SERVICE PARTS LIST BULLETIN NO MAG STAND ASSEMBLY CATALOG NO. D84A SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS
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1 00 0 EXAMPLE: Component Parts (Small #) Are Included When Ordering The Assembly (Large #). SERVICE PARTS LIST SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS CATALOG NO. MAG STAND ASSEMBLY STARTING SERIAL NUMBER D84A REVISED BULLETIN BULLETIN NO DATE Mar DRILL MOTOR WIRING INSTRUCTION See Page 5 MAG STAND WIRING INSTRUCTION See Pages 6 & 7 FIG. PART NO. DESCRIPTION OF PART QTY Ball Bearing (1) Ball Bearing (1) Ball Bearing (1) Ball Bearing (1) Ball Bearing (1) Needle Bearing (1) Needle Bearing (1) Needle Bearing (1) Woodruff Key (2) Woodruff Key (1) Hex Nut (2) Nameplate Rivet (2) x 1-1/4" Pan Hd. Slotted T-20 (2) x.50 Pan Hd. Slotted Plastite T-15 (2) x.708 Pan Hd. PT Screw T-10 (2) x 2.50 Pan Hd. Slotted Plastite T-20 (2) x Pan Hd. Slotted Plastite T-20 (1) x Pan Hd. Slotted Plastite T-20 (2) Service Nameplate (1) Armature (1) Field (1) Carbon Brush Assembly (2) Brush Holder Assembly (1) Motor Cord Assembly (1) Brush Holder Cap (2) Gasket (1) Gearcase (1) Diaphragm (1) Baffl e (1) Motor Cover-Left Half (1) Motor Cover-Right Half (1) Motor Housing (1) Intermediate Gear (1) nd Intermediate Gear (1) Spindle Gear (1) External Retaining Ring (1) Retaining Ring (1) Intermediate Pinion (1) FIG. PART NO. DESCRIPTION OF PART QTY nd Intermediate Pinion (1) Spindle (1) Grounding Pin (1) Fan (1) Screw Gasket (3) Leadwire Assembly (Not Shown) (1) Leadwire Assembly (Not Shown) (1) FIG. NOTES: 53 Ball bearing seal to face towards the commutator. 53,54,70 Press ball bearings to armature shaft shoulder. 56,57,79 Press needle bearings to.105 ±.005 above machined face of diaphragm. 74,81,82 Using a 22mm crows foot wrench, apply 40 in/lbs of torque to fi tting nut and to locking nut when assembling the motor cord assembly to the motor covers. FIG. LUBRICATION: 51,78 Apply 3.75 oz. type "Y" grease, No near ball bearing #1 in gearcase. SEE PAGES 6 AND 7 FOR OPERATIONAL CHECK LIST AND WIRING INSTRUCTIONS FOR MAG STANDS MILWAUKEE ELECTRIC TOOL CORPORATION W. Lisbon Road, Brookfi eld, WI Drwg. 3
2 Using a 22mm crows foot wrench, apply 40 in/lbs of torque to the straight thru fi tting and to the dome nut when assembling the motor cord to the stand EXAMPLE: Component Parts (Small #) Are Included When Ordering The Assembly (Large #). Using a 7/8" crows foot wrench, apply 45 in/lbs of torque to the pigtail fi tting and 35 in/lbs of torque to the locking nut when assembling the power cord (17) to the control panel (18). SEE PAGES 6 AND 7 FOR OPERATIONAL CHECK LIST AND WIRING INSTRUCTIONS FOR MAG STANDS
3 FIG. PART NO. DESCRIPTION OF PART QTY Needle Bearing (1) Roll Pin (1) /4 x 3/8" Socket Head Screw (2) /4 x 5/8" Socket Head Screw (5) /4-20 x 1.00" Socket Head Screw (2) /4-20 x 1.25" Socket Head Sems Screw (2) /4-20 x 5/8" Button Head Cap Screw (2) x 1/4" Hex Hd. Sems Screw (1) x.38 Taptite Screw T-20 (5) x 1/2" Set Screw (4) /8-24 x 1/4" Flat Point Set Screw (2) /16-24 x 1/4" Set Screw (2) Slt. Hex Hd. Sems Machine Screw (2) /4" Split Ring Lock Washer (9) Danger Label (1) Power Cord Assembly (1) Panel Assembly (See Pages 6 and 7) (1) Motor Bracket (1) Stabilizer and Needle Bearing Kit (1) Mag Stand (1) Cable Clamp (1) Pinion Gear (1) Retaining Ring-External (2) Retaining Ring-Internal (2) Conical Pilot Pin Spring (1) Cutter Shaft Kit (1) Bushing (2) Dovetail Cover (1) Stationary Collar (1) Gib Plate (1) Wrench Keeper (1) Electromagnet (1) Spacer (1) Rack (1) FIG. PART NO. DESCRIPTION OF PART QTY Spring Seat (1) Shim (2) Drill Switch Assembly (1) Magnet Switch (1) Potted PCB Kit (1) Stop Knob (1) Plastic Knob (3) Handle Screw (1) Feed Handle (3) Handle Hub Kit (1) ' Safety Strap (Not Shown) (1) /32" Hex Key (Not Shown) (1) /16" Hex Key (Not Shown) (1) TROUBLE SHOOTING ACTION RESPONSE POSSIBLE CAUSE SOLUTION Magnet is on. Tool does not operate. 1. Drill switch was on 1. Turn drill switch off, Drill switch is on. Magnet switch lamp when magnet then back on. is on. was turned on. 2. Control module is 2. Replace control Magnet switch is Magnet switch lamp 1. Magnet is 1. Check magnet turned on. turns on, then off. resistance, 970 to 1000 ohms. 2. Wiring from 2. Repair or replace magnet to control wiring. module is 3. Control module is 3. Replace control 4. Voltage is too low/ 4. Check for 230 extension cord is too VAC at cord end. long or wrong gauge. Check extension cord length and gauge. Magnet switch is Magnet switch lamp 1. Motor brushes are 1. Replace brushes. turned on. Drill is on, turns off when worn. switch is turned on. drill switch is turned "on". 2. Control module is 2. Replace control
4
5 WIRING INSTRUCTIONS - MAG STAND DRILL MOTOR AS AN AID TO REASSEMBLY, TAKE NOTE OF WIRE ROUTING AND POSITION IN WIRE GUIDES AND TRAPS WHILE DISMANTLING TOOL. INSERT RED LEADWIRE #4 AND BLACK LEADWIRE #5 INTO TRAPS ON BRUSH TUBE HOLDER. INSERT GREEN GROUND WIRE #3 INTO WIRE TRAP GROOVE ON THIS SIDE OF THE MOTOR HOUSING. CORD JACKET TO EXTEND.13 TO.25 MINIMUM PAST FITTINGS. USING A 22MM CROWS FOOT WRENCH, APPLY 40 IN/LBS OF TORQUE TO FITTING NUT AND TO LOCK- ING NUT WHEN ASSEMBLING THE MOTOR CORD ASSEMBLY TO THE MOTOR COVERS. WIRING SPECIFICATIONS Wire No. Wire Color Origin or Part No. Gauge Length Terminals, Connectors and End Wire Preparation 1 Brown " Component of motor cord assy. Strip.18 for T3. 2 Blue " Component of motor cord assy. Strip.18 for T3. 3 Green " Component of motor cord assy. Strip.18 for T1. 4 Red " Strip.18 for T1 and strip.25 for T2. 5 Black " Strip.18 for T1 and strip.25 for T2. BULK LEAD WIRE - BULLETIN NOTE: All lead lengths are before stripping. All leads must be held to ±.125" unless specified elsewhere. Strip wire per ES Crimp terminals per ES TERMINAL DESCRIPTION Code Part No. Qty. T T T
6 WIRING INSTRUCTION AND SERVICE PARTS LIST - MAG STAND CONTROL PANEL 00 0 EXAMPLE: Component Parts (Small #) Are Included When Ordering The Assembly (Large #). IMPORTANT! Remove the fi lm from the back of the terminal pad prior to assembly. SEE PAGE 7 BEFORE WIRING FOR IMPORTANT NOTES AND OPERATIONAL CHECK PROCEDURE See note 2. FIG. PART NO. DESCRIPTION OF PART NO. REQ x 1/4" Rd. Hd. Sems x 3/8" Pan Hd. Slt. Tapt. T Sems Machine Ground Screw Power Cord Assembly Control Panel Assembly Mag Stand Housing Motor Cord Assembly Electromagnetic Base Drill Switch Assembly Magnet Switch Electronics Assembly 1 Place wires as shown. Apply electrical tape to contain wires. See note Route two magnetic base leads (brown wires #10 and 11) through the opening in the bottom of the mag stand housing #21. CHOKE DETAIL 2. Secure the cord #24 from drill in the top opening of the mag stand housing. The cord jacket is to extend.13 to.25 minimum beyond the fi ttings. 3. Secure the power cord assembly #17 to the control panel kit #18. The cord jacket is to extend.13 to.25 minimum beyond the fi ttings. 4. Attach ground terminals from green wires #3 and #6 to mag stand housing with ground screws #13. Orient the terminals as shown. 5. Orient terminal pad (component of the potted pcb kit), as shown. Remove film from the back of the terminal pad and secure to mag stand housing with screw #8. 6. Attach the leads from the magnetic base, as shown. Note: the leads from the magnetic base are intrerchangeable and can be attached to the panel in either location. 7. Route brown wire #4 from the power cord assembly next to the wire trap on the electronics assembly, as shown. 8. Connect all wires, as shown. In assembly, wires #5, #6, #10 and #11 must be contained beneath the electronics boat. 9. Apply electrical tape, as shown, to contain wires on the face of the electronics boat. 10. Align the potted boat with the groove in the mag stand housing cavity. Gently push the bundle of wires and the control panel assembly into the housing. Avoid pinching wires as the control panel is being installed. ATTENTION Observe precautions for handling electrostatic sensitive devices WIRE TIE DETAIL Wire tie wires in this area, as shown. Wires that are affected: 7, 8, 12, 13, 14, 15, 17, 18 and 19. TERMINAL DESCRIPTION Code Part No. Qnty. T T T T
7 OPERATIONAL CHECK LIST 1. DIELECTRIC POTENTIAL TESTING Dielectric potential testing should be conducted on a fully assembled tool that has successfully completed a ground continuity test. The dielectric potential voltage should be between 1200 and 1320 VAC. 2. SET UP A. Place the magnetic drill stand on a steel plate. B. Verify that the magnet switch is "OFF". C. Verify that the drill switch is "OFF". D. Plug magnetic drill stand into a 230 V AC receptacle. Response: Motor does not operate. Red lamp on the magnet switch is off. 3. MAGNET SWITCH TEST A. Push the magnet switch "ON". Response: Red lamp on magnet switch is lit. The motor does not operate. B. Verify that the magnetic drill stand cannot be easily moved on the steel surface. 4. NORMAL DRILLING A. Pull the drill switch "ON". Response: Magnet is on, "MAGNET" button is lit, drill motor is on (operating). 5. LINE LOCKOUT A. Push the drill switch "OFF". Response: The motor stops operating. B. Push the magnet switch "OFF". Response: The magnet and red lamp are off. C. Pull drill switch "ON". Response: The motor will not operate. D. Turn magnet switch "ON". Response: The motor will not operate. Magnet is on, "MAGNET" button is lit. 6. END OF TEST A. Turn both switches "OFF". B. Unplug magnetic drill stand from 230 V AC receptacle TROUBLE SHOOTING ACTION RESPONSE POSSIBLE CAUSE SOLUTION Magnet is on. Tool does not operate. 1. Drill switch was on 1. Turn drill switch off, Drill switch is on. Magnet switch lamp when magnet then back on. is on. was turned on. 2. Control module is 2. Replace control Magnet switch is Magnet switch lamp 1. Magnet is 1. Check magnet turned on. turns on, then off. resistance, 970 to 1000 ohms. 2. Wiring from 2. Repair or replace magnet to control wiring. module is 3. Control module is 3. Replace control 4. Voltage is too low/ 4. Check for 230 extension cord is too VAC at cord end. long or wrong gauge. Check extension cord length and gauge. Magnet switch is Magnet switch lamp 1. Motor brushes are 1. Replace brushes. turned on. Drill is on, turns off when worn. switch is turned on. drill switch is turned "on". 2. Control module is 2. Replace control
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