Fein BOP 10-2 Repair Instructions
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Fein BOP 10-2 Repair Instructions

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BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A)
Repair instructions
C-SC_CSSM
Version 1.0
2017-10-12
All rights reserved by FEIN, especially in case of property rights applications.
FEIN retains all rights of disposal, such as copying and circulation
.
Page 1 of 65

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  • Page 1 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) Repair instructions C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications. Page 1 of 65 FEIN retains all rights of disposal, such as copying and circulation...

  • Page 2: Table Of Contents

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) Contents 1. Models described 2. Technical data 3. Notes and requirements 4. Tools required 5. Lubricants and auxiliary substances required 6. Removal 7. Fitting 8. Troubleshooting 9. Connection diagram C-SC_CSSM Version 1.0...

  • Page 3: Models Described

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 1. Models described These repair instructions describe how to repair the following models: Model Order number BOP 6 (A) 7 205 52 ..BOP 10 (A) 7 205 53 ..

  • Page 4: Technical Data

    Up-to-date test data for all models can be found on the FEIN Extranet (Customer Service → Repair Guides). Lubricants The lubricants and container sizes available from FEIN can be found on the FEIN Extranet (Customer Service → Repair Guides). Lists of spare parts Lists of spare parts and exploded views are available online at www.fein.com...

  • Page 5: Notes And Requirements

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 3. Notes and requirements Please note These instructions are only intended for persons with suitable technical training. It is assumed that the reader has mechanical and electrical training.

  • Page 6: Tools Required

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 4. Tools required Standard tools Special tools Open-ended spanner 17 mm Drawing-off socket cap 6 41 04 150 00 8 (width = 4 mm) Socket head wrench 10 mm...
  • Page 7 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 4. Tools required Standard tools Sleeve 30 mm inner diameter 40 mm inner diameter 12 mm inner diameter 30 mm inner diameter 20 mm inner diameter 28 mm inner diameter...

  • Page 8: Lubricants And Auxiliary Substances Required

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 5. Lubricants and auxiliary substances required Lubricants BOP 6 (A) Grease 0 40 101 0100 4 12 g Gearbox housing BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A)

  • Page 9: Removal

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing 1. Insert the socket head wrench into the quick-action chuck. Tools: 2. Turn the quick-action chuck (1) downwards. - Socket head wrench 3.
  • Page 10 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 6 (A)] 1. Pull off the grooved ball bearing (1). Tools: 2. Remove the circlip (2). - Drawing-off socket cap 3.
  • Page 11 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 6 (A)] 1. Remove the clutch ring (1). Tools: 2. Remove the six rollers (2). - Arbor press 3. Remove the circlip (3).
  • Page 12 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 6 (A)] 1. Remove the circlip (1). Tools: 2. Press down on the grooved ball bearing (2). - Circlip pliers...
  • Page 13 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 10 (A)] 1. Pull off the grooved ball bearing (1). Tools: 2. Remove the circlip (2). - Drawing-off socket cap 3.
  • Page 14 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 10 (A)] 1. Remove the gear-wheel (1). Tools: 2. Remove spring washer (2). - Circlip pliers 3. Pull off the clutch ring (3).
  • Page 15 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 10 (A)] 1. Press out the shaft (1). Tools: 2. Remove the disc (2). - Arbor press 3. Remove the circlip (3).
  • Page 16 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 10 (A)] 1. Press down on the grooved ball bearing (1). Tools: 2. Press the gear-wheel [z = 30 mm] (2) down.
  • Page 17 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the two shafts (1) with gear-wheels. Tools: - Plastic hammer C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications.
  • Page 18 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the plate (1). Tools: 2. Remove the switch pushbutton (2). - Slotted screwdriver - Combination pliers NOTE: The two leaf springs (5) are tensioned and could jump out.
  • Page 19 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Pull off the ball bearing (1). Tools: 2. Remove the circlip (2). - Drawing-off socket cap 3.
  • Page 20 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the clutch ring (1) and the rollers (2). Tools: 2. Remove the grooved ball bearing (3).
  • Page 21 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Press out the shaft (1). Tools: 2. Remove the disc (2). - Arbor press - Sleeve:...
  • Page 22 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the circlip (1). Tools: 2. Press down on the grooved ball bearing (2). - Circlip pliers...
  • Page 23 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Pull off the grooved ball bearing (1). Tools: 2. Press down on the gear-wheel (2). - Drawing-off socket cap...
  • Page 24 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the circlip (1). Tools: 2. Remove the three draw keys (2). - Circlip pliers 3. Remove the disc (3).
  • Page 25 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the gearbox housing [applies to: BOP 13-2 (A)] 1. Remove the six balls (1). C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications.
  • Page 26 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the handle half shell 1. Unscrew the three screws (1). Tools: 2. Unscrew the countersunk screw (2). - PH1/PH2 cross-head screwdriver 3. Remove the switch pushbutton (3).
  • Page 27 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the cable with plug 1. Unscrew the screw (1). Tools: 2. Remove the cable clamping piece (2). - PH1/PH2 cross-head screwdriver 3. Remove the speed setting switch (3).
  • Page 28 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the speed setting switch 1. Remove the capacitor (1). Tools: 2. Remove the cable (2). - Slotted screwdriver (small) 3. Remove the holder (3). C-SC_CSSM Version 1.0...
  • Page 29 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the speed setting switch 1. Disconnect all cables (1). 2. Disconnect the cable (2). 3. Disconnect the cable (3). 4. Remove the handle half shell (4).
  • Page 30 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the carbon brushes and carbon brush holders 1. Remove the two cables (1). Tools: 2. Lift the spring (2) to one side [on both sides].
  • Page 31 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the motor housing 1. Remove the armature (1) together with the intermediate gearbox. C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications.
  • Page 32 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the armature 1. Press out the armature (1). Tools: 2. Pull off the grooved ball bearing (2). - Drawing-off socket cap 3. Pull off the grooved ball bearing (3).
  • Page 33 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 6. Removal Removing the motor housing 1. Remove the air guide ring (1). Tools: 2. Unscrew the two screws (2). - PH2 cross-tip screwdriver 3. Remove the stator (3) from the motor housing.

  • Page 34: Fitting

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the armature 1. Press on the grooved ball bearing (1). Tools: 2. Press on the grooved ball bearing (2). - Arbor press 3. Press in the armature (3).
  • Page 35 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the motor housing 1. Put the carbon bush holder (1) in place and use the screw (2) to fasten it [0.6 Nm +0.1 Nm]. Tools: 2.
  • Page 36 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the motor housing 1. Remove the cables (1) from the stator. Tools: 2. Use the two screws (2) to fasten the stator [1 Nm +0.4 Nm].
  • Page 37 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the carbon brush [on both sides] 1. Insert the carbon brush (1) in the correct position and connect it. Tools: 2. Place the spring (2) on the carbon brush.
  • Page 38 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the electronics 1. Connect the long radio shielding cables (1) to the brush holders.  See “Connection diagram”. 2. Route the cables (2) as shown in the photograph.
  • Page 39 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the electronics 1. Slide the cable grommet (1) onto the cable (2). Tools: 2. Connect the cable and the capacitor to the speed setting switch (3).
  • Page 40 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the switch 1. Connect the two black connection cables (1) from the stator to the speed setting switch. 2. Connect all cables to the toggle switch (2).
  • Page 41 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the motor housing 1. Put all the electronic components in place in the housing half as shown in the first photograph. Tools: 2. Route all the cables as shown in the first photograph.
  • Page 42 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 6 (A)] 1. Press on the grooved ball bearing (1). Tools: 2. Fit the circlip (2). - Arbor press ...
  • Page 43 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 6 (A)] 1. Press in the shaft (1). Tools: 2. Fit the circlip (2). - Arbor press - Sleeve...
  • Page 44 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 6 (A)] 1. Place the clutch ring (1) in the correct position. Tools: 2. Fit the six rollers (2).
  • Page 45 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 6 (A)] 1. Position the spring washer (1). Tools: 2. Place the gear-wheel [z = 43] (2) in the correct position.
  • Page 46 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Press on the grooved ball bearing (1). Tools: 2. Fit the circlip (2). - Arbor press ...
  • Page 47 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Press in the shaft (1). Tools: 2. Fit the circlip (2). - Arbor press - Sleeve...
  • Page 48 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Press on the gear wheel (1). Tools: 2. Press in the grooved ball bearing (2). - Arbor press...
  • Page 49 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Place the clutch ring (1) in the correct position. Tools: 2. Fit the six rollers (2).
  • Page 50 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Place the spring washer (1) on the shaft. Tools: 2. Position the gear wheel (2). - Circlip pliers 3.
  • Page 51 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 10 (A)] 1. Position the disc (1). Tools: 2. Press on the grooved ball bearing (2). - Arbor press 3.
  • Page 52 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Press on the gear wheel (1). Tools: 2. Press in the grooved ball bearing (2). - Arbor press...
  • Page 53 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 3. Press on the gear wheel (1). Tools: 4. Press in the grooved ball bearing (2). - Arbor press...
  • Page 54 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Press on the grooved ball bearing (1). Tools: 2. Fit the circlip (2). - Circlip pliers ...
  • Page 55 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Press in the shaft (1). Tools: 2. Fit the circlip (2). - Circlip pliers  Replace the circlip during each fitting.
  • Page 56 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Position the clutch ring (1). Tools: 2. Fit the six rollers (2). - Forceps C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications.
  • Page 57 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Apply a layer of grease to the six balls (1). Tools: 2. Insert the six balls (1).

  • Page 58: Circlip Pliers

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Fit the circlip (1). Tools: 2. Insert the draw keys (2). - Slotted screwdriver (small) 3. Press draw keys outwards.
  • Page 59 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Position the spring washer (1). 2. Insert the gear-wheel (2) in the correct position. 3. Insert the two shafts (3).
  • Page 60 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Fit the sleeve (1) in the correct position. Tools: 2. Fit the circlip (2). - Assembly aid C-SC_CSSM Version 1.0...
  • Page 61 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Insert the bolt (1) in the correct position. 2. Insert the bolt (2). 3. Insert the two leaf springs (3).

  • Page 62: Mm Outer Diameter

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing [applies to: BOP 13-2 (A)] 1. Insert the switch pushbutton (1). Tools: 2. Insert the plate (2). - Arbor press 3. Press on the grooved ball bearing (3).
  • Page 63 BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 7. Fitting Fitting the gearbox housing 1. Fit the pin (1). Tools: 2. Position the seal (2). - Torx T20 3. Fit the gearbox housing (3) on the motor housing.

  • Page 64: Troubleshooting

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 8. Troubleshooting Currently unavailable. C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications. Page 64 of 65 FEIN retains all rights of disposal, such as copying and circulation...

  • Page 65: Connection Diagram

    BOP 6 (A); BOP 10 (A); BOP 10-2 (A); BOP 13-2 (A) 9. Connection diagram C-SC_CSSM Version 1.0 2017-10-12 All rights reserved by FEIN, especially in case of property rights applications. Page 65 of 65 FEIN retains all rights of disposal, such as copying and circulation...

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