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