Milwaukee AG 16-125 XC User manual

PAGE

4939 5228 01

Special Tools

Require

■

Forcing discs 4931 5990 18

■

TX 15 4931 5990 05

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

Detaching

the handle

Unscrew the handle (1).

Machines with QUIK-LOK:

Pull off the

Quick-Lock connection cable (2).

Removing the

carbon brushes

Loosen the screws (1) on both service

covers (2) with TX 15.

Carefully lever off the service cover (2)

with aid of a screwdriver.

Loosen the plug contact of the carbon

brushes (3) on both sides and remove the

carbon brushes (3).

Detaching the

guard cap

Fold away the hoop on the Fixtec nut (1)

and unscrew the Fixtec nut (1).

☞

In case of stiffness, a pin-type face

spanner can be used.

Remove the grinding disc (2).

Remove the clamping flange (3).

Loosen three screws (4) and remove the

spring washer (5).

Remove the guard cap (6).

PAGE

4939 5228 01

Removing the

complete spindle

assembly

Loosenfourscrews(1)onthebearingend

plate (2).

Remove the complete bearing end

plate (2).

Removing

the bearing

Pull off the bearing (2) from the front gear

box with aid of an interior extractor (1) in

direction of arrow.

Dismantling the

spindle assembly

Place the complete bearing end plate (2) -

(7) on a press. Apply pressure on the spin-

dle in direction of arrow. A gap will appear

betweenbevelgearwheel (2) and bearing

end plate (5). Insert the forcing discs

(service tool) into this gap and press off

thebevelgearwheel(2).Finally, pressout

the spindle assembly.

Dismantle the spindle assembly as fol-

lows:

– bevel gear wheel (2),

– O-ring (7),

– upper disc (6),

– bearing end plate (5),

– lower disc (4),

– spindle (3).

PAGE

4939 5228 01

Removing

the complete

armature

Loosen four screws (2).

Remove the gear box (6) with the com-

plete armature (4).

☞

If necessary, hit the gear box lightly

with a plastic hammer to remove it.

Steady the nut (3) with a fork wrench

(SW12) and grasp the armature (4)

care-

fully

with pliers (5). Loosen them contra-

rotating. (The armature can also be care-

fullyfixedinaviceprovidedwithprotective

jaws.)

Remove the nut (3).

Machineswith

seal ring:

Removing

the pinion

Remove the locking ring (7) and the fol-

lowing parts:

– disc (6),

– seal ring (5),

– press off the bearing (4),

– washer (3).

Remove the pinion (1) with the washer (2)

from the gear box.

Remove the washer (2) from the pin-

ion (1), if necessary, peel it off with aid of

a screwdriver.

Machineswith

sealing

washer:

Removing

the pinion

Remove the locking ring (7) and the fol-

lowing parts:

– disc (6),

– seal ring (5),

– press off the bearing (4),

– washer (3).

Remove the pinion (1) with the washer (2)

from the gear box.

PAGE

4939 5228 01

Machines

without

electronics:

Detaching the

armature

Remove the following parts from the ar-

mature (4):

– bearing sleeve (1),

– press off the bearing (2),

– insulating disc (3).

Machineswith

electronics:

Detaching the

armature

Remove the following parts from the ar-

mature (5):

– bearing sleeve (1),

– magnetic disc (2),

– press off the bearing (3),

– insulating disc (4).

Removing the

spindle lock

Press the press ram with a suitable man-

drel (steel pin) in direction of arrow onto

the middle of the push button (1).

Remove the push button (1), the pressure

spring (2) and the locking bolt (3).

☞

The push button is destroyed (1).

Removing the air

deflector ring

Remove the air deflector ring (1) with the

holding-down devices (2) from the motor

housing (3).

PAGE

4939 5228 01

Machines

without

electronics:

Removing

the field

Remove seven screws (5) and (A) from

the handle (B) and detach the handle.

Branch off the field wires (e, d, f, g) and re-

move the brush holders (4) and the con-

necting cables (3) and (8) from both sides.

Unscrew the strain relief (7).

Remove the switch (9) and branch off the

mains feed lines (6) (a, b).

Remove the mains connection cable (C).

Remove the field (1) from the motor hous-

ing (2).

☞

If necessary, hit the motor housing (2)

lightly with a plastic hammer for sup-

port.

Machineswith

electronics:

Removing

the field

Removing

the electronic

component

Remove seven screws (5) and (A) from

the handle (B) and detach the handle.

Branch off the field wires (e, d, f, g, k) and

remove the connecting cables (3) and the

brush holders (4) from both sides.

Unscrew the strain relief (7).

Branch off the switch (8) and remove it.

Branch off the mains feed lines (6) (a, b).

Remove the mains connection cable (9).

Machines with QUIK-LOK:

Remove the

insert (E).

Machines with speed electronics:

Remove the electronic element (C).

Machines with constant electronics:

Remove the electronic element (D).

Remove the field (1) from the motor hous-

ing (2).

☞

If necessary, hit the motor housing (2)

lightly with a plastic hammer for sup-

port.

3 8

4 B

PAGE

4939 5228 01

Maintenance

General

It is recommended to submit the machine to maintenance after the carbon brushes have switched off.

Cleaning 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 for wear Check the disassembled parts for wear (visual inspection) and replace worn parts.

Electrical tests 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.

Legend

■Use a total of 12 g grease Centoplex O Est (4931 621 977 - 100 g Tube).

ACover with 2 g grease Centoplex O Est.

BFill with 10 g grease Centoplex O Est.

Torques Screws in plastic 1.8 Nm

Screws in metal 2.5 Nm

Nut 6.0 Nm

10 g 10 g

PAGE

4939 5228 01

Assembly

Mounting the

bearing sleeve 1Insert the bearing sleeve (2) into the hous-

ing (1) as far as it will go.

☞Do not pre-assemble the bearing

sleeve (2) on the armature. When

mounting the armature in the motor

housing (1), the bearing sleeve (2) is

pushed into the magnetic disc of the

armature. This might result in malfunc-

tion of the machine!

Machineswith

electronics:

Mounting

the field

Mounting

the electronic

element

1Insert the field (1) into the motor hous-

ing (2).

2Machines with constant electronics:

Connect the electronic element (D) to the

field (1) (e, d, f, g, k) and insert it.

3Machines with speed electronics:

Connect the electronic element (C) to the

field (1) (e, d, f, g, k) and insert it.

4Machines with QUIK-LOK: Mount the in-

sert (E) (to connect the Quick-Lock cable).

5Insert the mains connection cable (9).

Connect the mains feed lines (a, b) (6) to

the switch (8). Insert the switch (8).

6Screw down the strain relief (7).

7Connect the connecting cables (3) to the

carbon brush holders (4) and insert them

on both sides.

8Put together the handle halves (B)

and fasten them with seven screws (A)

and (5).

☞Take care that all electronic parts are

inserted properly into the handle (B)

and that no part is squeezed or

jammed!

4 B

PAGE

4939 5228 01

Machines

without

electronics:

Mounting

the field

1Insert the field (1) into the motor hous-

ing (2). Press it in, if necessary.

2Insert the mains connection cable (C) and

connect the mains feed lines (a, b) (6) to

the switch (9).

3Screw down the strain relief (7).

4Connectthe connecting cables(3) and(8)

(e, d, f, g) to the field (1). Connect the con-

necting cables (3) to the carbon brush

holders on both sides (4) and insert them

on both sides.

5Put together the handle halves (B)

and fasten them with seven screws (A)

and (5).

Mounting the air

deflector ring 1Insert both holding-down devices (2) into

the motor housing (3).

2Put on the air deflector ring (1).

Mounting the

spindle lock 1Mounta newpushbutton(1), thepressure

spring (2) and the locking bolt (3) and in-

sert them into the front gear box.

3 8

4 B

1 2

PAGE

4939 5228 01

Machines

without

electronics:

Mounting the

armature

1Mount the following parts on the arma-

ture (1):

– insulating disc (2),

– press on the bearing (3).

Machineswith

electronics:

Mounting the

armature

1Mount the following parts on the arma-

ture (1):

– insulating disc (2),

– press on the bearing (3),

– magnetic disc (4).

Machineswith

sealing

washer:

Mounting

the pinion

1Mount the following parts in the front gear

box:

– washer (3),

– press in the bearing (4),

– seal ring (5),

– disc (6),

– locking ring (7).

2Insert the washer (2), the pinion (1) and

the nut (8) into the gear box in preparation

for mounting the armature.

Machineswith

seal ring:

Mounting

the pinion

1Mount the following parts in the front gear

box:

– washer (3),

– press in the bearing (4),

– seal ring (5),

– disc (6),

– locking ring (7).

2Mount the washer (2) on the pinion (1).

3Insert the assembled pinion (1) and the

nut (8) into the gear box in preparation for

mounting the armature.

PAGE

4939 5228 01

Inserting

the complete

armature

1Insert the completely assembled arma-

ture (4) into the front gear box, rotating it.

Carefully hold the armature with pliers for

support. (The armature can also be care-

fullyfixedinaviceprovidedwithprotective

jaws.)

☞Machines without electronics: Mag-

netic disc (A) does not exist.

2Machines with sealing washer: Put the

washer (9) on the end of the shaft.

3Put the pinion (8) and the nut (3) on the

end of the armature shaft (4).

Useaforkwrench(SW12)andpliers (5)to

screw in the armature, contra-rotating.

4Use four screws (2) to fasten the front

gear box to the motor housing (7).

Assembling

the spindle 1Mount the following parts on the spindle

shaft (6):

– disc (5),

– bearing end plate (4),

– disc (3),

– O-ring (2),

– press on the bevel gear wheel (1) flush

in direction of arrow.

Mounting

the bearing 1Press the bearing (1) into the front gear

box as far as it will go.

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