DM100W & DM100D Service Manual pg 2 I General A Notes The diamond core drill should only be repaired by an authorized service center The following ins

Transcription

1 SERVICE MANUAL (DM100W Shown) DM100W & DM100D Hand-Held Core Drill Motors Contents I General II Motor Section III Gearing Section IV Re-Assembly V Check-List for Testing Machine VI Grease and Glue VII Wiring Diagram VIII Parts List 0A7773 Copyright August, 1997 DBInc Printed in U S A West 119th Street Olathe, Kansas Customer Service Corp Office Cust Service FAX Corp Office FAX Int l FAX

2 DM100W & DM100D Service Manual pg 2 I General A Notes The diamond core drill should only be repaired by an authorized service center The following instructions along with a complete parts list should be used to properly repair the drill Note that numbered items refer to items as listed in the parts list (see section VIII) of this document For example: Item 1 of the parts list would simply be refered to as (1) throughout the document B Before You Begin To avoid electric shock, unplug the drill from the power supply before attempting service! Read any information obtained from the user concerning how the motor failed as well as the symptoms that the faulty drill motor is experiencing Next, run the motor to verify the faulty symptoms It may be necessary to run the motor under load to experience the fault If the motor is equipped with a PRCD (portable residual current device) and the motor will not run, bypass the PRCD to determine that the PRCD is not at fault Mark areas of the motor and gear housing so that reassembly in the same orientation is possible II Motor Section A Initial Preparation Remove the side handle and the water supply so they are not in your way Next loosen the four machine screws M5x2O (46) and pull off the gearbox (39) Remove the gearbox seal (32) and the grease from gear bearing holder (31) Now dismantling of motor part can start fig 1 B Handle Half Removal (fig 1) Remove the three self-tapping screws 4 2x22 (29) which fasten both halves of the handle together Remove the two selftapping screws 4 8x45 (21) which fix the upper half of handle onto motor housing After removing upper half of handle (12), the switch, anti-parasitic capacitor, piezo-alarm transmitter, and electronic card are exposed C Switch Remove & Testing (fig 2) Disconnect all connections to the switch (24) and remove (see section VII) Test the continuity from to with the switch engaged There should read continuity only with the switch engaged If there is no continuity, then the switch is faulty The switch could be faulty even if it passes this test fig 2 D Complete Handle Removal & Motor Test (fig 3) Remove the second half of the handle to fully expose the electronic card (15) Disconnect all leads from the motor to the electronic card Before removing the electronic card, test the motor by applying the correct voltage across the two white wires (A & B) Apply 110V or 220V depending on the motor type Be sure and apply this voltage for only 1-2 seconds because this test bypasses the speed control provided by the electronic card If the motor appears to work properly during this test, then it is likely that the electronic card is at fault An Ohm meter placed between (A & B) will reveal the following values: 110V = Ohm, 220V = 2-4 Ohm Turn the rotor to different contacts to check that all contacts fall within the correct Ohm range

3 DM100W & DM100D Service Manual pg 3 fig 3 E Electronic Card Removal (fig 3&4) Attention: Glue is used to affix the speed sensor (C) of the electronic card to the motor housing To remove the electronic card, scrape away the glue that holds the speed sensor into the motor housing Then remove the two self- tapping screws 4 2x25 (17) Carefully lift off the electronic card taking care not to damage the speed sensor (C) F Brush Removal (fig 5) Remove both brush holder covers (5) Pull the carbon brushes (7) out of the brush holder Inspect the brushes for excessive wear or damage fig 4 G Rotor Removal (fig 6&7) Unscrew the gear bearing holder (31) from motor housing by removing the four screws 4 5x50 (37) Subsequently, slide the bearing shield and the rotor together out of motor housing Remove the two machine screws M4x16 (11) and press the rotor (1) out of the gear bearing holder Now the rotor can be checked and repaired if it is necessary Give care to the magnetic disc (D), the bearings (E) and the correct position of the fig 5 bearing cap (F) If magnetic disc shows damages of any kind or the disc is sliding on the rotor shaft, exchange the complete rotor The magnetic disk is held onto the rotor shaft with special glue, and is difficult to repair The speed control will not work correctly with a faulty magnetic disc A special press is needed to remove the bearings from the rotor shaft Note: The DM100W and DM100D have different rotor designs and are not interchangeable fig 6 fig 7

4 DM100W & DM100D Service Manual pg 4 H Motor Housing Replacement If it is necessary to replace the motor housing (3) do the following: Disconnect the stator from brushes Unscrew the brush holders (6) from motor housing Remove the air cooling ring (4) out of the motor housing Remove the two selftapping screws 4 2x25 (17) that hold the stator (2) in place Press out the stator III Gearing Section A Coupling Assembly Removal (fig 8 & 9) Before dismantling gears, remove grease After that, take out the coupling (51)(fig 8) The torque of the safety clutch must be set at in lbs (35-40 N m) for DM100W or in lbs (28-30 N m) for DM100D Coupling assembly must be replaced if torque is not within this tolerance A special fixture is used to determine the torque setting The width of the special washers (Y) set the torque of the clutch Note that the gear cut of the coupling wheel (49)(Z) is 25 on the DM100W The DM100D uses a 15 wheel Earlier versions of the DM100W that used the 15 wheel must have the coupling assembly and rotor replaced The retaining ring (X) must be rotated to a position where good contact is made at all points Pay attention to the orientation of the Belville washers as denoted by a ( or ) in the diagram (fig 9) These symbols represent the direction of bow in the washer Special grease is used between coupling wheel (49) and coupling half (50) (see section VI) fig 8 fig 9 B Gear Switch Removal (fig 10) Now lift out the gear switch (61) with mounting lever Pay attention to the spring (62) and the small ball (63) in the switch Install new O-rings (64&65) if they are damaged Don t install the same switch if tabs are broken or bent fig 10 C Spindle Shaft Removal (fig 11) Remove the 20mm snap-ring (59) that holds the spindle shaft (60) in place Next, press out the spindle toward the direction of the threaded end Examine the spindle for excessive wear or damage

5 DM100W & DM100D Service Manual pg 5 D Bearing and Water Seal Removal (fig 12, 13 & 14) Press out the front bearing (45)(fig 12) Replace the shaft seals (40&41)(fig 13) with new genuine parts The shaft seals of the DM100W may have been damaged by dry drilling The two seals of the DM100W are different and must be placed in the orientation shown (item 40&41 fig 14) Note that the DM100D uses only one shaft seal (41) The seals also require a special seal grease to be placed within them (see section VI) Maximum water pressure for seal is 145psi (10bar) Dismantling bearings in gearbox housing and gear bearing holder can be accomplished easier by heating up the gearbox housing (39) fig 12 fig 13 fig 14 IV Re-Assembly A Re-Assemble Motor Assembly starts with the motor housing (3) Press in the stator (2) without damaging any wires and fix the stator in its position with two self-tapping screws 4 2x25 (17) After that, connect the brush holders (6) to the motor housing with selftapping screws 2 9x9 5 (10) Now insert the air conditioning ring (4) with the hole located on same side as the warning label Next, put a small amount of gearbox grease (see section VII) on the bearing cap (72) to ease rotor assembly Press the rotor (2) in the gear bearing holder (31) and lock the rotor with two machine screws (11) Press the prepared arrangement into the motor housing, and fasten using four self-tapping screws 4 5x50 (37) The rotor should move freely Note: No wires must touch the rotor Next, insert the brushes (7) into position and attach the brush holder covers (5) Continue assembly by attaching the electronic card (15) to the motor housing using the spacers (14) and two self-tapping screws 4 2x25 (17) Use silicon glue to fix the speed sensor into position in the motor housing Make necessary connections to the electronic card (see section VII) Next, fasten the lower half of handle cover and place switch and cord with electric cable grommet Make all electric connections; switch / electronic card, switch cord, ground wire cord (see section VII wiring diagram) Attention, all wires must be neatly arranged so they will not be damaged Connect the piezo-alarm transmitter with electronic card, then install it in the handle cover Finish the assembly of motor part with installation of upper half of hand cover

6 DM100W & DM100D Service Manual pg 6 B Re-Assemble Gearbox Start with gearbox housing (39) First insert the inner bearing (44) into the gearbox housing Then place the shaft seal(s) (two for DM100W, one for DM100D) into proper position (see fig 14) Be sure and use special seal grease within the seals before installation (see section VI) After inserting the outer bearing (45), press the spindle shaft (60) into place Secure the spindle with the snap-ring (59) Locate the gearblock (58)(large gear first) onto spindle Coat the gear switch O-rings (64&65) with gearbox grease before installation (see section VI) With the proper O-rings in place, press the gear switch (61) into position in the gearbox housing paying special attention to the spring (62) and ball (63) The O-rings (64&65) must not be damaged or squeezed Take special care not to damage the coupling (51) Coupling wheel (49) and coupling half (50) must slide well on intermediary shaft in order to guarantee the full functionality of the safety clutch In addition, it is very important to use only couplings that meet the specified torque settings Place the coupling (51) in the gear housing (39) and fill half full with special gearbox grease Next, put the gearbox seal (41) on the gear bearing holder (31) and fasten motor section to gear section using four machine screws (46) Lastly, assemble side handle (67) and water supply (67-74)(DM100W version only) V Check-List for Testing Machine G G G G Check for correct assembly Check the functionality of the machine in first and second gear Test speed control in different switch positions Check that machine is properly grounded VI Grease and Glue Special grease and glue are used in various locations on the drill motor Below is a description of the special grease or glue and where it is used: 1 Gearbox Grease Product: Rhenus Norlith LPG 00 Where Used: --Inside gearbox housing (39)(about 1/2 full) --On bearing cap (72) to aid in installation of rotor --On O-rings (64&65) gear switch (61) 2 Clutch Grease Product: Lubcon Special Turmogrease NBI2 Where Used: --Between coupling wheel (49) and coupling half (50) 3 Seal Grease Product: Where Used: Rhenus Norlith LZP2 --Inside shaft seal(s) (40&41) 4 Sensor Glue Product: Silicon Glue Where Used: --To hold speed sensor on electronic card (15) into position in motor housing (3)

7 DM100W & DM100D Service Manual pg 7 VII Wiring Diagram

8 DM100W & DM100D Service Manual pg 8 VIII Parts List DM100W (Wet)

9 DM100W & DM100D Service Manual pg 9 DM100D (Dry)

10 DM100W & DM100D Service Manual pg 10 DBI P/N English Description Part Wear Qty Q/100 Pack Wt (g) 1 W Rotor Complete (110V) - Wet A (High Wear) 1 5 Carton 1015 W Rotor Complete (220V) - Wet A (High Wear) 1 5 Carton 1015 D Rotor Complete (110V) - Dry A (High Wear) 1 5 Carton 1015 D Rotor Complete (220V) - Dry A (High Wear) 1 5 Carton W D Stator Complete (110V) A (High Wear) 1 3 Carton 1100 W D Stator Complete (220V) A (High Wear) 1 3 Carton W D Motor Housing B (Med Wear) 1 5 Carton W D Air Cooling Ring B (Med Wear) 1 5 Carton 19 5 W D Brush Holder Cover C (Low Wear) 2 10 Plastic Bag 5 6 W D Brush Holder B (Med Wear) 2 10 Carton W D Brushes A (High Wear) 2 20 Plastic Bag W D Contact Washer C (Low Wear) 2 10 Plastic Bag W Machine Screw C (Low Wear) 1 10 Plastic Bag W D Self-Tapping Screw C (Low Wear) 4 20 Plastic Bag W D Machine Screw C (Low Wear) 2 10 Plastic Bag W D Handle Cover Half C (Low Wear) 1 10 Carton W D Spring Washer C (Low Wear) 5 20 Plastic Bag W D Spacer C (Low Wear) 2 10 Plastic Bag W D Electronic Card Complete (110V) B (Med Wear) 1 5 Carton 33 W D Electronic Card Complete (220V) B (Med Wear) 1 5 Carton W D Self-Tapping Screw C (Low Wear) 2 10 Plastic Bag W D Piezo-Alarm Transmitter C (Low Wear) 1 5 Plastic Bag W D O-Ring C (Low Wear) 1 3 Plastic Bag W D Cylinder Screw C (Low Wear) 2 10 Plastic Bag W D Self-Tapping Screw C (Low Wear) 4 20 Plastic Bag 5 22 W D Anti-Parasitic Capacitor C (Low Wear) 1 5 Plastic Bag W D Washer C (Low Wear) 2 5 Plastic Bag W D Switch A (High Wear) 1 5 Plastic Bag W Cord w/ PRCD (220V) - Wet C (Low Wear) 1 3 Carton 585 W D Cord w/ Plug (110V) W/D C (Low Wear) 1 3 D Cord w/ Plug (220V) - Dry C (Low Wear) W D Electric Cable Grommet C (Low Wear) 1 3 Plastic Bag W D Wire Locking Flange C (Low Wear) 1 3 Plastic Bag W D Self-Tapping Screw C (Low Wear) 4 10 Plastic Bag W D Self-Tapping Screw C (Low Wear) 3 20 Plastic Bag 2 30 W Ground Wire C (Low Wear) 1 3 Plastic Bag 6 31 W Gear Bearing Holder - Wet C (Low Wear) 1 3 Carton 72 D Gear Bearing Holder - Dry C (Low Wear) 1 3 Carton W D Gearbox Seal C (Low Wear) 2 10 Plastic Bag W D Ring C (Low Wear) 3 Plastic Bag Radial Shaft Seal -->[1] C (Low Wear) 1 3 Plastic Bag W D Needle Bearing C (Low Wear) 2 5 Plastic Bag W D Needle Bearing C (Low Wear) 1 3 Plastic Bag W D Screw C (Low Wear) 4 20 Plastic Bag 3 38 W D Contact Pin C (Low Wear) 1 3 Plastic Bag W Gearbox Housing - Wet C (Low Wear) 1 3 Plastic Bag 555 D Gearbox Housing - Dry C (Low Wear) 1 3 Plastic Bag W Shaft Seal B (Med Wear) 1 3 Plastic Bag W D Shaft Seal B (Med Wear) 1 3 Plastic Bag 7.5

11 DM100W & DM100D Service Manual pg 11 DBI P/N English Description Part Wear Qty Q/100 Pack Wt (g) 42 W Screw Cap C (Low Wear) 1 5 Plastic Bag W Seal C (Low Wear) 2 5 Plastic Bag W D Ball Bearing C (Low Wear) 1 3 Plastic Bag W D Ball Bearing C (Low Wear) 1 3 Plastic Bag W D Machine Screw C (Low Wear) 4 20 Plastic Bag 4 47 W D Spring Ring (Lockwasher) C (Low Wear) 4 20 Plastic Bag W D Gear Shaft B (Med Wear) 1 5 Carton W Coupling Wheel - Wet B (Med Wear) 1 3 Carton 58 D Coupling Wheel - Dry B (Med Wear) 1 3 Carton W D Coupling Half B (Med Wear) 1 3 Carton W Coupling Complete - Wet B (Med Wear) 1 3 D Coupling Complete - Dry B (Med Wear) W D Key C (Low Wear) 1 3 Plastic Bag W D Adjusting Washer B (Med Wear) 1 3 Plastic Bag W Adjusting Washer C (Low Wear) 1 3 Plastic Bag 0.5 D Adjusting Washer C (Low Wear) 1 3 Plastic Bag W D Pressure Washer B (Med Wear) 1 3 Plastic Bag 1 56 W D Safety Washer (Snap-Ring) C (Low Wear) 1 3 Plastic Bag W D Spring Washer B (Med Wear) 4 20 Plastic Bag W D Gear B (Med Wear) 1 5 Carton W D Safety Ring (Snap-Ring) C (Low Wear) 1 3 Plastic Bag W Shaft - Wet B (Med Wear) 1 3 Carton 359 D Shaft - Dry B (Med Wear) 1 3 Carton W D Gear Switch (Incl. Items 62-65) B (Med Wear) 1 10 Plastic Bag W D Spring C (Low Wear) 63 W D Ball C (Low Wear) 64 W D O-Ring B (Med Wear) 65 W D O-Ring B (Med Wear) 66 W Water Hose C (Low Wear) 1 5 Plastic Bag W D Side Handle Complete C (Low Wear) 1 5 Carton W Plate C (Low Wear) 1 5 Plastic Bag W Water Tap C (Low Wear) 1 5 Plastic Bag W Seal C (Low Wear) 2 10 Plastic Bag W Fitting, 1/4-19 BSPP - QD A (High Wear) 1 20 W Coupling C (Low Wear) 1 5 Plastic Bag W D Bearing Cap C (Low Wear) 1 5 Plastic Bag W Fitting, 3/4F Garden Hose - QD B (Med Wear) 1 5 Notes: [1] P/N NLA on DM100D - SN (230V), SN (110V)

12 17400 W 119th Street Olathe, Kansas Customer Service Corp Office Cust Service FAX Corp Office FAX Int l FAX