Special Tools Require Important! Torx TX0 bit 0 0 Screwdriver Torx 0 0 0 Forcing Discs 0 Before beginning the maintenance work, perform an initial check with a high voltage test according to VDE (see chapter Electrical and Mechanical Test Instructions). Before all repair work, pull the power plug from the socket! Disassembly Removing the QUIK-LOK cable Pull off the QUIK-LOK cable from the machine. Loosen the screw () and take apart the plug into two parts () and (). The screw () has a centrical pin (see enlargement). It can only be removed with a respective Torx screwdriver with a cantrical boring (A)! This Torx screwdriver is part of the service tool kit. It can also be ordered with order number 0. Pull down the cable entry sleeve () slightly. Loosen the screw () and disassemble the inner plug into three parts (), (), and (). Remove the contacts () with cables. A Removing the housing Remove the four screws () from the front part of the housing () and pull the housing off towards the front. In case of stiffness, tap the receiver with a plastic hammer for support! Loosen the six screws () and take apart the housing ().
Disassembling the gear Pull the complete gear assembly from the housing (A) and remove the following parts: washer () bearing () anvil () shaft assembly () bearing () planetary wheels () gear () planetary wheels (). Machines with /"-receiver: remove additional bearings () from the pins of the gear (). A Disassembling the housing Put the housing () on the press as shown in the illustration, and press out the bearing () with aid of a bushing (Ø =. mm) (). A suitable bushing is, for example, the driver of 00K/0K (). Remove two O-rings () from the bearing (). Ø.mm
Machines with /"-receiver To remove the pin () and the spring () from the anvil, please proceed as follows: Disassembling the anvil Bend a paper clip or a piece of wire as shown in illustration, so it will be shaped like a hook (. mm). Insert the hook into the opening in the anvil and turn it 0, such that the hook reaches under the spring. Pull the hook upwards until the pin disengages from the spring. Pull out the pin to the side and the spring upwards.. mm 0 Machines with /"-receiver Disassembling the anvil Bend open the ring () and remove it. Remove the O-ring (). Disassembling the anvil Fix the anvil () in a vice and pull out the needle bearing () with aid of an interior extractor. Remove the ball () from the anvil.
Removing the balls Put the shaft assembly () on the press and press it together until both balls () fall out. Machines with /"-receiver Disassembling the shaft assembly Remove the following parts from the shaft (): ram () bearing () washer () spring (). Machines with /"-receiver Disassembling the shaft assembly Remove the following parts from the shaft (): ram () bearing () washer () spring () two washers ().
Disassembling the gear case Remove the following parts from the gear case (): gear () gear () washer () O-ring (). Pull out both carbon brushes () upwards. Pull the armature () together with the gear case from the field. Remove the gasket () from the gear case (). Dispose of the gasket (), it can t be reused! Removing the armature Insert the armature () with the gear case () into the sleeve () ( inner Ø = mm) and put it on the press as shown in illustration. Press the armature from the gear case () with the plunger of the press (). 0
Removing the bearing Put the gear case () with the sleeve () ( inner Ø = mm) on the press and press out the bearing (). Pressing off the bearing Remove the rubber cap () from the bearing (). Put the armature () and the forcing discs on the press as shown in illustration, and press off the bearing () facing the collector.
Disconnecting the electric parts Remove the following parts from the housing halves: field () with field connector () switch () with set of wires () and capacitor () blade housing () carbon brush holders () and carbon brushes six rubber bungs (). Pull the field connector () from the field ().
Maintenance General Cleaning Check for wear Electrical tests It is recommended to regularly submit the tool to maintenance. Clean all parts with the exception of the electrical parts with cold cleaning agent. Caution! No cleaning agent should penetrate into the bearing. Clean the electrical parts with a dry brush. Check the disassembled parts for wear (visual inspection) and replace worn parts. Before reassembling, perform an electrical test on all relevant parts (see chapter Electrical and Mechanical Test Instructions). Lubrication Each time maintenance is performed, the machine is to be lubricates as stated in the lubrication plan. After the machine is fully disassembled, completely remove the old grease and replace with new grease. The grease must be applied to the machine as indicated in the lubrication plan. Lubrication chart: Fill res. cover with a total of 0 g grease type Z (Order No.: -0-). g g g g g g g g g g Torques Housing screws. Nm Gear case screws. Nm
Assembly Assembling the electric parts Insert three rubber bungs () into each one of the housing halves. Put the field connector () on the field () and insert them both into the housing half (). Mount the switch () with the set of wires () and the capacitor (). For detailed wiring diagram, see page 0. Insert the blade housing () into the lower part of the housing half (). Mount the carbon brushes in the brush holders () but do not yet insert them into the housing (). First insert the armature, then insert the brush holders () with the carbon brushes into the housing ().
0 Wiring diagram Detail choking coil insert into housing to carbon brush black wire from switch Detail field connection white wire from switch black wire from switch blue wire from switch blue wire from the lower carbon brush Switch bottom view blue blue black brown black black lead wire through domes lead wire between pin and housing ribs inser wire and into this relief white wire to field connector black wire to upper carbon brush black wire to lower carbon brush lead wire through domes black wire to field connector (connection ) brown mains cable blue mains cable black wire to field connector (connection ) blue wire to field connector (connection ) anti-interference capacitor
Mounting the bearing on the armature Press the bearing facing the collector () onto the armature shaft. Pull the rubber cap () over the bearing (). Mounting the bearing in the gear case Press the bearing () into the gear case () as far as it will go, using a press. Pressing on the gear case Press the gear case () onto the armature shaft ().
Inserting the armature Pull a new gasket () over the gear case (). Insert the gear case () together with the armature into the field () as far as it will go. Insert the carbon brushes () on both sides into the reliefs in the housing, next to the collector. Mount the following parts in the gear case (): O-ring () washer () gear () gear (). Machines with /"-receiver Assembling the shaft Mount the following parts on the shaft (): spring () washer () bearing () ram ().
Machines with /"-receiver Assembling the shaft Mount the following parts on the shaft (): two washers () spring () washer () bearing () ram (). Mounting the balls Put the shaft assembly () on the press and depress it against resilience (in direction of arrow) and insert both balls () into the grooves of the shaft. Slowly release the pressure. Mounting the anvil Insert the ball () into the anvil (). Press the needle bearing () into the anvil. Machines with /"-receiver Mounting the anvil First insert the pin (), then the spring () into the anvil (). The groove of the pin must be in the anvil! Depress the spring () with a hook (see page, illustration top), until the pin () engages.
Machines with /"-receiver Mounting the anvil Insert the O-ring () into the groove. Pull over the ring (). Mounting the housing Mount two O-rings () on the bearing (). Press the bearing () into the housing () with aid of a bushing (Ø =. mm) (). A suitable bushing is, for example, the driver of the machines 00K/0K (). 0 Assembling the gear Machines with /"-receiver: Mount three bearings () on the pins of the gear (). Mount the following parts on the gear shaft () and insert the assembly into the housing (A): bearing () planetary wheels () gear () planetary wheels () anvil () bearing () washer (). A
Mounting the housing Fix the housing halves () with six screws (). Put the complete front part of the gear case () on the machine, at the same time carefully insert the gear assembly into the machine and turn the square seat until the front part of the gear case () is flush with the motor housing. Fix the front part of the gear case () with four screws (). Insulating the mains cable Insulate the mains cable as shown in illustration. Meet the following measures: Insulating length of wires: approx. mm Wire length with insulation: approx. mm mm mm
Mounting the QUIK-LOK cable Producing a strain relief Insert the mains cable into the new crimping contacts () in accordance with regulations and make a correct crimp connection with aid of a crimping tool (see both illustrations of the crimp connection on the right). Only a correct crimp connection can meet all mechanical and electrical requirements! Insert the crimping contacts () with wires () into the sleeve. Insert the plug halves () and () into the sleeve () on both sides and fix them with the screw (). Provide mm wire for strain relief (see lower illustration)! correct crimp connection cross section: crimp barrel Insert the cable entry sleeve () and the assembled sleeve () into the plug (). Put together the two halves of the plug () and () and fasten them with the screw (). The screw () has a centrical pin (see enlargment). It can only be fastened with a Torx screwdriver with a respective centrical guide boring (A)! This Torx screwdriver is part of the service tool kit. It is also available as service bit Lfb (order number 0). A mm Test Run Electrical Test Test run the machine and pay attention to noises. Let the machine run-in. Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).