SPECIAL TOOLS. Core Drilling Machines SERVICE MANUAL. Page 1
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1 SPECIAL TOOLS Core Drilling Machines Page 1 SERVICE MANUAL
2 Service Manual Necessary Tools for machine assembly BEAST by BBTEC Core Drilling Machines 1 Soft Hammer (preferred plastic head) Art Torque Wrench Range: 0-25 Nm. (19 mm square drive or socket head type) For BCR130/5BG & MG safety clutch Art Torque Wrench Range: > 100 Nm (22 mm square drive type) For BCR164/6 & BCR300/12 safety clutch Art Circlip Pliers for external retaining rings (10-25 mm) Art Outside snap ring Circlip Pliers (15-60 mm, with special tips for snap-rings and spring-clips) Art Circlip Pliers for internal retaining rings (straight, mm) Art Page 2
3 Service Manual 7 Bearing Puller Tool (0-40 mm) Art Separator Tool (D max. > 50 mm) Art Blind Bearing Pullers / Split Collet Pullers ( mm, mm, mm) Bench Press Tool Art Special Toolkit Case (see Service Manual Special Tools for use of each tool) 11 Page 3
4 Service Manual Special Tool BCR130/5BG & MG, BCR164/6, BCR300/12 Special tool to secure gear box with drill spindle to a vice STEP 1 Slide and Slide the special tool on the drill spindle STEP 2 Lock Lock the special tool with the gearbox to a vice Page 4
5 Service Manual Special Tool BCR130/5BG & MG Special tool to assemble seals in BCR130/5BG & MG gear box To assemble seals, position number 7, in gear box BCR130/5BG & MG, position number 23, see supported exploded view Assembly parts Gear box BCR130/5BG & MG Part # x Seals Part # STEP 1 STEP 2 Grease Apply silicon based grease to both seals Grease and position Apply silicon based grease on the inside of the gear box. Position the first seal horizontally in the gear box with the open side upward. Page 5
6 STEP 3 Press Press the seal using the special tool all the way down. STEP 4 Second seal Position the second seal horizontally in the gear box with the open side downward. Press the seal using the special tool down until the ring levels with the wider part of the gear box. Page 6
7 Service Manual Special Tool BCR130/5BG & MG Special tool to assemble seals in BCR130/5BG & MG gear box To assemble seals, position number 16, to gear box BCR130/5BG & MG, position number 23, see supported exploded view Assembly parts Gear box BCR130/5BG & MG, part # x Seal, part # STEP 1 Grease Grease the seal hole with silicon based grease STEP 2 Position Position the seal with the open side downward on top of the special tool. Turn over and place the tool above the seal hole. Page 7
8 STEP 3 Press Press the the seal gently in the hole Page 8
9 Service Manual Special Tool BCR130/5BG & MG Special tool to assemble ball bearings in BCR130/5BG & MG gearbox To assemble ball bearing, position number 24, to gear box BCR130/5BG & MG, position number 23, see supported exploded view Assembly parts Gear box BCR130/5BG & MG part # Ball bearing part # STEP 1 Grease and position Grease the ball bearing hole with silicon based grease and position the bearing horizontally in the hole STEP 2 Position tool and assemble Position the special tool on the ball bearing. Tap with caution the bearing gently in place with a rubber hammer. Page 9
10 / Service Manual Special Tool / BCR130/5BG & MG Special tools and for BCR130/5BG & MG safety clutch For fastening and adjusting the nut with a torque wrench To assemble a BCR130/5BG & MG safety clutch Assembly parts 1 Gear spindle, part # x Washer, part # Bearing bush, part # Gear wheel #2, part # Ring, part # Spring washer, part # Nut, part # Used oil, cleaner and glue Shell Spirax AX 80W-90 Würth sabesto IndustrieClean, part # E or Loctite 7235 Nettoyant/Reiniger, part # ThreeBond 1374 glue STEP 1 Lock and mount Lock the special tool in a vice and mount the gear spindle (1) STEP 2 Oil Brush oil on the gear wheel STEP 3 Mount Mount the first washer (2) Page 10
11 / STEP 4 STEP 5 Oil Brush oil on the washer (2) Mount Mount the bearing bush (3) STEP 6 Mount Mount gear wheel #2 (4) STEP 7 STEP 8 STEP 9 Oil Brush oil on the gear wheel (4) Mount Mount the second washer (2) Oil Brush oil on the washer (2) STEP 10 Mount Mount ring (5) STEP 11 Secure Secure ring (5) in correct place STEP 12 Mount Mount spring washer (6) STEP 13 STEP 14 Clean Clean nut thread of gear spindle oil free Page 11 Glue Glue thread of nut (7) with Three- Bond 1374 STEP 15 Mount Mount the nut (7)
12 / STEP 16 Fasten Fasten the nut (7) with a torque wrench hand tight STEP 17 Mount tool Mount the special tool STEP 18 Fasten Fasten the special tool with a torque wrench to 16/17 Nm STEP 19 Adjust Now repeat Step 15, 16 and 17 by loosening or fastening the nut (7) until the safety clutch slips with the torque wrench set to 16/17 Nm Page 12
13 Service Manual Special Tool BCR130/5BG & MG Special tool to assemble seals and ball bearings in BCR130/5BG & MG motor cover To assemble seal, position number 35, and ball bearing position number 36, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view Assembly parts Motor cover BCR130/5BG & MG, part # x Ball bearing, part # x Seal, part # STEP 1 Grease Grease the seal hole with silicon based grease STEP 2 Position seal Position the seal horizontally in the seal hole with open side downward STEP 3 Position tool Position the special tool on top of the seal Page 13
14 STEP 5 Press 2 Turn over the special tool and center position the tool on top of the seal. Press the seal a second time. STEP 4 Press 1 Press the seal in place STEP 6 Grease and position Grease the ball bearing hole with silicon based grease and position the bearing STEP 7 Position tool, press Position the special tool on top of the ball bearing. Press the bearing in place. Page 14
15 Service Manual Special Tool BCR130/5BG & MG Special tool to assemble needlebearings in BCR130/5BG & MG motor cover To assemble needle-berarings, position number 21, to motor cover BCR130/5BG & MG, position number 34, see supported exploded view Assembly parts Motor cover BCR130/5BG & MG part # x Needle-bearings part # STEP 1 Grease and position Grease both bearing holes with silicon based grease. Position the needlebearings horizontally in the holes with shown text down. STEP 2 Press 1 Press both needle-bearings in the holes STEP 3 Position tool and press 2 Position the special tool and press the needle-bearings one by one in place Page 15
16 Service Manual Special Tool BCR164/6 Special tool for BCR164/6 safety clutch For fastening a BCR164/6 assembled safety clutch with a torque wrench STEP 1 Lock Lock the special tool in a vice STEP 2 Position Position the BCR164/6 assembled safety clutch in the special tool STEP 3 Secure Tighten the nut with a torque wrench to 9 kn/90 Nm. Attention: left handed thread CCW Page 16
17 Service Manual Special Tool BCR164/6 Special tool to support the fan when assembling to BCR164/6 armature To support the fan, position number 38, when assembling to the BCR164/6 armature, position number 37, see supported exploded views Assembly parts Armature, part # Fan, part # STEP 1 Position Position the fan on top of the special tool with the metal ridge downward STEP 2 Grease Lightly grease the the fan connecting part of the armature STEP 3 Mount Mount the armature on top of the fan. You are now ready to press. STEP 4 Press Press the armature on the fan in a straight upright position step by step while rotating the tool Page 17
18 H Service Manual Special Tool H BCR164/6 / BCR300/12 Special tool H to mount seals in the BCR164/6 or BCR300/12 water bush To assemble 2x seals in water bush, BCR164/6: seals position number 55 water bush, position number 54 BCR300/12: seals position number 19 water bush, position number 18 See supported exploded views Assembly parts 1 2 2x Seals, part # Water bush BCR164/6, part # Water bush BCR300/12, part # STEP 1 STEP 2 STEP 3 Grease Apply silicon based grease inside the water bush Put on seal 1 Put the first seal on the long end of the special tool with the open side upward Position tool Positon the tool over the water bush. Keep the ridge on the water bush to the bottom. Page 18
19 H STEP 4 Press Press the seal in the water bush all the way down STEP 5 Put on seal 2 Put the second seal on the short end of the special tool with the open side downward STEP 6 Position and press Positon the tool over the water bush. Press the second seal in the water bush. Attention! Mount the lock ring, position number 56 on the supported exploded view Page 19
20 Service Manual Special Tool G BCR300/12 Special tool G for BCR300/12 safety clutch For fastening a BCR300/12 assembled safety clutch with a torque wrench STEP 1 Lock Lock the special tool in a vice STEP 2 Position Position the BCR300/12 assembled safety clutch in the special tool STEP 3 Secure Tighten the nut with a torque wrench to 9 kn/90 Nm. Attention: right handed thread CW Page 20
21 G 1 Service Manual Special Tool / BCR300/12 Special tool to assemble ball bearings in BCR300/12 gearbox with drill spindle To assemble ball bearings, position number 32, to gear box BCR300/12, position number 7, see supported exploded view Special tool to secure gear box with drill spindle to a vice Assembly parts Gear box BCR300/12 part # x Ball bearings part # STEP 1 STEP 2 Slide and lock Slide the special tool on the drill spindle and lock the tool to a vice Grease Grease both bearing holes with silicon based grease STEP 3 Position bearing 1 Position a ball bearing horizontally in place STEP 3 Position tool Position the special tool on top of the bearing STEP 4 Assemble Tap with caution the bearing gently in place with a rubber hammer. Page 21
22 / STEP 5 Position bearing 2 Position the second ball bearing horizontally in place STEP 6 Position tool Position the special tool on top of the second bearing STEP 7 Assemble Tap with caution the second bearing gently in place with the rubber hammer. Page 22
23 / Service Manual Special Tool / F BCR300/12 Special tool to secure gear box with drill spindle to a vice Special tool F to secure the drill spindle to BCR300/12 gearbox To secure lock ring, position number 5, and lock nut, position number 4, for gear spindle to gear box BCR300/12, position number 7, see supported exploded view Assembly parts Gear box BCR300/12 part # Lock ring part # Lock nut part # STEP 1 STEP 2 Slide and lock Position lock ring Slide the special tool on the drill spindle and lock the tool to a vice. ATTENTION: Be sure the ball bearings position number 32, part # are first mounted according sheet 1. STEP 3 Mount lock nut Page 23
24 / F STEP 4 Position tool Position the special tool over the drill spindle on the lock nut in such way that the tool tabs fits into the nut slots STEP 5 Tighten nut Secure the lock nut hand tight STEP 6 STEP 7 Position nut When tightened, position the lock nut in such way that one of the nut slots is above a lip of the lock ring Bend lip Bend the lip of the lock ring with a screwdriver into a positioned nut slot Page 24
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