Milwaukee IPWE 400 RQ User manual

1
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
1
Pull off the QUIK-LOK cable from the
machine.
2
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.
3
Pull down the cable entry sleeve (7)
slightly.
4
Loosenthescrew(3)anddisassemblethe
inner plug into three parts (4), (5), and (6).
5
Remove the contacts (8) with cables.
Removing
the housing
1
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!
2 Loosen the six screws (2) and take apart
the housing (1).
1
2
9
34
5
6
7
8
A
1
2
3
1
4
2

2
PAGE
4939 5449 01
Disassembling
the gear
1
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).
2
Machines with 3/4"-receiver: remove
additional 3 bearings (2) from the pins of
the gear (3).
Disassembling
the housing
1
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).
2
Remove two O-rings (1) from the bear-
ing (2).
1
6
7
89
2345
A
3
Ø 29.5mm
1
2
3
4
4

3
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:
1
Bend a paper clip or a piece of wire as
shown in illustration, so it will be shaped
like a hook (3.5 mm).
2
Insert the hook into the opening in the an-
vil and turn it 90°, such that the hook
reaches under the spring.
3
Pull the hook upwards until the pin disen-
gages from the spring.
4
Pull out the pin to the side and the spring
upwards.
Machineswith
3/4"-receiver
Disassembling
the anvil
1
Bend open the ring (2) and remove it.
2
Remove the O-ring (1).
Disassembling
the anvil
1
Fix the anvil (3) in a vice and pull out the
needle bearing (1) with aid of an interior
extractor.
2
Remove the ball (2) from the anvil.
90°
12
34
3.5 mm
1
2
5
1
2
5
1
2
2
3
6

4
PAGE
4939 5449 01
Removing
the balls
1
Put the shaft assembly (1) on the press
andpressittogether until both balls (2)fall
out.
Machineswith
1/2"-receiver
Disassembling
the shaft
assembly
1
Remove the following parts from the
shaft (1):
– ram (5)
– bearing (4)
– washer (3)
– spring (2).
Machineswith
3/4"-receiver
Disassembling
the shaft
assembly
1
Remove the following parts from the
shaft (1):
– ram (6)
– bearing (5)
– washer (4)
– spring (3)
– two washers (2).
1
2
7
1
5
2
34
8
12
3
456
8

5
PAGE
4939 5449 01
Disassembling
the gear case
1
Remove the following parts from the gear
case (7):
– gear (6)
– gear (5)
– washer (4)
– O-ring (3).
2
Pull out both carbon brushes (1) upwards.
3
Pull the armature (2) together with the
gear case from the field.
4
Remove the gasket (8) from the gear
case (7).
☞
Dispose of the gasket (8), it can’t be re-
used!
Removing
the armature
1 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.
2
Press the armature from the gear case (2)
with the plunger of the press (1).
6
5
4
3
2
7
8
1
9
1
3
2
10

6
PAGE
4939 5449 01
Removing
the bearing
1
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
1
Remove the rubber cap (1) from the bear-
ing (2).
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.
1
2
3
1
11
1
2
3
2
12

7
PAGE
4939 5449 01
Disconnecting
the electric parts
1
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).
2
Pull the field connector (6) from the
field (5).
1
3
2
56
4
8
7
13

8
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
15 g
3 g
8 g
1 g
2 g

9
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).
1
3
2
56
4
8
7
9
1

10
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

11
PAGE
4939 5449 01
Mounting the
bearing on
the armature
1Press the bearing facing the collector (2)
onto the armature shaft.
2Pull the rubber cap (1) over the bear-
ing (2).
Mounting the
bearing in the
gear case
1Press the bearing (1) into the gear
case (2) as far as it will go, using a press.
Pressing on
the gear case 1Press the gear case (1) onto the armature shaft (2).
1
2
2
1
2
3
1
2
4

12
PAGE
4939 5449 01
Inserting
the armature 1Pull a new gasket (3) over the gear case (4).
2Insert the gear case (4) together with the
armature into the field (2) as far as it will
go.
3Insert the carbon brushes (1) on both
sidesintothereliefsinthe housing,nextto
the collector.
4Mount the following parts in the gear
case (4):
– O-ring (5)
– washer (6)
– gear (7)
– gear (8).
Machineswith
1/2"-receiver
Assembling
the shaft
1Mount the following parts on the shaft (1):
– spring (2)
– washer (3)
– bearing (4)
– ram (5).
1
3
6
5
78
4
2
5
1
5
2
34
6

13
PAGE
4939 5449 01
Machineswith
3/4"-receiver
Assembling
the shaft
1Mount the following parts on the shaft (1):
– two washers (2)
– spring (3)
– washer (4)
– bearing (5)
– ram (6).
Mounting
the balls 1Put the shaft assembly (2) on the press and depress it against resilience (in direc-
tion of arrow) and insert both balls (1) into
the grooves of the shaft.
Slowly release the pressure.
Mounting
the anvil 1Insert the ball (2) into the anvil (3).
2Press the needle bearing (1) into the anvil.
Machineswith
1/2"-receiver
Mounting
the anvil
1First insert the pin (1), then the spring (3)
into the anvil (2).
☞The groove of the pin must be in the
anvil!
2Depress the spring (3) with a hook
(see page 3, illustration 5 top), until
the pin (1) engages.
12
3
456
6
1
2
7
1
2
3
8
1
3
2
9

14
PAGE
4939 5449 01
Machineswith
3/4"-receiver
Mounting
the anvil
1Insert the O-ring (1) into the groove.
2Pull over the ring (2).
Mounting
the housing 1Mount two O-rings (1) on the bearing (2).
2Press the bearing (2) into the housing (3)
with aid of a bushing (Ø = 29.5 mm) (4).
☞A suitable bushing is, for example, the
driver of the machines 900K/950K (4).
Assembling
the gear 1Machines with 3/4"-receiver: Mount three bearings (2) on the pins of the
gear (3).
2Mount the following parts on the gear
shaft (6) and insert the assembly into the
housing (A):
– bearing (5)
– 5 planetary wheels (4)
– gear (3)
– 3 planetary wheels (1)
– anvil (7)
– bearing (8)
– washer (9).
1
2
9
1
2
3
4
10
1
6
7
89
2345
A
11

15
PAGE
4939 5449 01
Mounting
the housing 1Fix the housing halves (1) with six screws (2).
2Put the complete front part of the gear
case (3) on the machine, at the same time
carefully insert the gear assembly into the
machine and turn the square seat until the
front part of the gear case (3) is flush with
the motor housing.
3Fix the front part of the gear case (3) with
four screws (4).
Insulating the
mains cable 1Insulate the mains cable as shown in illus- tration. Meet the following measures:
– Insulating length of wires:
approx. 4 mm
– Wire length with insulation:
approx. 12 mm
2
4
1
3
12
12 mm
4 mm
13

16
PAGE
4939 5449 01
Mounting the
QUIK-LOK cable
Producing a
strain relief
1Insert the mains cable into the new crimp-
ing contacts (8) in accordance with regula-
tionsandmakeacorrectcrimpconnection
with aid of a crimping tool (see both illus-
trations of the crimp connection on the
right).
☞Only a correct crimp connection can
meet all mechanical and electrical re-
quirements!
2Insert the crimping contacts (8) with
wires (6) into the sleeve.
3Insert the plug halves (4) and (5) into the
sleeve (6) on both sides and fix them with
the screw (3).
☞Provide 3 mm wire for strain relief
(see lower illustration)!
4Insert the cable entry sleeve (7) and the
assembled sleeve (6) into the plug (9).
5Put together the two halves of the plug (2)
and (9) and fasten them with the
screw (1).
☞The screw (1) has a centrical pin
(see enlargment). It can only be fas-
tened with a Torx screwdriver with a
respective centrical guide boring (A)!
This Torx screwdriver is part of the
service tool kit.
It is also available as service bit
Lfb (order number 4931 599 085).
Test Run
Electrical Test
Test run the machine and pay attention to noises.
Let the machine run-in.
Perform an electrical test on the machine (see chapter Electrical and Mechanical Test Instructions).
cross section:
crimp barrel
correct
crimp connection
1
2
9
34
5
6
7
8
A
3 mm
14