemble Ball bearing 6203DDW. (Fig. 7)

(1) Put fresh Ball bearing 6203DDW into Bearing box and secure the Ball bearing with Bearing retainer 50 by

screwing M5x16 Pan head screws. (Fig. 7)

(2) Assemble Spindle by pressing with Arbor press through Ball bearing and Large spiral bevel gear. (Fig. 6)

(3) Assemble Ring spring 15 and Ball bearing 6000ZZ. (Fig.5)

1. Remove Large spiral bevel gear.

2. Remove bearing retainer 50 by unscrewing

three M5x16 Tapping screws.

Fig. 7

M5x16 Pan head

screws (3pcs.)

Bearing

retainer 50

Large spiral

bevel gear

3. Remove Ball bearing 6203DDW by striking Bearing box

against Worktable.

Note 1: Cover Worktable with something soft to avoid

the damage on Bearing box before disassembling.

Ball bearing

6203DDW

Note 2: Do not re-use Ball bearing 6203DDW, because it is

already damaged when removing Spindle.

(center of Fig. 6)

P 7/ 9

Repair

[4] DISASSEMBLY/ASSEMBLY

[4]-4. Shaft lock

DISASSEMBLYING

Fig. 8 Fig. 9

Setting 1R268 to Shoulder pin 5 through the small hole on Pin

cap, and tap 1R268 with Plastic hammer.

Shoulder pin 5 comes out from Gear housing complete.

Release 1R268 from Pin cap carefully

so that Pin cap does not be slung by

Compression spring 12.

Note: Do not reuse Pin cap, removal of

Shoulder pin 5 damages the inside

surface of Pin cap, producing plastic

dust.

Shoulder pin 5

(1) Remove Bearing box section from Gear housing complete. (Fig. 1)

(2) Shaft lock mechanism can be disassembled. (Figs. 8, 9)

1R268

Pin cap

Compression

spring 12

Fig. 10 Fig. 11

Pin cap

Compression spring 12

(1) Be sure to use a new Pin cap for replacement and to remove all the plastic dust on Shoulder pin 5. (Fig. 10)

(2) Assemble the Parts for Shaft lock mechanism. (Fig. 11)

Plastic dust

Shoulder pin 5

Remove Plastic dust from

the constricted part of

Shoulder pin 5.

Assemble Compression spring 12 and Pin

cap by pressing them to Shoulder pin 5.

Insert Shoulder pin 5 through the hole

of Gear housing complete.

ASSEMBLING

Shoulder

pin 5

Shoulder

pin 5

Circuit diagram

P 8/ 9

Power supply cord

Switch Field

Noise

suppressor

This Lead wire is blue for

some countries.

This Lead wire is brown for

some countries.

Color index of lead wires' sheath

Black

Fig. D-1

White

Noise suppressor is not used

for some countries.

Wiring diagram

Wiring in Handle set (L)

P 9/ 9

Wiring in Motor housing on the Commutator side

Pass Field lead wires

through hooks.

Hooks

To be connected

to Switch

Field lead wires (black)

Switch

Noise Suppressor

Power supply cord

Pass the Lead wires of Power

supply cord between Ribs.

Put Noise suppressor

here if it is used.

Fix Field lead wires

(2 x black) with Lead

wire holder.

Field lead wires

(black)

Rib

Handle Set (L)

Fig. D-2

Fig. D-3

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