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 4270-59 STARTING SERIAL NUMBER D84A REVISED BULLETIN BULLETIN NO. 55-46-0070 DATE Mar. 2013 DRILL MOTOR WIRING INSTRUCTION See Page 5 MAG STAND WIRING INSTRUCTION See Pages 6 & 7 FIG. PART NO. DESCRIPTION OF PART QTY. 51 02-04-0640 Ball Bearing (1) 52 02-04-0820 Ball Bearing (1) 53 02-04-0845 Ball Bearing (1) 54 02-04-0911 Ball Bearing (1) 55 02-04-1536 Ball Bearing (1) 56 02-50-1640 Needle Bearing (1) 57 02-50-1645 Needle Bearing (1) 58 02-50-2440 Needle Bearing (1) 59 06-42-0800 Woodruff Key (2) 60 06-42-2000 Woodruff Key (1) 61 06-55-0835 Hex Nut (2) 62 06-72-1710 Nameplate Rivet (2) 63 06-82-2390 8-32 x 1-1/4" Pan Hd. Slotted T-20 (2) 64 06-82-7240 6-19 x.50 Pan Hd. Slotted Plastite T-15 (2) 65 06-82-9207 6-19 x.708 Pan Hd. PT Screw T-10 (2) 66 06-82-7375 8-16 x 2.50 Pan Hd. Slotted Plastite T-20 (2) 67 06-82-7382 8-16 x 1.625 Pan Hd. Slotted Plastite T-20 (1) 68 06-82-7410 8-16 x 1.875 Pan Hd. Slotted Plastite T-20 (2) 69 12-99-3360 Service Nameplate (1) 70 16-34-0490 Armature (1) 71 18-32-0532 Field (1) 72 22-18-1015 Carbon Brush Assembly (2) 73 22-22-1385 Brush Holder Assembly (1) 74 22-64-3295 Motor Cord Assembly (1) 75 23-44-0145 Brush Holder Cap (2) 76 43-44-1075 Gasket (1) 78 28-14-1922 Gearcase (1) 79 28-28-0611 Diaphragm (1) 80 31-05-0055 Baffl e (1) 81 31-15-2060 Motor Cover-Left Half (1) 82 31-15-2061 Motor Cover-Right Half (1) 83 31-50-0020 Motor Housing (1) 84 32-40-1251 Intermediate Gear (1) 85 32-75-2051 2nd Intermediate Gear (1) 86 32-75-2651 Spindle Gear (1) 87 34-60-1200 External Retaining Ring (1) 88 34-80-2500 Retaining Ring (1) 89 36-66-2811 Intermediate Pinion (1) FIG. PART NO. DESCRIPTION OF PART QTY. 90 36-66-3980 2nd Intermediate Pinion (1) 91 38-50-5485 Spindle (1) 92 44-60-0530 Grounding Pin (1) 93 22-84-0531 Fan (1) 94 43-44-1160 Screw Gasket (3) 23-94-6120 Leadwire Assembly (Not Shown) (1) 23-94-6370 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. 49-08-5270 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 13135 W. Lisbon Road, Brookfi eld, WI 53005 Drwg. 3
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. 00 0 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
FIG. PART NO. DESCRIPTION OF PART QTY. 1 --------------- Needle Bearing (1) 2 --------------- Roll Pin (1) 3 06-75-2900 1/4 x 3/8" Socket Head Screw (2) 4 06-75-3005 1/4 x 5/8" Socket Head Screw (5) 5 06-75-3100 1/4-20 x 1.00" Socket Head Screw (2) 6 06-75-5865 1/4-20 x 1.25" Socket Head Sems Screw (2) 7 06-81-4770 1/4-20 x 5/8" Button Head Cap Screw (2) 8 06-81-8655 6-32 x 1/4" Hex Hd. Sems Screw (1) 9 06-82-7252 8-32 x.38 Taptite Screw T-20 (5) 10 06-83-1650 10-32 x 1/2" Set Screw (4) 11 06-83-5170 3/8-24 x 1/4" Flat Point Set Screw (2) 12 06-83-6015 5/16-24 x 1/4" Set Screw (2) 13 06-81-8625 6-32 Slt. Hex Hd. Sems Machine Screw (2) 14 06-97-4050 1/4" Split Ring Lock Washer (9) 16 10-98-7050 Danger Label (1) 17 22-64-4270 Power Cord Assembly (1) 18 23-35-0380 Panel Assembly (See Pages 6 and 7) (1) 19 28-10-0099 Motor Bracket (1) 20 14-46-5405 Stabilizer and Needle Bearing Kit (1) 21 28-50-0600 Mag Stand (1) 22 31-17-0185 Cable Clamp (1) 23 32-60-0200 Pinion Gear (1) 24 34-60-3690 Retaining Ring-External (2) 25 --------------- Retaining Ring-Internal (2) 26 --------------- Conical Pilot Pin Spring (1) 27 14-73-0290 Cutter Shaft Kit (1) 28 42-40-0060 Bushing (2) 29 42-40-1055 Dovetail Cover (1) 30 --------------- Stationary Collar (1) 31 43-48-0150 Gib Plate (1) 32 43-94-0070 Wrench Keeper (1) 33 44-26-0080 Electromagnet (1) 34 44-66-6220 Spacer (1) 35 44-80-0200 Rack (1) FIG. PART NO. DESCRIPTION OF PART QTY. 36 --------------- Spring Seat (1) 37 45-14-0290 Shim (2) 38 23-66-2315 Drill Switch Assembly (1) 39 23-66-2295 Magnet Switch (1) 40 14-20-1205 Potted PCB Kit (1) 41 06-87-2570 Stop Knob (1) 43 43-98-0050 Plastic Knob (3) 44 06-87-2550 Handle Screw (1) 45 43-62-0070 Feed Handle (3) 46 14-46-5400 Handle Hub Kit (1) 48-58-0090 4' Safety Strap (Not Shown) (1) 49-96-0050 3/32" Hex Key (Not Shown) (1) 49-96-0080 3/16" Hex Key (Not Shown) (1) 23-35-0380 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
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 22-64-3295 18 4" Component of motor cord assy. Strip.18 for T3. 2 Blue 22-64-3295 18 5" Component of motor cord assy. Strip.18 for T3. 3 Green 22-64-3295 18 10" Component of motor cord assy. Strip.18 for T1. 4 Red 23-94-6120 18 5.5" Strip.18 for T1 and strip.25 for T2. 5 Black 23-94-6370 18 5.6" Strip.18 for T1 and strip.25 for T2. BULK LEAD WIRE - BULLETIN 58-01-0003 NOTE: All lead lengths are before stripping. All leads must be held to ±.125" unless specified elsewhere. Strip wire per ES 13-11. Crimp terminals per ES 13-15. TERMINAL DESCRIPTION Code Part No. Qty. T1 23-74-0605 1 T2 23-74-1060 4 T3 23-74-0410 2
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. 8 06-81-8650 6-32 x 1/4" Rd. Hd. Sems 1 9 06-82-7252 8-32 x 3/8" Pan Hd. Slt. Tapt. T-20 4 13 06-95-5150 Sems Machine Ground Screw 2 17 22-64-4270 Power Cord Assembly 1 18 23-35-0380 Control Panel Assembly 1 21 28-50-0600 Mag Stand Housing 1 24 22-64-3295 Motor Cord Assembly 1 33 44-26-0080 Electromagnetic Base 1 38 23-66-2315 Drill Switch Assembly 1 39 23-66-2295 Magnet Switch 1 40 14-20-1200 Electronics Assembly 1 Place wires as shown. Apply electrical tape to contain wires. See note 2. 1. 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. T1 23-74-0895 2 T2 23-74-0440 4 T3 23-74-0430 8 T4 --------------- 2
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. 23-35-0380 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