SPECIAL TOOLS Core Drilling Machines Page 1 SERVICE MANUAL
Service Manual Necessary Tools for machine assembly BEAST by BBTEC Core Drilling Machines 1 Soft Hammer (preferred plastic head) Art. 6.512.096 2 Torque Wrench Range: 0-25 Nm. (19 mm square drive or socket head type) For BCR130/5BG & MG safety clutch Art. 6.512.097 3 Torque Wrench Range: > 100 Nm (22 mm square drive type) For BCR164/6 & BCR300/12 safety clutch Art. 6.512.098 4 Circlip Pliers for external retaining rings (10-25 mm) Art. 6.512.099 5 Outside snap ring Circlip Pliers (15-60 mm, with special tips for snap-rings and spring-clips) Art. 6.512.100 6 Circlip Pliers for internal retaining rings (straight, 19-60 mm) Art. 6.512.101 Page 2
Service Manual 7 Bearing Puller Tool (0-40 mm) Art. 6.512.102 8 Separator Tool (D max. > 50 mm) Art. 6.512.103 9 10 Blind Bearing Pullers / Split Collet Pullers (8-10.5 mm, 10.5-12.5 mm, 13-17 mm) Bench Press Tool Art. 6.512.104 Special Toolkit Case (see Service Manual Special Tools for use of each tool) 11 Page 3
08-170-162-01 Service Manual Special Tool 08-170-162-01 BCR130/5BG & MG, BCR164/6, BCR300/12 Special tool 08-170-162-01 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
06-220-833 Service Manual Special Tool 06-220-833 BCR130/5BG & MG Special tool 06-220-833 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 # 6.000.063 2x Seals Part # 6.502.013 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
06-220-833 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
06-220-836 Service Manual Special Tool 06-220-836 BCR130/5BG & MG Special tool 06-220-836 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 # 6.000.063 1x Seal, part # 6.502.014 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
06-220-836 STEP 3 Press Press the the seal gently in the hole Page 8
06-220-837 Service Manual Special Tool 06-220-837 BCR130/5BG & MG Special tool 06-220-837 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 # 6.000.063 Ball bearing part # 6.504.012 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
12-170-100-1 / 09-120-002-01 Service Manual Special Tool 12-170-100-1 / 09-120-002-01 BCR130/5BG & MG Special tools 12-170-100-1 and 09-120-002-01 for BCR130/5BG & MG safety clutch For fastening and adjusting the nut with a torque wrench To assemble a BCR130/5BG & MG safety clutch 1 7 6 5 4 3 2 Assembly parts 1 Gear spindle, part # 6.130.008 2 2x Washer, part # 6.130.009 3 Bearing bush, part # 6.130.011 4 Gear wheel #2, part # 6.130.010 5 Ring, part # 6.130.012 6 Spring washer, part # 6.505.017 7 Nut, part # 6.503.004 Used oil, cleaner and glue Shell Spirax AX 80W-90 Würth sabesto IndustrieClean, part # 0893 140-E or Loctite 7235 Nettoyant/Reiniger, part # 35953 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
12-170-100-1 / 09-120-002-01 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)
12-170-100-1 / 09-120-002-01 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
06-220-835 Service Manual Special Tool 06-220-835 BCR130/5BG & MG Special tool 06-220-835 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 # 6.130.013 1x Ball bearing, part # 6.504.021 1x Seal, part # 6.502.021 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
06-220-835 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
06-220-834 Service Manual Special Tool 06-220-834 BCR130/5BG & MG Special tool 06-220-834 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 # 6.130.013 2x Needle-bearings part # 6.504.011 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
08-170-165-01 Service Manual Special Tool 01-100-114-1 BCR164/6 Special tool 01-100-114-1 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
08-170-165-01 Service Manual Special Tool 08-170-165-01 BCR164/6 Special tool 08-170-165-01 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 # 6.513.098 Fan, part # 6.513.099 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
98-0090-02H Service Manual Special Tool 98-0090-02H BCR164/6 / BCR300/12 Special tool 98-0090-02H 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 # 6.502.125 1. Water bush BCR164/6, part # 6.164.040 2. Water bush BCR300/12, part # 6.250.020 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
98-0090-02H 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
01-100-114-1 Service Manual Special Tool 98-0090-02G BCR300/12 Special tool 98-0090-02G 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
98-0090-02G 1 Service Manual Special Tool 08-170-161-01 / 08-170-162-01 BCR300/12 Special tool 08-170-161-01 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 08-170-162-01 to secure gear box with drill spindle to a vice Assembly parts Gear box BCR300/12 part # 6.000.060 2x Ball bearings part # 6.504.060 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
08-170-161-01 / 08-170-162-01 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
08-170-161-01 / 08-170-162-01 2 Service Manual Special Tool 08-170-162-01 / 98-0090-02F BCR300/12 Special tool 08-170-162-01 to secure gear box with drill spindle to a vice Special tool 98-0090-02F 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 # 6.000.060 Lock ring part # 6.505.090 Lock nut part # 6.503.070 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 # 6.504.060 are first mounted according sheet 1. STEP 3 Mount lock nut Page 23
08-170-162-01 / 98-0090-02F 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