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4939 5258 01
Special Tools
Forcing discs
Require
Allen key 4 mm
Allen key 5 mm
Sleeve
Pin-type face spanner
Important!
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
1
Removing the
Remove the handle (1) by turning it
auxiliary handle
counter-clockwise.
1
Disassembling
Unscrew the knob (3) and remove the
the handle
screw (1).
2
Press the spring ring (2) in direction of the
arrow and remove the handle (4).
4931 599 018
4931 599 001
4931 599 002
4931 599 098
4931 599 099
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Summary of Contents for Milwaukee K900K
- Page 1 PAGE 4939 5258 01 Special Tools Forcing discs 4931 599 018 Require Allen key 4 mm 4931 599 001 Allen key 5 mm 4931 599 002 Sleeve 4931 599 098 Pin-type face spanner 4931 599 099 Important! Before beginning the maintenance work, perform an initial check with a high voltage test according to VDE (see chapter Electrical and Mechanical Test Instructions).
- Page 2 PAGE 4939 5258 01 Removing the Remove both retainers (1). spring ring Slightly spread the spring ring (2) and pull it off the machine towards the front. Removing the Remove the four screws (4) with an Allen tool acceptance key and remove the tool acceptance (1). If necessary, tap the tool accept- ance (1) with a plastic hammer for support!
- Page 3 PAGE 4939 5258 01 Combined Expel the complete spindle assembly with light taps on the rear spindle end (1) with drill/chisel a plastic hammer. hammer: Removing the spindle Chisel Loosen the seal ring (3) with circlip pliers from the spindle groove. hammer: Expel the complete spindle assembly with light taps on the rear spindle end (4) with...
- Page 4 PAGE 4939 5258 01 Disassembling Remove the thrust collar (1) from the the spindle spindle (7). Remove the O-ring (2) from the thrust collar (1). Expel the percussion body (5) from the spindle (7) by tapping it lightly with a plastic hammer.
- Page 5 PAGE 4939 5258 01 Disassembling Machines with date of manufacture up 06/2004 the spindle to 06/2004: Turn the cross bracket (1) (width 7 mm) 90° and remove it through one of the openings i the spindle (2). 7 mm 36 mm oder 39 mm 90°...
- Page 6 PAGE 4939 5258 01 Removing the Bring the piston (3) into the upper dead piston assembly centre position and remove it from the upwards position. Loosen the O-ring (2) from the piston (3). Combined drill/chisel hammer: Additionally remove the spindle bevel gear (1).
- Page 7 PAGE 4939 5258 01 Disassembling Loosen three Allen screws (8) from the the armature bearing end plate (7) and pull the complete armature assembly (B) with the bearing end plate (7) from the gear box (1). Remove the seal (2) from the gear box (1). Insert the pin-type face spanner (service tool) (3) into the seal ring (4) and remove the seal ring (4) counter-clockwise.
- Page 8 PAGE 4939 5258 01 Removing the Loosen two screws (1) and remove the gear cover gear cover (2). The exposed plane surface serves only for manufacturing the gear box and has no other function! Disassembling Remove the four screws (1) from the the electronic handle and remove the handle half (2).
- Page 9 PAGE 4939 5258 01 Removing the Remove the air deflector ring (5). anti-vibration Remove the screw (4). Detach the follow- mechanism ing parts of the anti-vibration mechanism and the field from the motor housing (8): – thrust piece (1) – spring (2) –...
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Page 10: Maintenance
PAGE 4939 5258 01 Maintenance General It is recommended that maintenance be performed on the machine at regular intervals or when the car- bon brushes switch off at the latest. Cleaning Clean all parts – with the exception of the electrical parts – with cold cleaning agent. Caution! No clean- ing agent should penetrate into the bearing. - Page 11 PAGE 4939 5258 01 Lubrication: Combined drill/chisel hammer Put approx. 48 g of Darina grease (A) into the spindle housing (gear box from the front) Fill 35 g grease Urethyn (B) into the spindle (the percussion body takes up some grease) Apply 80 g grease Darina (A) to the safety clutch Apply 20 g of Darina...
- Page 12 PAGE 4939 5258 01 Lubrication: Chisel hammer Put approx. 48 g of Darina grease (A) into the spindle housing (gear box from the front) Fill 35 g grease Urethyn (B) into the spindle (the percussion body takes up some grease) Put 20 g of Darina grease (A) to the crank wheel Put 120 g of Darina grease (A)
- Page 13 PAGE 4939 5258 01 Sequence and torques of the screws: Torques Bearing cover 4 Nm Top gear cover 4.5 Nm Gear cover 3 Nm Chisel acceptance 18 Nm Motor housing 13 Nm Service cover 1.3 Nm Handle 3 Nm Field 2 Nm Anti-vibration mechanism 3 Nm...
- Page 14 PAGE 4939 5258 01 Assembly Mounting the Insert the field (6) into the motor hous- anti-vibration ing (8) and fix it with two screws (7) mechanism (torque = 2 Nm). and the field Insert the following parts of the anti- vibration mechanism into the motor housing (8): –...
- Page 15 PAGE 4939 5258 01 Wiring in the machine red: red: field – carbon brush holder field – carbon brush holder white: carbon brush holder – white: carbon brush carbon brush holder – carbon brush red: blue: field – electronic field – electronic brown: carbon brush –...
- Page 16 PAGE 4939 5258 01 Mounting the Fix the gear cover (2) with two screws (1) gear cover onto the gear box (torque = 3 Nm). Mounting the Combined drill/chisel hammer: Press crank wheel the needle bearings (2) and (3) flush into the gear box (4).
- Page 17 PAGE 4939 5258 01 Assembling Press on the bearing (B) and put on the the armature rubber sleeve (C). See illustration below: Press the fan (9) onto the indicated bear- ing measure. Afterwards, apply some in- stant glue (e. g. Sicomet) on the armature shaft (marked with arrows).
- Page 18 PAGE 4939 5258 01 Mounting the Apply locking agent on the four screws (4). motor housing Insert the gear box with the armature (5) into the motor housing (6) and fix them with the four screws (4) cross-wise (torque = 13 Nm). Insert the carbon brushes (3) on both sides and connect them.
- Page 19 PAGE 4939 5258 01 Mounting Combined drill/chisel hammer: the piston Insert the spindle bevel gear (1) into the gear box. Mount the O-ring (2) on the piston (3). Put the piston (3) on the tappet of the crank wheel (4). Insert the piston into the spindle bevel gear (1).
- Page 20 PAGE 4939 5258 01 Assembling Machines with a date of manufacture 06/2004 the spindle up to 06/2004: Insert the cross bracket (1) (width 7 mm) into the spindle openings (2) turn it 90°. The smooth side of the cross brack- et (1) (illustrated dark ) must face 7 mm...
- Page 21 PAGE 4939 5258 01 Mounting Insert the thrust ring (C) and the back the spindle pressure ring (B) into the spindle (E). Insert the back pressure ring (B) in the right position: the land of the back pressure ring (B) must face the snap die (8)! Mount the three O-rings (9) on the snap die (8).
- Page 22 PAGE 4939 5258 01 Mounting the If the old spindle sleeve (up to DoM percussion body 06/2004) was exchanged for the new one (4931 375 803 (drill/chisel ham- mer), 4931 375 802 (chisel hammer)), it is imperative that the new percus- sion body (9) (4931 375 782) is used! Otherwise the spindle is destroyed 4931 375 782...
- Page 23 PAGE 4939 5258 01 Chisel To prepare insert the O-ring (1), the at- tachment ring (2) and the locking ring (3) hammer: into the gear box (5). Insert the complete spindle assembly (4) Inserting into the gear box (5) and lead it through the spindle the O-ring (1), the attachment ring (2) and the locking ring (3).
- Page 24 PAGE 4939 5258 01 Inserting the Mount the O-ring (2) on the thrust col- thrust collar lar (3). Insert the thrust collar (3) into the gear box (1) and push it over the spindle as far as it will go. Put the sleeve (service tool) (4) on the thrust collar (1).
- Page 25 PAGE 4939 5258 01 Mounting the Push the spring ring (2) over the spring ring machine from the front and mount both retainers (1). Mounting Press together the retainers (2) on both the handle sides and mount the handle (4). Insert the screw (1) and screw down the knob (3).