Milwaukee K900K User manual

PAGE

4939 5258 01

Special Tools

Require

■

Forcing discs 4931 599 018

■

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).

■

Before all repair work, pull the power plug from the socket!

Disassembly

Removing the

auxiliary handle

Remove the handle (1) by turning it

counter-clockwise.

Disassembling

the handle

Unscrew the knob (3) and remove the

screw (1).

Press the spring ring (2) in direction of the

arrow and remove the handle (4).

PAGE

4939 5258 01

Removing the

spring ring

Remove both retainers (1).

Slightly spread the spring ring (2) and pull

it off the machine towards the front.

Removing the

tool acceptance

Remove the four screws (4) with an Allen

key and remove the tool acceptance (1).

☞

If necessary, tap the tool accept-

ance (1) with a plastic hammer for

support!

Remove the seal ring (3) with circlip pliers

from the gear box (2).

Disassembling

the tool

acceptance

Expel res. press off the latch bar (7)

and remove the following parts:

– latch (4)

– spring (5)

– sleeve (6).

Lever off the seal ring (3) and the

O-ring (2) from the tool acceptance (1)

with a screwdriver.

Disassembling

the gear cover

Remove six screws (1) with washers from

the gear cover (2).

Remove the felt (4) from the gear cover.

Remove the gasket (3) from the groove of

the gear cover (5).

1 2 3

4 5 6 7

PAGE

4939 5258 01

Combined

drill/chisel

hammer:

Removing

the spindle

Expel the complete spindle assembly with

light taps on the rear spindle end (1) with

a plastic hammer.

Chisel

hammer:

Removing

the spindle

Loosen the seal ring (3) with circlip pliers

from the spindle groove.

Expel the complete spindle assembly with

light taps on the rear spindle end (4) with

a plastic hammer.

Remove the seal ring (3), the attach-

ment ring (2) and the O-ring (1) from the

gear box.

321

PAGE

4939 5258 01

Disassembling

the spindle

Remove the thrust collar (1) from the

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.

Remove the O-ring (6) from the percus-

sion body (5).

☞

The type of the percussion body (5) de-

pends on the type of the spindle (7)!

Remove the Seeger circlip ring (3) from

the spindle with Seeger circlip pliers (4).

Disassembling

the spindle

☞

Illustration No. 9 shows the latest type

of the spindle sleeve; further types are

described on the following pages.

Remove the following parts from the

spindle (C):

– ball race (1)

– disc (2)

– damping ring (3)

– attachment ring (4).

Remove the four rolls (B) with a magnetic

screwdriver from the spindle (C).

☞

Turn the driver sleeve (5) and the spin-

dle (C) in opposite directions to remove

the rolls (see enlargement below)!

☞

Should the rolls (B) be stuck, expel

them with light blows with a plastic

hammer.

Combined drill/chisel hammer:

pull the

driver sleeve (5) (with hexagon socket)

from the spindle (C).

Chisel hammer:

remove the driver

sleeve (5) (without hexagon socket)

from the spindle (C).

Remove the following parts from the

driver/sleeve (5):

– snap die (7)

– O-ring (6).

Remove three O-rings (8) from the

snap die (7).

Remove the thrust collar (9) and the back-

pressure ring (A) from the spindle (C).

1 2 3

567

PAGE

4939 5258 01

Disassembling

the spindle

Machines with date of manufacture up

to 06/2004:

Turn the cross bracket (1)

(width 7 mm) 90° and remove it through

one of the openings i the spindle (2).

With reversion kit No. 4931 375 788

Spindle opening = 36 mm:

Remove the chromium platet cross brack-

et (3) (width 8 mm wide) from the front part

of the spindle (4).

Spindle opening = 39 mm:

Turn the chromium platet cross bracket (5)

(width 8 mm) 90° and remove it through

one of the spindle openings (6).

Machines with date of manufacture

from 07/2004:

Remove the ring (7) from

the front part of the spindle (8).

5 mm

8 mm

06/2004

07/2004

7 mm

36 mm

39 mm

8 mm

36 mm

39 mm

oder

90°1.

PAGE

4939 5258 01

Removing the

piston assembly

Bring the piston (3) into the upper dead

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).

Dismantling the

motor housing

Remove the two screws (1) from the

service cover (2) and pull out the service

cover (2) in direction of arrow.

Put aside the springs (3) on both sides of

the carbon brush cover and pull the car-

bon brush out (4). Pull the carbon brush

cable off.

Remove four Allen screws (4) from the

motor housing.

Pull the gear box (5) with the armature

from the motor housing.

123

PAGE

4939 5258 01

Disassembling

the armature

Loosen three Allen screws (8) from the

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.

Remove the bearing end plate (7).

Remove the locking ring (5) from the

bearing end plate (7) and press out the

bearing (6).

Separate the fan (9) from the armature (B)

with the forcing discs (A).

Remove the rubber sleeve (D) and press

off the bearing (C).

Detaching the

crank wheel

Remove the following parts from the gear

box (4):

–crank wheel (5)

–disc (8)

–axial bearing (9)

–disc (B).

Pull the needle bearings (6) and (7) with

the interior extractor (A) from the crank

wheel (5).

Combined drill/chisel hammer:

Additionally remove the safety clutch (1)

from the gear box (4). Pull the needle

bearings (2) and (3) with the interior

extractor (A) from the gear box (4).

☞

The chisel hammer does not have

a safety clutch (1) and needle bear-

ings (2) and (3)!

23456

PAGE

4939 5258 01

Removing the

gear cover 1Loosen two screws (1) and remove the

gear cover (2).

☞The exposed plane surface serves

only for manufacturing the gear box

and has no other function!

Disassembling

the electronic

component

1Remove the four screws (1) from the

handle and remove the handle half (2).

2To branch off the mains cable, remove

two screws (4) from the switch.

3Remove the screw (5) from the strain

relief (6) and remove the mains cable (7).

4Detach the following parts:

–four O-rings (C)

–two wires (D)

–two screws (A)

–two carbon brush holders (B)

–electronic part (E)

–four screws (8)

–secured washer (9).

PAGE

4939 5258 01

Removing the

anti-vibration

mechanism

and the field

1Remove the air deflector ring (5).

2Remove the screw (4). Detach the follow-

ing parts of the anti-vibration mechanism

from the motor housing (8):

–thrust piece (1)

–spring (2)

–transition piece (3).

☞Danger of injury! Pay attention when

loosening the screw (4): the thrust

piece (1) is under pressure and must

be steadied!

3Loosen two screws (7) and remove the

field (6) from the motor housing (8).

☞Should the field be stuck, tap the

motor housing (8) lightly with a plastic

hammer for support.

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. 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.

The service set no. 4931 375 659 contains all listed spare parts.

120 g A

20 g A

35 g B

80 g A

20 g A

approx.

48 g A

35 g B

10 g B

2 g B

10 g B

2 g B

daub

thinly

daub

thinly

daub

thinly

daub

thinly

daub

thinly

daub

thinly

1 g A

approx.

48 g A

1 g A

3 g B3 g B

The illustration shows the spindle sleeve

used from date of manufacture 07/2004.

The illustration shows the spindle sleeve

used from date of manufacture 07/2004.

Lubrication chart: Chisel hammer

A: Fill res. daub with a total of 190 g grease type Darina

(order no.: 215 922, 100-g-tube).

B: Fill res. daub with 50 g grease type Urethyn

(order no.: 4931 6243 75, 45-g-tube).

Lubrication chart: Combined

drill/chisel hammer

A: Fill res. daub with a total of 150 g grease type Darina

(order no.: 215 922, 100-g-tube).

B: Fill res. daub with 50 g grease type Urethyn

(order no.: 4931 6243 75, 45-g-tube).

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