Milwaukee IPWE 400 RQ User manual

PAGE

4939 5449 01

Special Tools

Require

■

Torx TX20 bit 4931 5990 08

■

Screwdriver Torx 20 4931 5990 05

■

Forcing Discs 4931 599 018

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

Removing the

QUIK-LOK cable

Pull off the QUIK-LOK cable from the

machine.

Loosen the screw (1) and take apart the

plug into two parts (2) and (9).

☞

The screw (1) has a centrical pin (see

enlargement). It can only be removed

witharespectiveTorxscrewdriverwith

a cantrical boring (A)! This Torx screw-

driver is part of the service tool kit.

It can also be ordered with order

number 4931 599 085.

Pull down the cable entry sleeve (7)

slightly.

Loosenthescrew(3)anddisassemblethe

inner plug into three parts (4), (5), and (6).

Remove the contacts (8) with cables.

Removing

the housing

Remove the four screws (3) from the front

part of the housing (4) and pull the hous-

ing off towards the front.

☞

In case of stiffness, tap the receiver

with a plastic hammer for support!

Loosen the six screws (2) and take apart

the housing (1).

PAGE

4939 5449 01

Disassembling

the gear

Pull the complete gear assembly from the

housing (A) and remove the following

parts:

– washer (9)

– bearing (8)

– anvil (7)

– shaft assembly (6)

– bearing (5)

– 5 planetary wheels (4)

– gear (3)

– 3 planetary wheels (1).

Machines with 3/4"-receiver:

remove

additional 3 bearings (2) from the pins of

the gear (3).

Disassembling

the housing

Put the housing (3) on the press as

shown in the illustration, and press out

the bearing (2) with aid of a bushing

(Ø = 29.5 mm) (4).

☞

A suitable bushing is, for example, the

driver of 900K/950K (4).

Remove two O-rings (1) from the bear-

ing (2).

2345

Ø 29.5mm

PAGE

4939 5449 01

Machineswith

1/2"-receiver

Disassembling

the anvil

To remove the pin (1) and the spring (2) from

the anvil, please proceed as follows:

Bend a paper clip or a piece of wire as

shown in illustration, so it will be shaped

like a hook (3.5 mm).

Insert the hook into the opening in the an-

vil and turn it 90°, such that the hook

reaches under the spring.

Pull the hook upwards until the pin disen-

gages from the spring.

Pull out the pin to the side and the spring

upwards.

Machineswith

3/4"-receiver

Disassembling

the anvil

Bend open the ring (2) and remove it.

Remove the O-ring (1).

Disassembling

the anvil

Fix the anvil (3) in a vice and pull out the

needle bearing (1) with aid of an interior

extractor.

Remove the ball (2) from the anvil.

90°

3.5 mm

PAGE

4939 5449 01

Removing

the balls

Put the shaft assembly (1) on the press

andpressittogether until both balls (2)fall

out.

Machineswith

1/2"-receiver

Disassembling

the shaft

assembly

Remove the following parts from the

shaft (1):

– ram (5)

– bearing (4)

– washer (3)

– spring (2).

Machineswith

3/4"-receiver

Disassembling

the shaft

assembly

Remove the following parts from the

shaft (1):

– ram (6)

– bearing (5)

– washer (4)

– spring (3)

– two washers (2).

456

PAGE

4939 5449 01

Disassembling

the gear case

Remove the following parts from the gear

case (7):

– gear (6)

– gear (5)

– washer (4)

– O-ring (3).

Pull out both carbon brushes (1) upwards.

Pull the armature (2) together with the

gear case from the field.

Remove the gasket (8) from the gear

case (7).

☞

Dispose of the gasket (8), it can’t be re-

used!

Removing

the armature

Insert the armature (1) with the

gear case (2) into the sleeve (3)

(

inner

Ø = 68 mm) and put it on the

press as shown in illustration.

Press the armature from the gear case (2)

with the plunger of the press (1).

PAGE

4939 5449 01

Removing

the bearing

Put the gear case (2) with the sleeve (3)

(

inner

Ø = 68 mm) on the press and press

out the bearing (1).

Pressing off

the bearing

Remove the rubber cap (1) from the bear-

ing (2).

Put the armature (3) and the forcing discs

on the press as shown in illustration, and

press off the bearing (2) facing the collec-

tor.

PAGE

4939 5449 01

Disconnecting

the electric parts

Remove the following parts from the hous-

ing halves:

– field (5) with field connector (6)

– switch (7) with set of wires (2)

and capacitor (3)

– blade housing (8)

– carbon brush holders (1)

and carbon brushes

– six rubber bungs (4).

Pull the field connector (6) from the

field (5).

PAGE

4939 5449 01

Maintenance

General

It is recommended to regularly submit the tool to maintenance.

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. 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 Me-

chanical 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 50 g grease type “Z” (Order No.: 49-08-7655).

Torques Housing screws 2.5 Nm

Gear case screws 4.5 Nm

1 g3 g

3 g 2 g

15 g

3 g

8 g

1 g

2 g

PAGE

4939 5449 01

Assembly

Assembling the

electric parts 1Insert three rubber bungs (4) into each

one of the housing halves.

2Put the field connector (6) on the field (5)

and insert them both into the housing

half (9).

3Mount the switch (7) with the set of

wires (2) and the capacitor (3).

☞For detailed wiring diagram,

see page 10.

4Insert the blade housing (8) into the lower

part of the housing half (9).

5Mount the carbon brushes in the brush

holders (1) but do not yet insert them into

the housing (9).

☞First insert the armature, then insert

the brush holders (1) with the carbon

brushes into the housing (9).

PAGE

4939 5449 01

Wiring diagram

to carbon brush

insert into

housing

Detail field connection Switch – bottom view

Detail choking coil

anti-interference capacitor

lead wire 4 through domes lead wire 4 between pin and housing ribs

inser wire 8 and 6 into

this relief

white wire 8 to field connector

black wire 4 to upper carbon brush

black wire 3 to lower carbon brush

black wire 6 to field connector

(connection 2)

brown mains cable 1

black wire 5 to field connector

(connection 1)

blue mains cable 2

blue wire 7 to field connector (connection 3)

lead wire 3

through domes

blue

black

blue

black

brown

black

white wire 8

from switch

black wire 6

from switch

blue wire 7

from switch

blue wire 3 from the lower

carbon brush

black wire 5

from switch

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